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Workshop Manual.....................................................................................................2002 6-51250
Workshop Manual (TVT 195) ...................................................................................2002A 6-93080

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Functional description Injection System ...................................................................3001 6-51300
Functional description Injection System - Common Rail System (TVT 195) ............3001A 6-93150

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Functional description CAN Bus (Basics).................................................................4002 6-51350
Functional description and Troubleshooting – ADIC ................................................4003 6-91700
Function diagrams - Electrics ...................................................................................4008 6-92771
Function diagrams - Electrics (TVT 195) ..................................................................4008A 6-93221
Connectors, Wiring Harnesses, Electrical and Electronic Components ...................4009 6-92970
Connectors, Wiring Harnesses, Electrical and Electronic Components (TVT 195)..4009A 6-93290
Circuit diagram .........................................................................................................4010 6-51402
Circuit diagram (TVT 195) ........................................................................................4010A 6-93360

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Fault codes ...............................................................................................................4011 6-52632

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Functional description, Troubleshooting and Settings
Front Axle with Independent Suspension 20.25S.....................................................5001 6-51450
Functional description, Troubleshooting and Settings
Front Axle with Independent Suspension 20.29S.....................................................5002 6-51500
Workshop Manual - Front Axle - Carraro 20.25, 20.25 FR.......................................5005 6-51550
Workshop Manual - Independently Suspended Front Axle 20.25S and 20.25SI FR5006 6-51600
Workshop Manual - Independently Suspended Front Axle 20.29SI / FR .................5007 6-51651

 75$160,66,21
Functional description Transmission ........................................................................6001 6-51700
Troubleshooting - System hydraulics .......................................................................6002 6-51750
Cartridge - Removing and Fitting..............................................................................6005 6-51800
Cartridge - Disassembling and Assembling..............................................................6006 6-51850
Rear Axle - Removing and Fitting.............................................................................6007 6-51900
Rear Axle - Disassembling and Assembling.............................................................6008 6-51950
Parking Interlock, 4-wheel Drive Clutch and Bevel Pinion (Rear Module)................6009 6-52000

&1+gVWHUUHLFK*PE+ Copyright © 2006 CNH Österreich GmbH

Sva 6-92333
July 2006
 +<'5$8/,&6<67(0
Functional description CC-LS Hydraulic System (Closed Center-Load Sensing).... 8001 6-52051
Functional description and troubleshooting
High Pressure Hydraulic Circuit ............................................................................... 8002 6-92610
Functional description and troubleshooting
(Electronic 3-point hitch control system EDC) ......................................................... 8005 6-52100
Fault codes and fault description, EHS Auxiliary Control Units ............................... 8006 6-52150

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Functional description and troubleshooting Air Conditioning ................................... 9002 6-92840

Sva 6-92333 July 2006

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Fault codes .............................................................................................................. 4011 6-52632

Sva 6-92333 July 2006

Sva 6-92333 July 2006
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Functional description, Troubleshooting and Settings
Front Axle with Independent Suspension 20.25S.................................................... 5001 6-51450
Functional description, Troubleshooting and Settings
Front Axle with Independent Suspension 20.29S.................................................... 5002 6-51500
Workshop Manual - Front Axle - Carraro 20.25, 20.25 FR ...................................... 5005 6-51550
Workshop Manual - Independently Suspended Front Axle 20.25S and 20.25SI FR5006 6-51600
Workshop Manual - Independently Suspended Front Axle 20.29SI / FR ................ 5007 6-51651

 75$160,66,21
Functional description Transmission ....................................................................... 6001 6-51700
Troubleshooting - System hydraulics....................................................................... 6002 6-51750
Cartridge - Removing and Fitting............................................................................. 6005 6-51800
Cartridge - Disassembling and Assembling............................................................. 6006 6-51850
Rear Axle - Removing and Fitting............................................................................ 6007 6-51900
Rear Axle - Disassembling and Assembling............................................................ 6008 6-51950
Parking Interlock, 4-wheel Drive Clutch and Bevel Pinion (Rear Module)............... 6009 6-52000

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Functional description CC-LS Hydraulic System (Closed Center-Load Sensing) ... 8001 6-52051
Functional description and troubleshooting
High Pressure Hydraulic Circuit............................................................................... 8002 6-92610
Functional description and troubleshooting
(Electronic 3-point hitch control system EDC) ......................................................... 8005 6-52100
Fault codes and fault description, EHS Auxiliary Control Units ............................... 8006 6-52150

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Functional description and troubleshooting Air Conditioning................................... 9002 6-92840
TVT 195

Sva 6-92333 July 2006

Sva 6-92333 July 2006
 Chapter
2002

2002
ENGINE WORKSHOP MANUAL

CNH Österreich GmbH Sva 6-51250 EN © 2003 CNH Österreich GmbH

Technical Documentation July 2003
A – 4300 St. Valentin, Steyrer Straße 32
2002-2
TABLE OF CONTENTS

SPECIAL TOOLS .....................................................................................................................5

FOR THE USER ......................................................................................................................7

Engine code and serial number ...........................................................................................7

SAFETY REGULATIONS ........................................................................................................8

ENGINE DATA .........................................................................................................................9

Lifting the engine .................................................................................................................9

TECHNICAL DATA ................................................................................................................10

Conformance with exhaust standards ...............................................................................10
Cylinder block ....................................................................................................................10
Cylinder liners ....................................................................................................................10
Cylinder head .....................................................................................................................10
Valves, rocker arms and push rods ...................................................................................11
Camshaft ...........................................................................................................................12
Crankshaft .........................................................................................................................12
Flywheel .............................................................................................................................13
Gear drive, camshaft and injection pump ..........................................................................13
Con-rods ............................................................................................................................13
Pistons, piston rings and piston pins .................................................................................14
Lubrication system .............................................................................................................14
Lubrication oil pump ...........................................................................................................15
Thermostat .........................................................................................................................15
Coolant temperature indication and monitoring (signal from sensor B22) .........................15
Coolant pump ....................................................................................................................15
Schwitzer turbocharger S200 ............................................................................................15
Tightening torques .............................................................................................................16

CONSTRUCTION ..................................................................................................................17
General ..............................................................................................................................17
Cylinder block ....................................................................................................................17
Flywheel casing .................................................................................................................17
Cylinder head .....................................................................................................................18
Valve mechanism ..............................................................................................................18
Crankshaft drive .................................................................................................................20
Timing gears ......................................................................................................................21
Lubrication system .............................................................................................................22
Cooling system ..................................................................................................................23
Fan .....................................................................................................................................24
Intake/exhaust system .......................................................................................................25

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 2002-3
ELECTRONIC ENGINE CONTROL SYSTEM – EEM2 .........................................................26
Layout ................................................................................................................................27
Signals ...............................................................................................................................28
Function .............................................................................................................................28

JOB INSTRUCTIONS ............................................................................................................29

1. Cylinder block ................................................................................................................29
A. Measuring the cylinder liner wear ..............................................................................29
B. Removing the cylinder liner .......................................................................................29
C. Checking the cylinder block ......................................................................................29
D. Replacing the camshaft bearing bush .......................................................................29
E. Oversize bearing bushes for the camshaft ................................................................30
F. Fitting the plug at the rear camshaft end ...................................................................31
G. Fitting the plug at the rear camshaft end after inserting an oversize bearing bush ..31
H. Installing the oil dipstick tube ....................................................................................31
I. Fitting the cylinder liner ...............................................................................................31
2. Flywheel casing .............................................................................................................33
A. Fitting the flywheel casing .........................................................................................33
B. Replacing the rear crankshaft sealing ring ................................................................33
3. Cylinder head .................................................................................................................34
A. Removing the cylinder head ......................................................................................34
B. Removing the valves .................................................................................................34
C. Checking the cylinder head .......................................................................................34
D. Replacing the valve guides .......................................................................................35
E. Machining the valve seat ...........................................................................................36
F. Replacing the valve seat rings ...................................................................................36
G. Grinding the valves ...................................................................................................36
H. Fitting the valves .......................................................................................................37
I. Fitting the cylinder head ..............................................................................................37
4. Valve mechanism ...........................................................................................................38
A. Maintenance of the rocker arm system .....................................................................38
B. Replacing the camshaft/camshaft gear wheel ...........................................................38
C. Checking and adjusting the valve clearance .............................................................39
5. Crankshaft ......................................................................................................................40
A. Removing the crankshaft ...........................................................................................40
B. Checking the crankshaft ............................................................................................40
C. Replacing the crankshaft gear wheels ......................................................................40
D. Fitting the crankshaft .................................................................................................41
E. Crankshaft hub ..........................................................................................................41
F. Replacing the crankshaft belt pulley and the vibration damper .................................42
G. Checking the rubber element in the vibration damper ..............................................42
6. Pistons and con-rods .....................................................................................................43
A. Removing the pistons together with the con-rods .....................................................43
B. Checking and replacing the con-rod bearings ...........................................................43
C. Checking the con-rod ................................................................................................43
D. Checking and replacing the piston rings ...................................................................44
E. Checking the pistons .................................................................................................45
F. Fitting the piston pin ..................................................................................................45
G. Fitting the pistons and con-rods ................................................................................45

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2002-4
7. Flywheel .........................................................................................................................46
A. Replacing the starter ring gear on the flywheel .........................................................46
B. Fitting the flywheel ....................................................................................................46
8. Timing mechanism .........................................................................................................47
A. Removing the timing gear case .................................................................................47
B. Replacing the intermediate gear wheel bearing bush ...............................................47
C. Fitting the timing gear case .......................................................................................48
9. Lubrication system .........................................................................................................50
A. Checking the oil pressure valve ................................................................................50
B. Removing and checking the oil pump .......................................................................50
C. Assembling and fitting the oil pump ..........................................................................50
D. Fitting the sump ........................................................................................................51
E. Oil cooler ...................................................................................................................51
F. Piston cooling nozzles ...............................................................................................52
G. Recommended lubrication oils ..................................................................................52
10. Cooling system ............................................................................................................53
A. Thermostat ................................................................................................................53
B. Repairing the coolant pump ......................................................................................53
C. Coolant quality requirements ....................................................................................54
11. Intake/exhaust system .................................................................................................55
A. Checking the air filter ................................................................................................55
B. Checking the intake/exhaust system .........................................................................55
C. Checking the boost pressure ....................................................................................55
D. Checking the turbocharger ........................................................................................56
E. Fitting the turbocharger .............................................................................................57

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 2002-5
SPECIAL TOOLS
Pressing tool for the front crankshaft Assembly pin for the water pump seal
dust seal

SS00B068
SS00B064
1 x 380000005 (1TSW 523)
1 x 380000010 (1TSW 519)
Universal pin
Pressing tool for the front crankshaft
shaft sealing ring

SS00B077
1 x 1TSW 18390 M24

SS00B065
Pressing tool for valve guides
1 x 380000002 (1TSW 520)

Pressing tool for the rear crankshaft

shaft seal

SS00B069
1 x 380000007 (1TSW 524)

Valve spring tensioning lever

SS00B066
1 x 380000003 (1TSW 521)

Pressing tool for

cam shaft cover

SS00B071
1 x 380000008 (1TSW 014)

SS00B067
1 x 380000004 (1TSW 522)
Sva 6-51250 EN Edition 07/2003
2002-6
Extractor Mini-measuring connection

SS98J031
1 x 380001915 M12x1,5
SS00B070
1 x 1TSW 662 (available from your dealer)
Mini-measuring line
Cylinder liner extractor

SS98J030
1 x 380001127 (1TSW 635)

Pressure gauge and connection

SS00B072
1 x 1TSW 510 (available from your dealer)

SS00B076
Extraction plate
1 x 380001129 (1TSW 645) Connection
1 x 380001121 (1TSW 5002) Pressure gauge

Injection pump installation pin

SS00B073
1 x 380000011 (1TSW 508)

Dial test indicator and holder

SS03D046
380001487

SS00B075
1 x 380000364 (1TSW 5610) Holder
1 x 380000228 (1TSW 17049-6) Dial test indicator

Sva 6-51250 EN Edition 07/2003

 2002-7

FOR THE USER

The purpose of this manual is to provide basic information required to service and repair CNH diesel engines.
The engines are of the same design. Differences which have an influence on repair work are therefore listed in
the technical data and repair instructions. All dimensions are specified in millimetres and apply at a temperature
of +20 °C, if not specified otherwise.
Before starting repair work, make sure all necessary special tools, spare parts and accessories are available. It is
not absolutely necessary to have all the special tools mentioned in this manual. However, having them does
make it quicker and easier to carry out any repairs necessary. After a repair, the engine must be run in just like a
new engine.
If any questions arise, which cannot be clarified with the aid of this manual, please contact Customer Service at
CNH Österreich GmbH in St. Valentin or the respective importer.
IMPORTANT: When making any queries, please specify the following engine data and the current operating
hours count.
EEM2 = Electronic Engine Management
PCU = Pump Control Unit

Engine code and serial number

Engine Engine
type output
620.95 135 PS
620.96 145 PS
620.97 155 PS
620.98 170 PS

Manufacturer
620.99 190 PS
SISU Diesel Inc.
FIN-37240 Linnavuori
e17*97/68EA*97/68EA*0016*00

FINLAND
Type XXXX XXXXX 620.99
regulations large nonroad compression

Power 180 PS 2100 rpm

This engine conforms to199 U.S EPA

Engine number
Serial nr M19858 5.05.2003
Valve
0,35 mm
(serial number)
clearance
Timing
TDC 30 degrees
Low idle 850 rpm
ignition engines

Cust.
Part nr 620.99.00.0001
EU
Family D20AEE
EPA
Family 3SIDL7.4G4A
Displacement: 6.6 l Fuel: 2-D fuel oil

Assembled by:

This label is affixed to the right-hand

M07575
side of the engine.

SC03G005

Sva 6-51250 EN Edition 07/2003

2002-8

SAFETY REGULATIONS
There is always a risk of getting  Naked flames and smoking are not permitted in the
injured when performing serv- vicinity of fuel tanks or batteries. Electrical sparks
ice and repair work. Before com- should be avoided. (Particularly when charging the
mencing work, the following batteries. Explosion hazard!)
safety regulations and instruc-
tions must be read.
 Disconnect the cable at the negative battery pole
before carrying out service or repair work on the
 Never start repair work which you do not fully electrical system.
understand.
 If the engine gets excessively hot (over 300 °C), for
 Make sure that it is possible to work safely at the example, if it catches fire, the viton seals (e.g.
location and in the vicinity. bottom O-ring on the cylinder liner or the O-ring on
 Make sure the location is clean and in a good
the oil pressure valve) release highly caustic HF
acid. Never touch viton seals, which have been
state.
subjected to unusually high temperatures, with
 Never use wrong or unsuitable tools. bare hands. Always wear neoprene gloves or thick
 Remove all rings, chains and watches before
work gloves and safety goggles when removing
these harmful substances. Wash the seals and
commencing work.
contaminated surfaces with a 10 % hydroxide
 Use state of the art safety equipment. For solution or another alkaline solution. Collect the
example, wear goggles when using compressed material in air-tight sealed plastic bags and bring
air for cleaning, grinding, hammering or similar them to an authorised collecting depot.
work.
,03257$17Viton seals may never be burned!
 Use a lifting device for lifting or transporting heavy
 Fuel, lubrication oil and coolant can cause skin
(over 20 kg) parts. Make sure the hooks and
irritations, if contact is made over a longer period.
chains are in a good condition and sit firmly.
 Never work below an engine hanging from a lifting
 Avoid running the engine in idle unnecessarily.
device or raised by a jack. Always secure the  When carrying out service work, take measures to
engine with strong supports before commencing prevent fuel or other fluids from entering the
work. ground or drains.
 Only use original CNH spare parts.  All seals are asbestos-free.
 Only start the engine from the cab, using the  Be careful when washing the engine using a
ignition key. washing facility with a high water pressure. Do not
wash, for example, the electrical and fuel systems
 Never start the engine with the protective covers
under high pressure as they can easily be
removed.
damaged.
:$51,1* It is difficult to see the radiator fan when
the engine is running! Loose fitting clothes and long
hair can get caught in rotating engine parts!
 If the engine is started in a confined space,
sufficient ventilation must be provided.
 Never use auxiliary starting fuels on an aerosol
basis whilst the pre-glow starting facility is in
operation (explosion hazard).
 Ear muffs must be worn when testing the engine or
working close to the engine.
 Always switch the engine OFF before carrying out
repair work.
 Avoid touching the exhaust manifold, turbocharger
and other hot engine parts.
 When the engine is hot and the coolant is
pressurised, be careful on opening the radiator
sealing cover. Coolant and lubrication oil out of the
hot engine can cause severe injuries if contact is
made with the skin.
Sva 6-51250 EN Edition 07/2003
 2002-9

ENGINE DATA
Engine type 620.95 620.96 620.97 620.98 620.99
Number of cylinders 6
3
Capacity (dm ) 6,6
Bore (mm) 108
Stroke (mm) 120
Rated power in PS at 2100 rpm 135 145 155 170 190
acc. to ISO 14396
Delivery start mark on the
30
V-belt pulley (° before UDC)
Compression ratio 18,5 : 1 18,5 : 1
Method of combustion direct injection
Injection sequence 1-5-3-6-2-4
Compression pressure1 (bar) 24
2
Charge-air pressure (bar) 0,94 1,03 1,12 1,24 1,45
3
Weight (kg) 510
Direction of rotation of the Clockwise
crankshaft

1
) Minimum value at operating temperature and starter speed.
Highest permissible difference between the cylinders is 3 bar (max.)
2
) Measured behind the charge-air cooler (measuring point: see section entitled "Checking the boost pressure"
page 55), at full load, nominal engine speed and top fan speed
3
) Without flywheel and electrical equipment.
,03257$17After certain repairs to the engine, the fuel system must be bled before starting for the first time (for
details, refer to Chapter 3001, Injection system).
127( The plug-in connection on the PCU must be released and disconnected before performing any arc
welding work. Do not touch the plug-in contacts!

Lifting the engine

The engine is lifted safely by means of a lifting device,

on which the lifting force acts vertically on the lifting eyes.

A = Engine lifting eyes

A A

SS99N013

Sva 6-51250 EN Edition 07/2003

2002-10

TECHNICAL DATA
Conformance with exhaust standards
Europe: 97/68 EC Level 2
America: Tier 2

Cylinder block
Guide pin bore holes ...................................................................................................... 13.250 - 13.320 mm
Diameter of the crankshaft bearing base bore hole ....................................................... 91.000 - 91.025 mm
Diameter of the crankshaft bearing base bore hole (oversize) ...................................... 92.000 - 92.025 mm
Bore hole diameter of the cylinder liner:
– top ........................................................................................................................... 124.514 - 124.554 mm
– bottom ..................................................................................................................... 123.000 - 123.040 mm
Diameter of the camshaft bearing bush (fitted) .............................................................. 50.010 - 50.070 mm
Construction height of the cylinder block ................................................................... 428.170 - 428.430 mm

Cylinder liners
Liner height above the cylinder block................................................................................. 0.030 - 0.080 mm
Highest permissible height difference between cylinder liners......................................................... 0.02 mm
Diameter of the cylinder liner bore holes in the engine block:
– top end of liner ........................................................................................................ 124.475 - 124.500 mm
– bottom end of liner .................................................................................................. 122.961 - 122.986 mm
Cylinder liner bore hole .............................................................................................. 108.010 - 108.032 mm
Height, cylinder liner flange.................................................................................................... 9.03 - 9.05 mm
Height, cylinder liner flange, 1st oversize............................................................................... 9.08 - 9.10 mm
Height, cylinder liner flange, 2nd oversize ............................................................................. 9.13 - 9.15 mm
Height, cylinder liner flange, 3rd oversize .............................................................................. 9.23 - 9.25 mm
Outer diameter of the cylinder liner flange ................................................................. 131.700 - 131.800 mm

Cylinder head
Construction height of the cylinder head.................................................................... 104.800 - 105.000 mm
Minimum height of the cylinder head after surface grinding....................................................... 104.000 mm
Inner diameter of the valve guide (when not fitted) ............................................................ 9.000 - 9.015 mm
Outer diameter of the valve guide .................................................................................. 16.028 - 16.039 mm
Diameter of the bore hole for the valve guide in the cylinder head ................................ 16.000 - 16.018 mm
Projection of the valve guide over the cylinder head face................................................................... 21 mm
Depth, valve head below cylinder head surface:
– Inlet valve ................................................................................................... 0.7 ± 0.05 mm (max. 2,20 mm)
– Outlet valve ................................................................................................ 0.6 ± 0.05 mm (max. 2,20 mm)
Valve seat angle:
– Inlet valve ......................................................................................................................................... 35°+20’
– Outlet valve ...................................................................................................................................... 45°+20’
Valve seat width:
– Inlet valve ................................................................................................................................ 2.9 - 3.7 mm
– Outlet valve ............................................................................................................................. 1.3 - 2.3 mm
Diameter, outlet valve seat insert (standard).................................................................. 44.070 - 44.132 mm
Bore hole in cylinder head for outlet valve seat insert (standard) .................................. 44.000 - 44.025 mm
Diameter, outlet valve seat insert (oversize) .................................................................. 44.270 - 44.332 mm
Bore hole in cylinder head for outlet valve seat insert (oversize) ................................... 44.200 - 44.225 mm
Diameter, inlet valve seat insert (standard).................................................................... 48.570 - 48.632 mm
Bore hole in cylinder head for inlet valve seat insert (standard) .................................... 48.500 - 48.525 mm
Diameter, inlet valve seat insert (oversize) .................................................................... 48.770 - 48.832 mm
Bore hole in cylinder head for inlet valve seat insert (oversize) ..................................... 48.700 - 48.725 mm

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 2002-11
Valves, rocker arms and push rods
Valve control times at a valve play of 1.0 mm:
– Inlet valve opens ............................................................................................................0° ±2° before TDC
– Inlet valve closes.............................................................................................................16° ±2° after BDC
– Outlet valve opens .......................................................................................................39° ±2° before BDC
– Outlet valve closes............................................................................................................1° ±2° after TDC
Valve play when engine is cold/hot:
– Inlet valve...................................................................................................................................... 0.35 mm
– Outlet valve ................................................................................................................................... 0.35 mm
Valve head angle:
– Inlet valve.......................................................................................................................................... 35°-20’
– Outlet valve ....................................................................................................................................... 45°-20’
Valve head diameter:
– Inlet valve......................................................................................................................................... 48 mm
– Outlet valve ...................................................................................................................................... 41 mm
Maximum opening lift of the valves:
– Inlet valve...................................................................................................................................... 10,9 mm
– Outlet valve ................................................................................................................................... 12.1 mm
Diameter, inlet valve stem.................................................................................................. 8.960 - 8.975 mm
Diameter, outlet valve stem................................................................................................ 8.925 - 8.940 mm
Clearance, inlet valve stem (guide fitted in cylinder head)................................................. 0.025 - 0.055 mm
Wear limit (inlet valve stem) ............................................................................................................. 0.30 mm
Clearance, outlet valve stem (guide fitted in cylinder head) .............................................. 0.060 - 0.090 mm
Wear limit (outlet valve stem)........................................................................................................... 0.35 mm
Inner diameter of the valve guide (when not fitted)............................................................ 9.000 - 9.015 mm
Outer diameter of the valve guide.................................................................................. 16.028 - 16.039 mm
Diameter of the bore hole for the valve guide in the cylinder head................................ 16.000 - 16.018 mm
Projection of the valve guide over the cylinder head face................................................................... 21 mm
Depth, valve head below cylinder head surface:
– Inlet valve................................................................................................... 0.7 ± 0.05 mm (max. 2.20 mm)
– Outlet valve ................................................................................................ 0.6 ± 0.05 mm (max. 2.20 mm)
Length of the valve spring, relaxed .................................................................................................. 69.8 mm
Force of the valve spring compressed to a length of:
– 48,6 mm .....................................................................................................................................327 ± 17 N
– 37.4 mm .....................................................................................................................................500 ± 23 N
Diameter, rocker arm shaft............................................................................................. 22.970 - 22.990 mm
Diameter of rocker arm bore hole .................................................................................. 23.000 - 23.021 mm
Permissible radial deflection of the push rod (free)............................................................................ 0.4 mm
Length of the rocker arm spring, relaxed ............................................................................................ 80 mm
Force of the valve spring compressed to a length of 58 mm .........................................................80 - 100 N
Outer diameter of the tappet .......................................................................................... 29.939 - 29.960 mm
Diameter of the tappet bore holes in the cylinder block ................................................. 30.000 - 30.043 mm

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2002-12
Camshaft
Diameter, camshaft bearing journal No. 1 (front) ................................................................ 49.925 - 49.950 mm
Diameter, camshaft bearing journals No. 2, 3 and 4 ........................................................... 49.865 - 49.890 mm
Diameter, camshaft bearing journal No. 5........................................................................... 49.885 - 49.910 mm
Diameter, camshaft bearing No. 1 (bearing bush fitted)...................................................... 50.010 - 50.070 mm
Diameter of the other camshaft bearings (bearing bushes fitted) ....................................... 50.000 - 50.025 mm
Play, camshaft bearing No. 1 ................................................................................................. 0.060 - 0.145 mm
Play of camshaft bearings No. 2, 3 and 4 ...............................................................................0.110 - 0.160 mm
Play, camshaft bearing No. 5 .................................................................................................. 0.090 - 0.140 mm
Overlap of the bearing seats (press fit) in the cylinder block .................................................. 0.025 - 0.080 mm
Diameter of the bearing seat bore holes in the cylinder block ............................................ 55.620 - 55.650 mm
Axial play of the camshaft (with a 0.5 mm seal between the cylinder block and
timing case and between the timing case and timing case cover ................................................... 0.5 - 1.0 mm
Cam height (dimension between cam base circle and cam lobe):
– Inlet valve ......................................................................................................................... 41.180 - 41.430 mm
– Outlet valve ...................................................................................................................... 40.080 - 40.330 mm
Cam stroke:
– Inlet valve ............................................................................................................................................7.38 mm
– Outlet valve .........................................................................................................................................8.28 mm
Max. permissible radial deflection of the camshaft ................................................................................0.03 mm

Crankshaft
Diameter of the con-rod bearing journals:
– Standard dimension ......................................................................................................... 67.981 - 68.000 mm
– 1st. repair level 0.25 mm.................................................................................................. 67.731 - 67.750 mm
– 2nd. repair level 0.50 mm................................................................................................. 67.481 - 67.500 mm
– 3rd. repair level 1.00 mm ................................................................................................. 66.981 - 67.000 mm
– 4th. repair level 1.50 mm.................................................................................................. 66.481 - 66.500 mm
Width of the con-rod bearing journal ................................................................................... 40.000 - 40.160 mm
Diameter of the crankshaft journals:
– Standard dimension ......................................................................................................... 84.985 - 85.020 mm
– 1st. repair level 0.25 mm.................................................................................................. 84.735 - 84.770 mm
– 2nd. repair level 0.50 mm................................................................................................. 84.485 - 84.520 mm
– 3rd. repair level 1.00 mm ................................................................................................. 83.985 - 84.020 mm
– 4th. repair level 1.50 mm.................................................................................................. 83.485 - 83.520 mm
Diameter, crankshaft bearing casing................................................................................... 91.000 - 91.025 mm
Thickness of the main bearing shells
– Standard dimension ........................................................................................................ 2.955 - 2.965 mm
– 1st. repair level 0.25 mm................................................................................................. 3.080 - 3.090 mm
– 2nd. repair level 0.50 mm................................................................................................ 3.205 - 3.215 mm
– 3rd. repair level 1.00 mm ................................................................................................ 3.455 - 3.465 mm
– 4th. repair level 1.50 mm................................................................................................. 3.705 - 3.715 mm
Crankshaft bearing play ..................................................................................................... 0.050 - 0.127 mm
Width of the journal at the thrust bearing (crankshaft bearing at flywheel):
– Standard dimension (2 standard thrust washers) ....................................................... 45.000 - 45.080 mm
– 1st. repair level (one standard thrust washer and one with an oversize of 0.1 mm) ... 45.100 - 45.180 mm
– 2nd. repair level (one standard thrust washer and one with an oversize of 0.2 mm) .. 45.200 - 45.280 mm
– 3rd. repair level (one 0.1 mm thrust washer and one with an oversize of 0.2 mm)..... 45.300 - 45.380 mm
– 4th. repair level (two thrust washers with an oversize of 0.2 mm) .............................. 45.400 - 45.480 mm
Other crankshaft bearing journals must not be ground wider.
Axial play of the crankshaft ................................................................................................ 0.100 - 0.380 mm
Max. permissible out-of-true of the crankshaft or con-rod bearing journals ..................................... 0.03 mm
Max. permissible imbalance of the crankshaft .................................................................................1.0 Ncm.

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Flywheel
Overlap of the starter ring gear on the flywheel ................................................................. 0.425 - 0.600 mm
Before pressing the starter ring gear onto the flywheel, the
ring gear must be heated up to a temperature of....................................................................... 150 - 200 °C
Max. permissible imbalance at the flywheel...................................................................................... 1.0 Ncm
Max. permissible warpage of the clutch surface measured at the inner
edge of the clutch surface (diameter 200mm) ................................................................................. 0.06 mm

Gear drive, camshaft and injection pump

Tooth flank play:
Intermediate gear wheel – crankshaft.................................................................................... 0.05 - 0.25 mm
Intermediate gear wheel – camshaft...................................................................................... 0.05 - 0.25 mm
Intermediate gear wheel – injection pump ............................................................................. 0.05 - 0.25 mm
Max. permissible lateral runout of the wheels.................................................................................. 0.05 mm
Intermediate gear wheel (with friction bearing):
– Inner diameter, intermediate gear wheel bearing bush (fitted).................................... 55.000 - 55.030 mm
– Diameter, bearing journal for intermediate gear wheel ............................................... 54.951 - 54.970 mm
Inner diameter, camshaft gear wheel............................................................................. 32.000 - 32.025 mm
Diameter, front end of the camshaft............................................................................... 32.043 - 32.059 mm
Timing marks:
The alignment of the timing marks on the gear wheels correspond to the
top dead centre of the piston in the 1st cylinder, between the compression stroke and firing stroke.
On the crankshaft gear wheel ...........................................................................................2 dots on the teeth
On the intermediate gear wheel:
– opposite the crankshaft gear wheel ..........................................................................."0" mark on the tooth
– opposite the camshaft gear wheel .................................................................................. 1 dot on the tooth
– opposite the injection pump gear wheel.................................................................... 1 dot at the tooth gap
On the camshaft gear wheel ........................................................................................ 1 dot at the tooth gap
On the injection pump gear wheel ..................................................................................... 1 dot on the tooth

Con-rods
Inner diameter, piston-pin bush
(bearing bush pressed into the con-rod) ........................................................................ 40.025 - 40.040 mm
Outer diameter of the piston-pin bush............................................................................ 44.082 - 44.120 mm
Overlap of the bearing seat (press fit) in the con-rod......................................................... 0.057 - 0.120 mm
Bore, seat for piston-pin bush ........................................................................................ 44.000 - 44.025 mm
Bore, con-rod bearing end ............................................................................................. 71.730 - 71.749 mm
Thickness of the con-rod bearing shells:
– Standard ......................................................................................................................... 1.835 - 1.842 mm
– 1st. repair level 0.25 mm................................................................................................. 1.960 - 1.967 mm
– 2nd. repair level 0.50 mm ............................................................................................... 2.085 - 2.092 mm
– 3rd. repair level 1.00 mm ................................................................................................ 2.335 - 2.342 mm
– 4th. repair level 1.50 mm ................................................................................................ 2.585 - 2.592 mm
Con-rod bearing play ......................................................................................................... 0.046 - 0.098 mm
Con-rod bearing axial play ................................................................................................. 0.200 - 0.410 mm
Alignment of the con-rod bearing bore to the piston-pin bearing bore................................... within 0.15:100
Parallelism of the con-rod bearing bore to the piston-pin bearing bore ................................. within 0.05:100
The weight markings are punched in the bottom end of the con-rods
(on the camshaft side)
Max. permissible weight difference between con-rods in the same engine ............................................ 20 g

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Pistons, piston rings and piston pins
Smallest gap between the piston and cylinder head (measured
through the bore for the nozzle holder seat using lead wire) ............................................. 0.900 - 1.150 mm
Piston diameter (measured 17 mm above
the lower edge of the piston ....................................................................................... 107.873 - 107.887 mm
Diameter, piston pin bore hole in the piston ................................................................... 40.003 - 40.009 mm
Diameter, piston pin ....................................................................................................... 39.991 - 40.000 mm
Width of the piston ring grooves:
– 1st. groove (rectangular compression ring)..................................................................... 2.560 - 2.580 mm
– 2nd. groove ..................................................................................................................... 2.520 - 2.540 mm
– 3rd. groove ...................................................................................................................... 4.040 - 4.060 mm
Vertical play of the piston rings in their grooves:
– 1st. groove (rectangular compression ring)....................................................................... 0.07 - 0.102 mm
– 2nd. groove ....................................................................................................................... 0.03 - 0.062 mm
– 3rd. groove ........................................................................................................................ 0.05 - 0.082 mm
– Wear limit ...................................................................................................................................... 0.15 mm
Piston ring height (in direction of cylinder):
– 1st. groove (rectangular compression ring)..................................................................... 2.478 - 2.490 mm
– 2nd. groove ..................................................................................................................... 2.478 - 2.490 mm
– 3rd. groove ...................................................................................................................... 3.975 - 3.990 mm
End play of piston rings (with piston fitted):
– 1st. groove (wedge-type compression ring) ........................................................................ 0.40 - 0.55 mm
– 1st. groove (rectangular compression ring)......................................................................... 0.30 - 0.45 mm
– 2nd. groove ......................................................................................................................... 0.60 - 0.80 mm
– 3rd. groove .......................................................................................................................... 0.30 - 0.60 mm
– Wear limit, rings 1 and 3 ................................................................................................................. 1.0 mm
– Wear limit, ring 2 ............................................................................................................................. 1.5 mm
Max. permissible weight difference between pistons in the same engine............................................... 25 g
127(When fitting the pistons, make sure the piston recess is on the same side as the nozzle holders.

Lubrication system
Oil pressure at normal operating temperature:
– idling ................................................................................................................................... at least 1.0 bar
– at operational speed....................................................................................................................2.5 - 5 bar
Lubrication oil filter overflow valve opens at a differential pressure of ........................................... 2 ±0,5 bar
Oil pressure switch opens at .........................................................................................................p > 0.5 bar
Engine types 620.95 and 620.96:
Spring in oil pressure valve: length, relaxed .................................................................................... 49.5 mm
Spring length and force (with oil pressure valve fitted) ........................................................... 28.5 mm/76 N
Engine types 620.97, 620.98 and 620.99:
Spring in oil pressure valve: length, relaxed .................................................................................... 49.8 mm
Spring length and force (with oil pressure valve fitted) ......................................................... 28.5 mm/127 N
Oil pressure alarm at.....................................................................................................................p < 0.5 bar
Fault code EEM99 ............................................................................................................ Indicated on ADIC
Optical and acoustic warning, automatic
engine shutoff after ......................................................................................................................30 seconds
Overflow valves for the piston cooling nozzles: Opening pressure ...............................................3 ±0.25 bar

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Lubrication oil pump
Tooth flank play when the crankshaft lies firmly against the under side of the bearing
– between the crankshaft gear wheel and oil pump gear wheel .......................................... 0.05 - 0.025 mm
– between the oil pump gear wheels .................................................................................... 0.16 - 0.26 mm
Diameter of the drive shaft in the housing and cover..................................................... 17.966 - 17.984 mm
Diameter of the drive shaft bearing bores...................................................................... 18.000 - 18.018 mm
Diameter of the fixed shaft near the pump gear wheel .................................................. 17.966 - 17.984 mm
Diameter of the bearing bore in the pump gear wheel................................................... 18.000 - 18.018 mm
Diameter of the fixed shaft in the pump housing............................................................ 20.035 - 20.048 mm
Depth of the drive shaft end below the housing surface ............................................................ 0.5 - 1.0 mm
Thickness of the housing seal................................................................................................ 0.06 - 0.08 mm
Outer diameter of the gear wheels................................................................................. 55.824 - 55.870 mm
Housing diameter........................................................................................................... 56.000 - 56.120 mm
Width of the gear wheels ............................................................................................... 32.000 - 32.027 mm
Axial play of the gear wheels ................................................................................................. 0.03 - 0.11 mm
Housing depth................................................................................................................ 32.000 - 32.043 mm
Number of teeth on the drive gear wheel................................................................................................... 46

Thermostat
Type, version .......................................................................................................................... ∅ 54 mm/single circuit
Starts opening at................................................................................................................................ 79 °C±2
Fully open at ......................................................................................................................................... 94 °C
Max. stroke ........................................................................................................................................ 7.5 mm
Type, version .....................................................................................................................................∅ 67/dual-circuit
Starts opening at................................................................................................................................ 83 °C±2
Fully open at ......................................................................................................................................... 95 °C
Max. stroke ........................................................................................................................................... 8 mm

Coolant temperature indication and monitoring (signal from sensor B22)

Display on ADIC...................................................................................................................................analog
Warning at ADIC when temperature ........................................................................................... > 106± 3 °C
Fault code EEM112 (test values for sensor: see Service Tool)
Acoustic alarm (additionally) when temperature .......................................................................... > 113± 3 °C
Fault code EEM113 (test values for sensor: see Service Tool)

Coolant pump
Bearing outer diameter ....................................................................................................................... 52 mm
Bearing housing diameter .............................................................................................. 51.979 - 52.009 mm
Shaft diameter at bearing............................................................................................... 19.980 - 19.993 mm
Shaft diameter at impeller .............................................................................................. 15.907 - 15.920 mm
Diameter of impeller bore hole....................................................................................... 15.876 - 15.894 mm
Clearance between impeller and rear side of housing............................................................... 0.8 - 1.2 mm
(must be observed when pressed on)
Permissible imbalance of the fan ..................................................................... max. 0.3 Ncm max (30 pcm)
V-belt tension, when pressed in between the two pulleys,
amount of give ............................................................................................................................. 10 - 15 mm

Schwitzer turbocharger S200

Axial play of the shaft...............................................................................................................max. 0.10 mm
Radial play of the shaft (compressor end) ...............................................................................max. 0.88 mm
Tightening torque for the compressor housing bolts .......................................................................13.60 Nm
Tightening torque for the turbine housing bolts...............................................................................21.00 Nm
Tightening torque for the shaft nut (compressor end) .....................................................................13.60 Nm

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Tightening torques
Cylinder head nuts and bolts
(up to engine number N 8956) ................................80 Nm+90°+90° (+60° at coolant temperature of 75 °C)
Cylinder head nuts and bolts
(from engine number N 8957) .............................................................................................. 80 Nm+90°+90°
Cylinder head bolts in the cylinder block..............................................................................................30 Nm
Crankshaft bearing bolts ....................................................................................................................200 Nm
Con-rod bolts (Torx E18) ............................................................................................................ 40 Nm + 90°
Nut on crankshaft (face)...................................................................................................................1000 Nm
Belt pulley bolts ....................................................................................................................................30 Nm
Securing bolts for flywheel .................................................................................................................150 Nm
Securing bolts for flywheel casing:
– internal M10 bolts..............................................................................................................................80 Nm
– external M12 bolts...........................................................................................................................150 Nm
Retaining screws for intermediate gear wheel (with friction bearing):
– M10 ...................................................................................................................................................60 Nm
– M14 .................................................................................................................................................200 Nm
Overflow valve, piston cooling nozzle (620.97, 620.98, 620.99)..........................................................30 Nm
Nut for lubrication oil pump gear wheel................................................................................................60 Nm
Retaining screws for lubrication oil pump.............................................................................................60 Nm
Connecting part for (engine) oil cooler .................................................................................................60 Nm
Nut for belt pulley on coolant pump....................................................................................................120 Nm
Fastening, Visco fan on Visco hub .......................................................................................................30 Nm
Nuts/bolts for exhaust manifold............................................................................................................50 Nm
Bolts for air intake channel...................................................................................................................30 Nm
Nut for injection pump gear wheel........................................................................................................90 Nm
Retaining nuts, nozzle holder (for bolts)...............................................................................................15 Nm
Injection nozzle union nut.....................................................................................................................60 Nm
Injection line union nut .........................................................................................................................25 Nm

127(Use washers for aluminium parts.

If no particular tightening torques are specified,

always use the values specified in the table below.

M8 M10
±5
Cast iron 35 Nm 70±5 Nm
Aluminium 25±5 Nm 50±5 Nm

Bolts for the self-supporting oil sump

1 M8 25 Nm
3
2 M10 90 Nm
3 M14 160 Nm
4 M20 600 Nm 4 2
1 SS99N015

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CONSTRUCTION
General
The 620 series CNH diesel engines are water-
cooled, four stroke, in-line engines with direct
injection. All models are equipped with wet,
replaceable cylinder liners, an exhaust turbocharger
and charge-air cooling (air/air). As the engines are
equipped with an electronic diesel control system in
conjunction with an electronic engine control system
(CAN network including solenoid valve-controlled
distributor injection pump VP30), all models comply
with the exhaust-gas regulations in accordance with
Tier 2.

Cylinder block
The rib-reinforced cylinder block forms the main
engine unit, onto which other engine components are
mounted.
The wet, replaceable cylinder liners are supported in
the middle, thus reducing vibration and the coolant
flow is mainly directed to the upper section of the
cylinder liners.
The bottom part of the cylinder liner and the cylinder
block are sealed by three O-rings, which are inserted
in the grooves in the cylinder liner. The upper part is
sealed by the cylinder head gasket.
The camshaft is located in the cylinder block.
All camshaft bearings are equipped with replaceable
SS00F035
cylinder liners.
Guide bearings are fitted on both sides of the rear
crankshaft bearings (crankshaft – axial bearings).

Flywheel casing
The flywheel casing is fitted at the rear end of the
cylinder block. The seal for the rear end of the
crankshaft is fitted in a bore hole in the casing. The
flange for the starter is located in the flywheel casing.
The underside of the flywheel casing is used as a
sealing surface for the oil sump seal. This means that
the underside of the cylinder block must be flush with
the flywheel casing. When the flywheel casing is
fitted, its position is determined by sprung dowel
pins.

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Valve mechanism
The valve mechanism is operated by the camshaft in
the cylinder block. The drive power is transferred via
valve tappets and push rods. The camshaft gear
wheel is force fitted on the camshaft and fixed
(radially) by a feather key. The bearings are
lubricated with pressure oil through bore holes in the
engine block.

SS99N017

Cylinder head
The engines are equipped with two interchangeable
cylinder heads. Each cylinder has its own intake and
outlet channels in the cylinder head. To compensate
for thermal stress, an inlet valve is fitted between the
outlet valves
The cylinder head bolts are high-tensile pre-
tensioned bolts, which are tightened to their
elongation limit in accordance with the angular
tightening principle. Due to the high degree of
elongation, the retaining power is kept constant
throughout the entire service life, and the bolts do not
therefore have to be check tightened.
The injection nozzle seats are integrated into the
cylinder head. The inlet and outlet valve guides are
identical and can be interchanged. Furthermore, the
in/outlet valves are fitted with replaceable valve seat
inserts.

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BLANK PAGE

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2002-20
Crankshaft drive The pistons are equipped with two compression rings
and an oil scraper ring. In the case of engine types
The crankshaft is made from forged chrome alloy 620.95 and 620.96, the top molybdenum-coated
special steel and the bearing and sealing surfaces piston ring has a rectangular cross-section. Engine
are inductively tempered. The bearing points can be types 620.97, 620.98 and 620.99 have a top piston
re-ground four times without having to be re- ring with a trapezoidal cross-section.
tempered. The gear wheels are force fitted at the
front end of the crankshaft. They are used to drive The middle piston ring is a taper face ring (the outer
the camshaft, injection pump and oil pump. In diameter has a conical surface).
addition, the front end of the crankshaft has key-ways The oil scraper ring is sprung and has two chrome-
for seating the drive hub. The V-belt pulley and the plated scraping edges.
torsional vibration damper (with rubber element) are
fitted on the hub. The front PTO shaft (if fitted) is also The pistons are ring carrier pistons (the piston has a
driven via this hub. An oil deflector ring is fitted special cast iron ring carrier cast into it to seat the top
between the hub and gear wheel and a dust seal is piston ring). The friction surface of the piston skirt
fitted on the hub to protect the crankshaft sealing also has a graphite coating to ensure optimal
ring. The transmitter wheel for the engine speed running-in.
sensor is fitted on a crankshaft web. In the case of engine types 620.97, 620.98 and
A crankshaft bearing is located on both sides of each 620.99, the piston head is cooled from below by
cylinder. There are thus seven crankshaft bearings. additional oil spray as soon as the oil pressure
The crankshaft axial bearings are located on both exceeds 3 bar.
sides of the rearmost crankshaft bearing. The
flywheel is mounted at the rear end of the crankshaft
and carries a force fitted crown gear.
The forged con-rods have an I-shaped cross-section.
The con-rod bearing is split horizontally. The bearing
cover is secured by means of two special bolts. The
upper part has a wedge-shaped bearing seat in
which the small end bearing bush is force fitted.
The piston is made of an eutectic aluminium alloy.
There is a combustion space in the piston head. The
shape of the optimised combustion space ensures
an optimal carburetion of air and fuel. The pistons
have different types of piston rings depending on the
engine type (see next paragraph).

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SS03G080

Timing gears
The engine control gear wheels are hardened in the area of contact and have a helical gearing.
The gear wheels are located in the timing gear case, which is fitted at the front of the engine.
The timing gears drive the camshaft, the fuel injection pump and the oil pump.
The intermediate wheel runs in pressure-lubricated friction bearings (like the camshaft).
The bearing journal is fixed to the front surface of the cylinder block.

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7
6
5
1 5. Main oil duct
Lubrication system
The engine is equipped with a pressure lubrication
system, in which the oil pump (gear pump) is fixed to
the lower part of the cylinder block. The pump sucks
the oil in via an intake sieve. From the pump, the oil is
fed through an oil line to the oil cooler (heat
exchanger) and to the oil filter. The oil pressure valve
is located parallel. The oil is then fed into the main oil
duct, from which other oil bores branch off. The oil
flows through the oil bores to the crankshaft bearings
and through the crankshaft to the con-rod bearings.
The pressure oil flows from the main oil duct to the
turbocharger and to the air compressor (if fitted). In
addition, the intermediate gear wheel bearings,
camshaft bearings and valve mechanism are
lubricated with pressure oil via the main oil duct.
In the case of engines 620.97, 620.98 and 620.99, the
piston heads are sprayed with oil from below and
cooled as long as the lubrication oil pressure is higher
than 3 bar.
Sva 6-51250 EN
Lubrication system
1. Lubrication oil pump
2. Oil pressure valve
3. Oil filter
4. Turbocharger
6. Oil spray nozzles
7. Oil pressure switch
SS99N019
The oil pressure valve regulates the lubrication oil
pressure so that a constant value is maintained
independent of the engine speed. Depending upon the
grade of oil, the engine speed and temperature, the oil
pressure lies between 2.5 - 5 bar.
The oil pressure must be at least 1.0 bar at idling
speed.
The oil filter is a one-way main stream filter. An
overflow valve, on the underside of the filter, ensures
reliable engine lubrication after cold starting at
extremely low outside temperatures and sufficient
lubrication in the event of a filter blockage. A non-
return valve prevents the filter being completely
drained of oil after switching off the engine.
The oil pressure switch opens at a pressure of
> 0.5 bar.
Edition 07/2003
 2002-23

5 7

7
6

SS03G023

Cooling system
1. Coolant pump 5. Expansion chamber
2. Thermostat 6. Oil cooler
3. Bypass channel 7. Engine temperature sensor
4. Radiator

Cooling system
The belt-driven coolant pump is located at the front
end of the cylinder block. The thermostat housing
is situated above the pump. The cooling system is
equipped with two thermostats, which control the
coolant flow. The thermostats have different C
opening temperatures. If the coolant temperature
lies below the opening temperature, the coolant (A)
circulates back to the coolant pump via the bypass
channel. The smaller, single-action thermostat (1)
starts to open at 79 °C and lets some of the B
coolant (B) flow into the radiator. When the engine 1
temperature increases, the dual-circuit
thermostat (2) also starts to open at 83 °C. It
closes the bypass when it opens and allows all the 2
coolant (C) to flow into the radiator. A

SS00F031

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Fan
VISCO FAN REVERSIBLE FAN

SS03G024

SC03G004

Visco fan with modulating hub (standard equipment)

In the case of the modulating hub, every flow air temperature corresponds to a certain slip.
As long as there is little or no requirement for cooling, the fan rotates at low speed (= high slip), but dependent on
the engine speed. The air flow through the cooler/radiator assembly (air conditioning condenser, charge-air
cooler, transmission oil cooler, radiator for engine coolant) acts on the front of the Visco hub. A bimetal spring
located here continuously measures the discharge temperature behind the radiator (coolant). As the discharge
temperature increases (loading on the tractor increases), the control valve reduces the slip and the fan rotates
faster according to the temperature until the minimum slip of approx. 5 % is reached. When the discharge
temperature decreases (loading on the tractor decreases), the control valve increases the slip and the fan rotates
slower according to the temperature.
The Visco fan with a modulating hub has the following advantages: More exact adaptation of the cooling
performance to the tractor load, reduction of the fan’s power consumption and noise level.
The Visco fan is maintenance-free.
Reversible fan (optional equipment)
The blades on the reversible fan can be rotated on the hub. Integrated thermoelements vary the angle of the
blades during operation and the cooling performance of the fan is adapted to the cooling requirements. Return
springs hold the blades securely in position.
The following automatic process is activated on pressing the "Fan reversal" button:
The electronic central control unit (ECCU2) controls a small electric motor-operated air compressor and a
solenoid valve. This control unit is fitted on the left-hand side of the engine. Compressed air is supplied via a
pressure line and a special seal to the control cylinders (that rotate with the hub and blades) and turn the blades.
A powerful stream of air then blows in the opposite direction through the radiator/coolers and any grass,
blossoms, insects, etc., which have been sucked in are removed from the radiator/coolers. The blades
automatically return to their original position after 30 seconds. The fan reversal function can also be activated
automatically when programmed accordingly by the driver, i.e. in conjunction with automatic processes
concerning the front or rear hitch or EHS auxiliary valves.

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SC03G006

Intake/exhaust system
The filter system for the engine intake air comprises a The turbocharger is lubricated and cooled by oil from
pre-cyclone filter (integrated into the air filter) and a the engine lubrication system.
dry air filter with safety cartridge. The intake air is
Charge-air cooling
rotated in the pre-cyclone filter. This removes heavy
dirt particles, which are then discharged via the pre- The intake air compressed by the turbocharger can
cyclone filter’s dust discharge valve. reach a temperature of up to 150 °C under extreme
conditions. It is cooled down to 50 - 60 °C in a charge-
Ejector
air cooler (air/air version) located in front of the
The tractor can be equipped with an ejector system for radiator. The cooling of the charge-air reduces the
use in extremely dusty conditions. The exhaust pipe is thermal and mechanical strain on the engine and
fitted with an injector and there is a permanent suction reduces the discharge of nitrogen oxides and soot
effect at its hose connection when the engine is particles.
running. The dust particles separated in the pre-filter
Charge-air pressure/temperature
are continuously sucked in via a hose connection and
as engine control variables
discharged together with the exhaust gases.
A combined sensor is located in the air collector. It
Filter cartridges
continuously supplies information about the charge-air
The dirt particles in the air are collected in the main pressure/temperature to the electronic engine
cartridge, which can be cleaned as required. The management (EEM2). Fuel injection is optimised in
internal safety cartridge stops dirt particles getting into conjunction with the electronic injection control
the engine in the event of the main cartridge breaking system, thus substantially reducing the discharge of
or being fitted incorrectly. nitrogen oxides and soot particles.
Filter service indication The charge-air cooler is easy to service. It can be
folded up and can thus be effectively cleaned against
A differential pressure switch is located in the filter
the direction of the flow of outside air. By folding up
housing. This switch makes an indicator lamp on the
the charge-air cooler, the other coolers are easier to
ADIC light up when the air filter reaches a certain
access.
degree of soiling. The intake system also comprises
the air lines between the air filter and the
turbocharger, between the turbocharger and the
charge-air cooler and between the charge-air cooler
and the inlet manifold.
The exhaust manifold is fixed to the cylinder head by
means of special bolts, without a separate seal.
The special bolts do not have to be re-tightened.

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ELECTRONIC ENGINE CONTROL SYSTEM – EEM2

The electronic engine control system comprises the electronic engine control unit (EEM2), several sensors and
control switches, the electronic injection pump control unit (PCU) and the necessary cabling, including the
CAN connection between the EEM2 and PCU.

6 7

3
5

8 4

10

SC03G007

11

1. Engine control unit (EEM2) 7. Charge-air pressure/temperature sensor (B29)

2. Injection pump control unit PCU (A2/2) 8. Engine temperature sensor (B22)
3. Oil pressure switch (S6) 9. Test switch, fuel delivery pressure (B21)
4. Speed sensor (B20) 10. Fuel delivery pump (M13)
5. Heater flange (E10/1) 11. Optional equipment, sensor B23
6. Power relay (K8/2) "Water in fuel"

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Layout

DZG = Signal, crankshaft position

A2/2
(top dead centre)
PCU
MAB =Signal, emergency engine
shut-down

CAN H

CAN L

MAB
DZG
Switch S6
A2
Oil pressure

Sensor B29
Charge-air pressure
Charge-air
Starting aid E10/1
temperature
(heating flange)

Sensor B22
Coolant temperature
EEM 2
M13 Fuel
Test switch B21 feed pump
Fuel delivery pressure

Switch S22
Sensor B23 Coolant level
"Water in
fuel"
Sensor B2/1
Fuel level
Sensor B20
Engine speed and
crankshaft position

Limp home
A1
ADIC
Sensor B28
Man. oper.
accelerator slider
CAN H

CAN L

DISPLAY Warning
Fuel
level
too low
ARU

Warning Warning
Fuel
Coolant level feed pressure
too low
R8 sensors A4
Accelerator pedal FMGR Warning
Water in fuel
(optional extra)

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2002-28
Signals
The EEM2 receives values for various parameters which are important for controlling the engine.

Analog signals (voltage) Digital signal (level)

 Coolant temperature (from sensor B22)  Fuel delivery pressure
 Charge-air temperature (from sensor B29)
(from test switch B21)

 Charge-air pressure (from sensor B29)

 Engine oil pressure (from test switch S6)

 Water in fuel (from sensor B23)

Digital signal (CAN messages)

 Engine setpoint speed for Limp home

(from accelerator pedal sensor R8)
Digital signal (Frequency)
 Engine speed (from sensor B20)
Digital signal (coding)
 Crankshaft position (from sensor B20)
 Drive commands (from FMGR)
 Injection pump speed (from PCU)
 Actual start of delivery (from PCU)
 Spray adjustment angle (from PCU)
 Fuel temperature (from PCU)

Function
The EEM2 always has continuously updated values for various parameters which are important for controlling the
engine at its disposal. The EEM2 electronics evaluate this data and send corresponding control commands in the
form of CAN messages to the electronic control unit for the injection pump. Control variables such as the
maximum injection volume or start of delivery are continuously adjusted (in real-time). This ensures an optimum
engine power curve and torque increase, high economy and conformance with the more stringent emission
standards which are now valid. For Europe: 97/68 EC Level 2. For America: Tier 2.
Control variables which influence the dynamic delivery start
 Engine speed
 Engine load
 Coolant temperature
Control variables which influence the maximum injection volume
 Torque characteristics
 Coolant temperature
 Charge-air pressure
 Certain faults which occur (e.g. incorrect injection pump Serial No. in the EEM2 software, fault code 175).
Idling speed
The idling speed and final idling speed are electronically controlled and cannot be changed. Readjustment is not
necessary.
Engine protection when exceeding limit values
If limit values are exceeded, the engine control system intervenes to protect the engine. The engine power/speed
is reduced and the fuel injection is stopped as required, thus shutting down the engine.
Fault Detection
If a fault occurs, a fault warning appears on the ADIC and the corresponding EEM2 fault code is shown on the
display on the A column.
The fault can be localised and remedied by means of the CNH Service Tool. Also refer to Chapter 4011, Fault
codes.
127( Function, fitting and removing the injection pump, checking the delivery pressure, checking the injection
nozzles: see Chapter 3001 – Functional description of the injection system.

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JOB INSTRUCTIONS
1. Cylinder block
A. Measuring the cylinder liner wear
1. Set the dial test indicator to zero by means of a
micrometer screw or using a new cylinder liner (initial
dimension 108.00 mm).
2. Thoroughly clean the inner surface of the cylinder
liner before the measurement.
SS99N036
3. Measure cross-wise at the top end, bottom end
and in the middle of the cylinder liner.
4. Check the displayed value for max. wear and
ovality (compare with nominal values).
B. Removing the cylinder liner
1. If the cylinder liners are to be re-used, they must
be marked so they can be re-fitted in the same
positions.
2. Remove the cylinder liners using the 380000011
and 1TSW 510 extraction tools.
Sva 6-51250 EN
2002-29
1TSW 510
380000011
SS99N037
C. Checking the cylinder block
1. Clean the cylinder block and all oil lines.
2. Check the cooling channels and remove scale and
dirt deposits in order to ensure correct engine
cooling.
3. Check the tightness of the shell plugs and screw
plugs in the cylinder block and make sure the
cylinder block and sealing surfaces are in good
condition.
4. Measure the wear on the camshaft bearings
(compare with nominal values).
127( If the surface of the cylinder block has to be
re-ground, the pistons must be shortened by a
corresponding amount. Pay attention to the valve
head clearance at the top surface of the piston.
D. Replacing the camshaft bearing bush
1. Pull the bearing bush out using an internal
extractor. After removing the rear camshaft end
support piece, the bearing bush can be driven out
using a long drift.
2. Clean the bush seating.
0.1 - 0.4 mm
SS99N038
Edition 07/2003
2002-30
3. Press fit a new bearing bush. Pay attention to the position of the oil bore hole. The bearing bush does not have
to be reamed as it has the correct inner diameter if it is fitted correctly.
127( All camshaft bearing points are fitted with a separate bearing bush. Pay attention to the different outer
diameters when removing and fitting the bearing bushes.

5 4 3 2 1

SS99N039

The numbering starts at the front end of the engine.

Bore hole diameter
1. 55.62 - 55.65
2. 55.42 - 55.45
3. 55.22 - 55.25
4. 55.42 - 55.45
5. 55.64 - 55.67

E. Oversize bearing bushes for the camshaft

If the seat of the camshaft bearing bush (front bearing) is damaged, a bearing bush with an oversize outer
diameter of 0.4 mm can be fitted. The machining dimensions for the bearing bush seats are shown in the figure.
:$51,1*Observe the position of the bearing bush oil bore holes. (see section A-A)
The bearing bushes do not have to be reamed after being fitted.

266 mm
272 mm
134 mm
A-A 7,2...8,0 mm
A

0,1...0,4 mm

5 4 3 2 1

A SC03G008

Camshaft oversize bearing bushes

Bore hole diameter
1. 56.02 - 56.05
2. 55.62 - 55.65
3. 55.42 - 55.45
4. 55.62 - 55.65
5. 55.84 - 55.87

The numbering starts at the front end of the engine.

Sva 6-51250 EN Edition 07/2003


F. Fitting the plug at the rear camshaft
end
max. 1,0 mm
SC03G009
1. Clean the plug seating.
2. Apply sealant (e.g. Loctite 572) to the contact
surface of the plug.
3. Drive the plug in using pressing tool 380000004.
127( Do not drive the plug in too far, as it could
impair the axial play of the camshaft.
G. Fitting the plug at the rear camshaft
end after inserting an oversize bearing
bush
O-ring
Plug
SS00F003
Upon completion, the rear camshaft end plug is
replaced by the plug and the O-ring.
H. Installing the oil dipstick tube
1. Clean the tube seating.
2. Apply locking fluid (e.g. Loctite 601) to the bottom
end of the tube.
3. Drive the guide tube into the cylinder block to the
dimension shown in the figure.
Sva 6-51250 EN
2002-31
111 mm
SS99N045
127( The position of the tube influences the
measured engine oil level.
I. Fitting the cylinder liner
1. Clean the cylinder liner and liner recess in the
cylinder block. Without the O-ring, it must be easy to
turn the liner to its installation position.
2. Apply a thin coat of marking paint to the underside
of the cylinder liner flange. Fit the cylinder liner
without O-rings and turn it back and forth. Remove
the cylinder liner and check whether there is paint
over the entire contact surface.
3. Clean the contact surfaces.
0.03 - 0.08 mm
SS99N048
4. Fit the cylinder liners and secure each liner using
two clamps. Measure the cylinder liner height using a
dial test indicator and the holder (380000364). Set
the dial test indicator to zero on a flat surface, e.g.
the cylinder block. Measure each cylinder liner at four
points. The cylinder liner should protrude from the
top of the cylinder block by 0.03 - 0.08 mm.
Edition 07/2003
2002-32
The difference in height between the cylinder liners
below a cylinder head must not exceed 0.02 mm. In
addition, a middle cylinder liner must not be lower
than one of the outer ones.
5. If the cylinder liner height is insufficient, a liner with
a higher flange must be fitted.
7. Insert the O-rings in the grooves in the lower
cylinder section and lubricate them with liquid soap
(not with oil).
127( Stretch the O-rings as little as possible when
pulling them onto the cylinder liners.
The max. permissible elongation is 6 %.

SS99N049

Height Marking
(H) grooves
(quantity)

9.03+0.02 (standard)

9.08+0.02 1 SS99N051

9.13+0.02 2
8. Press the cylinder liners into the cylinder block. It
9.23+0.02 3 should be easy to press them into their initial
position. Make sure the cylinder liners do not move
An oversize of the cylinder liner (higher flange) is upwards once they have been fitted.
marked as follows on the outer circumference by
means of one or more marking grooves:
1. oversize, 0.05 mm = 1 marking groove
2. oversize, 0.10 mm = 2 marking grooves
3. oversize, 0.20 mm = 3 marking grooves
6. If the height of a cylinder liner is not the same over
the entire circumference, the cylinder liner flange and
recess depth must be checked. Cylinder liners with
warped flanges must be replaced. If necessary, ream
the liner seating in the cylinder block.

BLACK

GREEN

SS99N050

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 2002-33
2. Flywheel casing
Spacer ring
A. Fitting the flywheel casing
The flywheel casing is centred on the cylinder block
by means of two sprung dowel pins. The flywheel
casings, which are also available as a spare part, are
supplied with the bore holes for the pins.
1. Clean the sealing surfaces between the cylinder
block and flywheel housing.

SS99N054

127( If the crankshaft is worn at the sealing ring

seat, a 2 mm spacer ring (available as a spare part)
can be fitted between the flywheel casing and the
crankshaft sealing ring.
5. Carefully press the sealing ring in down to the
bottom of the flywheel casing using the 380000003
and 1TSW 662 fitting tools.

1TSW 662
SC03G010

2. Apply sealant (e.g. silicone) to the points shown in

the figure.
3. Lift the flywheel casing to the correct position and
insert all the bolts.
4. Centre the casing and fit the sprung dowel pins
using a mandrel.
380000003 SS99N056
5. Tighten the inner ring bolts to a torque of 80 Nm
and the outer ring bolts to a torque of 150 Nm. 127( Assembly of the sealing ring must be carried
out in a dry and oil-free state.
B. Replacing the rear crankshaft sealing
ring
1. Separate the tractor between the engine and
power unit.
2. Remove the flywheel.
3. Remove the sealing ring without damaging the
crankshaft.
4. Clean the sealing ring seat and grind away any
burrs.

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2002-34
3. Cylinder head
A. Removing the cylinder head
1. Clean the outside of the engine.

Drain plug

SS99N057

1. Screw a nut on a grub screw for the rocker arm

mechanism. There is no grub screw for the valves for
the middle cylinders. A screw of an appropriate
length should be used instead.
2. Compress the valve springs by means of lever
SS99B056 380000008. Remove the valve spring seat retainers,
the spring guide and the spring. Remove the valves.
Drain the coolant at the engine drain plug and the
drain cock on the underside of the radiator.
Disconnect the coolant hoses from the cylinder head
C. Checking the cylinder head
and the thermostat housing. 1. Remove carbon deposits in the outlet channels,
clean the sealing surfaces and wash the cylinder
2. Remove the intake lines between the exhaust
head.
turbocharger and the air filter and the charge-air lines
from the turbocharger and the intake manifold. 2. Check the cylinder head for cracks and any other
damage.
3. Remove the oil lines from the exhaust
turbocharger.
4. Remove the injection lines and leak oil collectors.
Remove the nozzle holders. Fit all open connections
with sealing caps.
5. Remove the intake and exhaust manifolds as well
as the thermostat housing.
127(It is also possible to remove the cylinder head
even when these parts are still fitted.
6. Remove the valve cover and air bleed hose.
SS99N058
7. Remove the rocker arm mechanism and the push
rods. 3. Check the evenness of the cylinder head using a
8. Loosen all cylinder head bolts by a ¼ of a straightedge. An uneven or bent surface must
revolution and then unscrew them. Remove the undergo surface grinding. After being ground, the
cylinder head. height of the cylinder head may not be less than
104.00 mm. The valve disk depth from the surface of
the cylinder head must be 0.60 mm for outlet valves
B. Removing the valves
and 0.70 mm for inlet valves.
Make sure that those valves which are to be re-used
are marked accordingly, so that they can be re-
inserted in their original seating.

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 2002-35
D. Replacing the valve guides

SS99N059

4. If necessary, clean the nozzle holder contact

surface in the cylinder head using a reamer.

SS99N061

1. Press or drive the old guides out using a mandrel.

Clean the valve guide seats.
2. Fit the new guides using pressing tool 380000007,
thus ensuring the correct installation height (21 mm
above the end face of the spring).

380000007

SS99N060

5. Measure the clearance between the valve stem

and guide by means of a dial test indicator. Lift the
valve so that the valve disk juts out of the surface of
the cylinder head by 15 mm mm and measure the
clearance. In the case of inlet valves, it may not
exceed 0.30 mm and 0.35 mm for outlet valves. To 21 mm
determine whether the valve guide is worn, a new
valve must be used for the measurement.

SS99N062

3. The same guides are used for inlet and outlet

valves. Make sure the steepest chamfer on the guide
points towards the valve spring. Also make sure the
valves do not stick in the guides.

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2002-36
E. Machining the valve seat Inlet valve
11±0,1 mm

48,500...48,525 mm

SC03G030

SS99N063
A damaged valve seat must be machined using a
milling cutter. If the width of the seat exceeds 2.3 mm
in the case of an outlet valve and 3.7 mm in the case
of an inlet valve, then it has to be reduced at the
outer edge, in particular.
The valve seat angle is 45°+20’ for outlet valves and
35°+20’ for inlet valves.
3. Clean the valve seat. Cool the new valve seat ring
in dry ice of liquid nitrogen.
4. Fit the valve seat ring using a suitable pressing
tool. Re-work the seat.
G. Grinding the valves
In order to ensure that a sufficient sealing effect is
attained around the valves, there are different sealing
surface angles. Thus, there is a particularly narrow
sealing surface, which ensures an effective sealing
effect even after prolonged operation.

F. Replacing the valve seat rings

The outlet valves are equipped with separate valve
seat rings. If the sealing surface is so badly damaged B
that it cannot be repaired, then the valve seat rings
have to be replaced. A

1. Grind the valve disk on a disused valve so that it C

fits snugly in the valve seat. Fit the valve and weld it
to the seat in the regular way. Cool it with water.
2. Turn the cylinder head round and drive the valve
out together with the seat. SC03G011

Outlet valve
A B C (mm)
10,1 mm -20’ +20’
INLET 35° 35° 0.7
-20’ +20’
OUTLET 45° 45° 0.6

1. Grind the damaged valve disk using a valve

grinding tool. Adjust the angle to 45°-20’ for outlet
valves and 35°-20’ for inlet valves.
44,000...44,025 mm
2. If the height of the edge of the valve disk is less
than 1.5 mm after grinding or the valve stem is bent,
the valve must be replaced.
SC03G029 3. Grind in the valves using grinding paste and check
the contact surface with marking dye.
4. Clean the grinding paste off the cylinder head and
valves.

Sva 6-51250 EN Edition 07/2003


H. Fitting the valves
1. Use a spring tester to check the straightness,
length and tension of the valve springs. Compare
these values with the technical data.
2002-37
127( From engine serial no. N 8957 (see Engine
code and serial number, page 7), steps 6 to 8 can be
skipped (modified cylinder head gasket).
1. Pre-tension of 80 Nm

2. Lubricate the valve stems and insert the valves in
the cylinder in the correct order.
3. Fit the valve springs, valve disks and valve spring
seat retainers in the cylinder head with the aid of
lever 380000008.
4. After inserting the valves, tap the ends of the valve
stems, e.g. with a plastic hammer, to make sure the
valve spring seat retainers are sitting correctly.
I. Fitting the cylinder head
1. Measure the length of the cylinder head bolts. The
length should lie within the limit values specified in
the figure. If this is not the case, the bolt must be
replaced.
2. Tighten by 90°.
3. Tighten by 90°.
4. Adjust the valve clearance (see page 39).
5. Fit the other engine parts, add coolant and
engine oil.
6. Let the engine run at low load until it reaches a
coolant temperature of 75 °C.
7. Tighten by 60°.
8. Adjust the valve clearance.
127( The cylinder head bolts do not have to be
tightened again after this procedure.

max. 142 mm

50 Nm

max. 188.5 mm

SS99N066

2. Screw the cylinder head grub screws into the SC03G012

cylinder head and a tighten them to a torque of
30 Nm. Insert the push rods, if they have been Tighten the exhaust manifold securing bolts/nuts to a
removed. torque of 50 Nm.
3. Make sure the sealing surfaces are clean and fit
the cylinder head gasket. Use a ruler to make sure
the cylinder heads are parallel to each other. Clean,
oil and insert the bolts.

SS99N067

4. The figure shows the bolt tightening sequence.

The correct sequence is also cast into the cylinder
heads.
5. Tighten the bolts in phases as follows:

Sva 6-51250 EN Edition 07/2003

2002-38
4. Valve mechanism
60°
A. Maintenance of the rocker arm system
1. Check the valve tappets, particularly the guide
surface on the camshaft. Replace worn and bent
valve tappets.

SS99N073

5. Fix a flange seal on one end of the rocker arm

shaft. Lubricate the shaft and assemble the parts in
the correct order. Make sure the shaft and the
bearing retainers are in the right position. The split
side of the retainers and the oil bore holes in the
shaft must be on the valve side, as shown in the
SS99N070 figure. Fix the other flange seal

2. Check the straightness of the push rod. Also check

the condition of the spherical faces at the ends of the
push rod.
3. Dismantle the rocker arm mechanism and clean
the components. Check the rocker arm shaft for wear
and the condition of the oil lines.

SC03G014

23,000...23,021
SC03G013 B. Replacing the camshaft/camshaft gear
wheel
4. If the pressure surface of the rocker arm is worn,
grind it until it has the right shape. Do not grind off 1. Remove the suction pipe between the
more than necessary as the pressure surface is turbocharger and the intake manifold. Remove the
hardened. cover for the valve mechanism and the bleed pipe.
Remove the rocker arm mechanism.
2. Remove the cooler/radiator assembly, fan,
alternator and the V-belts.
3. Loosen the crankshaft nut. Remove the V-belt
pulley with the hub (loosen the belt pulley first).
4. Remove the control box cover.
SS99N072

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 2002-39
C. Checking and adjusting the valve
clearance

0,35

SS99N075

5. Lock the valve tappets so that they do not fall down

on removing the camshaft and impair the installation
of the camshaft. Raise two adjacent valve push rods
by tilting them towards each other. Clamp adjacent
push rods together to form a pair (e.g. using an
O-ring) so they are under slight tension and the
tappets remain in the top position.
:$51,1* Excessive tensioning of the push rods
causes deformation.
SC03G015
The inlet and outlet valves have a clearance of
0.35 mm. It can be checked when the engine is hot
or cold. Check and adjust the valve clearances of a
cylinder whilst the piston is at top dead centre of the
compression stroke. Proceed according to the
injection sequence of the engine.

6. Turn the crankshaft, so the positioning marks on If the valve clearance deviates from the specified
the camshaft gear wheel and intermediate gear value, loosen the locking nut and adjust it to the
wheel coincide. Pull the camshaft out. correct value via the adjusting screw. A 0.35 mm
feeler gauge must fit tightly between the rocker arm
7. Loosen the camshaft gear wheel using a suitable and the end of the valve stem.
mandrel.
8. If the used camshaft or camshaft gear wheel is
going to be re-fitted, clean them before assembly.
9. Push the feather key into the corresponding
groove in the camshaft. Heat the camshaft gear E A E A E A E A E A E A
wheel up to 200 °C and fit it in the corresponding
position.
SC03G016
10. Grease the bearing surfaces and press the shaft I = INLET
into the cylinder block, paying attention to the
position marks on the camshaft gear wheel. O = OUTLET

11. Fit the control box cover and the belt pulley with
the hub.
12. Release the push rods and fit the rocker arm
mechanism. Adjust the valves. Then screw the valve
cover and air bleed hose onto the cylinder head. Also
fit the suction pipe between the turbocharger and
intake manifold.
13. Fit the alternator and V-belts. Tension the V-belts
accordingly. Fit the cooler/radiator assembly.
– turn the crankshaft in the direction of rotation until
the valves of cylinder 6 overlap. (Outlet valve closes,
inlet valve opens). Check the valves of the first
cylinder.
– turn the crankshaft 1/3 of a revolution in the
direction of rotation so that the valves of the 2nd
cylinder overlap. Check the valves of the 5th cylinder.
– continue work in the sequence of injection:

Injection sequence: 1 5 3 6 2 4

Valve overlap: 6 2 4 1 5 3

Sva 6-51250 EN Edition 07/2003

2002-40
5. Crankshaft For the correct undersize and corresponding
bearings, refer to the technical data. Make sure the
A. Removing the crankshaft radii do not change during the grinding process.

1. Unscrew the sump

2. Unscrew the securing bolts for the lubrication oil
pump pressure line in the cylinder block. Remove the
oil pump and the intake/pressure lines.
3. Remove the flywheel casing.
4. Remove the belt pulley/hub from the front end of
the crankshaft (also refer to the instructions
concerning the timing gears page 47).
5. Remove the con-rod bearing covers and push the
con-rods up so they are not in the way when SS99N079
removing the crankshaft.
6. Remove the crankshaft bearing covers and lift the
crankshaft out. 127( In the event of the crankshaft bearing base
bore holes being damaged or worn as a result of
bearing damage, crankshaft bearings are also
B. Checking the crankshaft available as a spare part with an oversize of 1.0 mm
(outside dimension) and an undersize of 0.5 mm
(inside dimension). The cylinder block must now be
machined to a dimension of 92.000 - 92.025 mm.
The crankshaft must be machined to a dimension of
84.485 - 84.520 mm. The bearing shell with a groove
and oil bore hole is fitted in the cylinder block and the
bearing shell without an oil bore hole in the bearing
cap.

C. Replacing the crankshaft gear wheels

1TSW 662

SS99N078

1. Clean the crankshaft. Do not forget to clean the oil

bore holes.
2. Measure the wear on the crankshaft bearing
journals at different points. Ovality, conicity or other
wear must not exceed 0.03 mm.
SS99N080
3. Insert the bearing caps with new bearing shells
and tighten them to the correct torque. Measure the 1. Attach an extractor to the crankshaft gear wheels
inner diameter with a dial test indicator, which has and pull off both gear wheels.
been reset to zero according to the dimensions
2. Clean the seat on the crankshaft using a wire
measured under item 2. The indicator thus displays
brush, for example.
the actual bearing play. If the bearing housing which
shows signs of wear is not round, take 3. Heat up the new gear wheels to 200 °C. Drive the
measurements at several points. gear wheels onto the shaft using a suitable sleeve or
soft mandrel. Pay attention to the position of the
4. If the bearing play exceeds 0.18 mm for the
feather key and make sure the alignment marks on
crankshaft bearings or 0.14 mm for con-rod bearings
the front gear wheel are visible. Allow the parts to
with new bearing shells, the bearing journals on the
cool down.
crankshaft must be ground.

Sva 6-51250 EN Edition 07/2003

 2002-41
D. Fitting the crankshaft 4. Insert the crankshaft bearing covers according to
their numbering, with axial bearings at the rear,
1. Clean the oil lines, bearing shells and seats. Make which have got joggles. Lubricate the bolts and
sure the crankshaft is clean. tighten them to a torque of 200 Nm.

0,10...0,38 mm

B
A

SC03G018

5. Make sure the crankshaft turns freely and without

SS99N082 sticking. Check the axial play using a dial test
indicator. The correct axial play is approx.
2. Fit a bearing shell (A) with an oil bore hole and oil 0.10 - 0.35 mm. If there is excessive axial play,
groove in the cylinder block and a bearing shell (B) oversized axial bearings must be fitted.
without an oil bore hole in the bearing cover. Make
sure the bearing shell joggles engage in the 127( The bearing shells may never be reamed or
corresponding notches and that the shells to be fitted machined and the sides of the bearing covers may
in the cylinder block have an oil bore hole which not be filed.
aligns with the oil bore hole in the cylinder block.
E. Crankshaft hub
3. Lubricate the bearing surfaces and fit the
crankshaft.
127( Check the transmitter wheel for the speed
sensor and do not damage it when fitting the
crankshaft!
Insert the axial bearings for the crankshaft so that the
lubrication grooves point towards the crankshaft.

200 Nm

SS99N085
7

When fitting the hub at the front end of the

crankshaft, make sure it is in the correct position
(injection mark on the vibration damper). The hub
has an installation marking: -- both lines on the hub
must lie adjacent to the dot marking • on a crankshaft
6

tooth.

SC03G017

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2002-42
F. Replacing the crankshaft belt pulley G. Checking the rubber element in the
and the vibration damper vibration damper

A
1.5 mm

SS00E039
SS99N087
1. Loosen the alternator securing bolts and remove
the V-belt. 1. If the lines (A) are misaligned by more than
1.5 mm, the vibration damper must be replaced.
2. Unscrew the bolts holding the belt pulley and
vibration damper and remove the parts. The belt OK
pulley and vibration damper are pinned together with
the crankshaft hub (injection mark on the vibration
damper).
3. Fix a new vibration damper or belt pulley onto the
crankshaft. Drive the dowel pins in and tighten the
securing bolts to a torque of 30 Nm.
127(Vibration dampers (belt pulleys) supplied as a
spare part do not have an injection marking. New
OK
vibration dampers must be marked after being fitted.
4. Turn the crankshaft until the piston of the first
cylinder is at top dead centre (TDC). Let the valve fall
against the cylinder head. Mount the dial test
indicator at the top of the valve stem and set it to zero
when the piston is at top dead centre. Then turn the
crankshaft against the direction of rotation until the OK
dial test indicator reads approx. 15 mm below TDC.
Then slowly turn the crankshaft in the direction of SS99N088
rotation until the dial test indicator shows the value
which corresponds to the injection marking (see table 2. Also check the condition of the rubber element. If
below). pieces of rubber are missing or the rubber part is
more than 3.5 mm below the surface, or if a forward
127( The setting value is 30° before TDC for all
motion of the inertial component (outer ring) is
engines.
discernible, the vibration damper must be replaced.
5. Inscribe the injection marking by means of an
electric engraving pen (do not punch it in).
127( Make sure the pointer is not loose or bent
before making the mark.

Piston stroke to top dead centre

in comparison to crankshaft angle
Degrees mm
30 10.213

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 2002-43
6. Pistons and con-rods 3. If the small end bearing bush is worn, it must be
driven out using a suitable mandrel.
A. Removing the pistons together with
the con-rods
1. Unscrew the sump and the lubrication oil pressure
and suction lines.
5
2. Unscrew the cylinder head.
40.025 -
3. Scratch the carbon ridge off the cylinder liner. 40.040
If necessary, scrape off the sharp abrasion edge at
the reversal point of the piston ring.
4. Remove the con-rod bearing covers and bearing
shells. If the bearing shells are to be re-used, their
order must be marked.
5. Push the piston and con-rod up by using the shaft
of a hammer or some similar object.
6. Remove the piston pin circlips. Push the piston pin
SS99N091
out.
127( If the piston pin does not move on applying 4. Press the new bush in. The oil channel in the bush
finger pressure, the piston must be gradually heated must coincide with the corresponding channel in the
up to 100 °C. con-rod. After fitting it, drill a hole with a ∅ 5 mm.
Use a reamer to ream the bush to the correct
B. Checking and replacing the con-rod diameter.
bearings
C. Checking the con-rod
1. Clean the con-rod and bearing shells. Fit the
bearing shells and tighten the old bolts to a torque of Clamp the con-rod in a suitable test device and
40 Nm + 90°. check it. (Test values: see Technical Data, page 13)
127(The con-rod bolts must not be re-used. The con-rods are split into weight groups of 20 g.
A letter designates the weight group. It is marked on
the side of the con-rod. All con-rods in an engine
must belong to the same weight group, which means
the permissible weight difference is 20 g.

SS99N090

2. Measure the inner diameter with a plug gauge,

which has been zeroed at the diameter of the
applicable bearing journal. If new bearing shells have
a clearance of more than 0.14 mm, the con-rod Torx E18
bearing journals must be ground and the next 40 Nm + 90°
bearing shell undersize fitted (repair level). SC03G019

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2002-44
The letter stands for the following weights: 3. Insert the piston ring in the cylinder and measure
Weight: the distance between the ring ends. The distance
measured for the 1st and 3rd rings must not exceed
F 1935 - 1954 g
1 mm and 1.5 mm for the 2nd ring.
V 1955 - 1974 g
4. Re-insert the piston rings with the aid of the piston
X 1975 - 1994 g ring pliers. Make sure the rings are fitted in the right
Y 1995 - 2014 g place and the letters TOP or the manufacturer’s
identification mark on the rings point(s) upwards.
W 2015 - 2034 g
Z 2035 - 2054 g
620.97
G 2055 - 2074 g 620.98
620.99 DS
D. Checking and replacing the piston
rings
1. Release the piston rings using piston ring pliers.
Do not expand the rings more than necessary. If the
same rings are to be re-used, then they should be
kept in the correct order.

620.95
620.96 D

SC03G020

SS99N098

2. Carefully clean the piston ring groove and then

measure the piston ring play in the groove. The play
must not exceed 0.15 mm. Check whether the play is
due to wear in the ring groove. The rings and/or the
pistons must then be replaced accordingly.

SS99N099

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E. Checking the pistons
Inspect the pistons and piston pins by performing a
visual check. Pay particular attention to possible
cracks at the edge of the combustion chamber or at
the upper part of the piston pin bore hole. Measure
the diameter of the piston at the point indicated in the
figure and compare the result with the specified
value. Replace the piston, if necessary.
2002-45
G. Fitting the pistons and con-rods
1. Insert the bearing shells in the con-rods. Make
sure the contact surfaces are clean and the bearing
shells sit correctly.
2. Lubricate the piston, piston rings and cylinder with
engine oil. Turn the piston ring gaps to different sides
of the piston.

∅107.873 -
107.887

17 mm
SS99N101

F. Fitting the piston pin

1. Insert the con-rod in the piston and push the
piston pin to its position.

SS99N103

3. Use a piston ring clamp or tapered installation tool

for fitting. Insert the piston and con-rod so that the
combustion space in the piston and the nozzle holder
in the cylinder head are on the same side (the arrow
on the piston must point forwards).
4. Oil the con-rod bearing journals and bearing shells
and push the piston down. Mount the bearing cover
so that the joggles on the bearing shells are on the
same side. Then tighten the bolts to a torque of
40 Nm+90°.
5. Check whether the lower con-rod bearing has
sufficient axial play on the crank journal.

SC03G021

:$51,1* The combustion chamber in the piston

and the letter for marking the weight class of the con-
rod are on the side.
2. Then fit the circlips for the piston pin. The ends of
the circlips must point upwards.

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2002-46
7. Flywheel
A. Replacing the starter ring gear on the B. Fitting the flywheel
flywheel 1. Clean the contact surfaces on the rear crankshaft
The ring gear cannot be re-finished because the flange and on the flywheel.
teeth on the side of the starter are chamfered and 2. Bolt the flywheel onto the crankshaft. Two M12
hardened. grub screws, which fit into the securing holes in the
1. Free the old ring gear by hitting it with a mandrel. flywheel, should be used as guide pins.
Clean the ring gear seat on the flywheel using a wire 3. Tighten the flywheel bolts evenly to a torque of
brush. 150 Nm.

SC03G022

2. Heat up the new ring gear to 150 - 200 °C. Mount

the ring gear. The chamfered inner edge must point
towards the flywheel and the tooth chamfer towards
the starter.
,03257$17 Allow the ring gear to cool down. Do
not use coolant.

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 2002-47
8. Timing mechanism
A. Removing the timing gear case B. Replacing the intermediate gear wheel
The timing gear case acts as a seal for the sump. bearing bush
127( The timing gear case can only be removed If the intermediate gear wheel bearing bush is to be
after removing the sump. replaced, press in a new bearing bush so that its rear
edge lies within the rear gear wheel edge by
1. Drain the engine oil and remove the sump. 0.1 - 0.25 mm (see fig.).
2. Remove the fan, alternator, belt pulley
and the V-belt. If the tractor is equipped with an 1
air-conditioning system or compressed air system,
the compressor must also be removed. 2
,03257$17 Do not disconnect the refrigerant
lines! Only swivel the air conditioning compressor
with the lines connected (suspend it so that there is
no strain on the lines).
3. Remove the V-belt pulley.
4. Loosen the crankshaft nut.
5. Remove the timing gear case cover and remove
the oil deflector ring from the crankshaft.
6. Remove the injection pump (see Chapter 3001).
127( If the timing gear case is not going to be
replaced, the injection pump can remain in place. In SS99N109
1. Lathe chuck
this case, disconnect all lines and pipes from the
2. Roller ø = 5 mm
pump. Fit all openings on the injection pump with
sealing caps. After fitting, machine the inner diameter of the
7. Unscrew the intermediate gear wheel bolts. intermediate gear wheel bearing bush to the correct
Remove the flange, gear wheel and bearing journal. size. Centre the intermediate gear wheel according
to the above figure so the tooth play is kept even.
8. Pull out the camshaft.
127(If the cylinder head and valve mechanism are
not removed, the valve tappets must be secured
against falling down (refer to instructions in
Chapter 4 B, page 38).
9. Unscrew the bolts on the timing gear case and
remove the timing gear case. If a soft wedge has to
be driven in between the engine block and timing
gear case, make sure the sealing surfaces are not
damaged.
10. Take the front crankshaft sealing ring off the 0.10 - 0.25
timing gear case and clean all parts which have been
removed. 55.00 -
55.03
30 SS99N118

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2002-48
C. Fitting the timing gear case
The position of the timing gear case and the cover is
determined by two sprung dowel pins. It therefore
does not have to be centred for the assembly
process. However, the clearance between various
gear wheels must be checked. The timing gear case
and cover supplied as spares already have bore
holes for the sprung dowel pins.
1. Fit the timing gear case on the cylinder block using
a new seal. Drive the sprung dowel pins in by means
of a mandrel. Tighten the nuts and bolts.
2. Install the injection pump and the injection pump
gear wheel (if removed) (see Chapter 3001).
SS99N112
3. Oil the camshaft bearings and fit the shaft in the
cylinder block. Release the push rods and valve 5. Check the tooth play.
tappets, if they have been suspended. It should be between 0.05 - 0.25 mm.

200 Nm

60 Nm 35 Nm
SS99N113

6. Mount the oil deflector ring on the crankshaft and

fit the timing gear case cover using a new seal. Drive
the sprung dowel pins in, by means of a mandrel
(mate the hollow pin with the grub screw). Tighten
the nuts and bolts to the specified torque.

SC03G023

4. Fit the intermediate gear wheel with the shaft grub

screw and make sure the marks are aligned correctly.
Insert the washer and tighten the bolts to the
specified torque.
127( Remove the assembly pin used for installing
the injection pump.

SS99N114

7. Insert the guard ring correctly in the sealing ring

seat (see sectional drawing) and insert the front
crankshaft sealing ring so that it is seated correctly
using special tool 380000002.

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 2002-49
11. Push the hub onto the profile on the crankshaft.
12. Apply a little oil to the thread on crankshaft nut.
Tighten the bolt to a torque of 1000 Nm.
13. Fit the vibration damper and V-belt pulley on the
hub. Tighten the bolts to the specified torque.
14. Re-fit the other parts which have been removed.

SS99N115

8. If it has been removed, re-fit the dust cap on the

V-belt pulley hub on the crankshaft. To do so, use
pressing tool 380000010.

1000 Nm
SC03G024

9. Lubricate the sealing surfaces on the sealing ring

and crankshaft as well as the profile for seating the
hub.
10. Align the mark on the hub with the mark on the
crankshaft (see graphic).

SS99N085

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2002-50
9. Lubrication system
A. Checking the oil pressure valve
Check whether the oil pressure valve is functioning if
the engine oil pressure is not sufficient or fluctuates
noticeably. However, first check whether there is
enough oil in the engine.
5. Clamp the pump, at the pump gear wheel, in a vice
with protected jaws and unscrew the nut on the drive
gear wheel. Use a plastic hammer to drive the pump
drive shaft off the gear wheel. Pull the drive shaft
gear wheel out of the pump body.
6. Wash the parts and check the wear. Compare the
actual dimensions with the specified values,
page 15, section entitled "Lubrication oil pump".
Replace worn parts and all gaskets.

Gear wheel

25 Nm

Loctite
638
SS00B054

127( Two different valve springs are used,

depending on the engine type. Although the length
(relaxed) of both springs is almost identical, the force
of the tensioned spring is much greater for engine
types 620.97, 620.98 and 620.99.
1. Remove the cover on the oil pressure valve and
the spring located underneath. Pull the valve cone
out of the cylinder block.
2. Clean the parts. Check that the valve cone moves
freely in the valve insert. If the valve cone sticks,
clean out any particles of dirt. If necessary, grind the
parts with fine abrasive wool or use new parts. Clean
the sealing surfaces between the cylinder block and
the cover.
3. Apply Loctite 638 to the outer diameter of the
cylindrical part of the valve insert. Drive the valve
insert into the engine block using a suitable insertion
tool. Insert the valve cone in the valve insert. Fit the
cover and spring using a new cover seal.
127( The spring must be fitted with the larger
diameter towards the cover.
B. Removing and checking the oil pump
60 Nm 0 Nm
+Loctite 243
SC03G025
7. The oil pump bearing points are fitted with
separate bearing bushes. On replacing the bearing
bushes, machine them to the dimension
18.000 - 18.018 mm after fitting them.
C. Assembling and fitting the oil pump
1. Insert the gear wheels in the recess in the pump
body. Fit a new seal between the pump body and
cover (as required). Tighten the securing bolts a little.
Turn the shaft and tap the cover laterally into the
position, in which it rotates most easily. Tighten the
cover securing bolts and check that the shaft still
rotates easily.

1. Drain the engine oil and remove the sump. 2. Mount the drive gear wheel on the pump shaft. Put
screw locking fluid Loctite 243 on the nut thread. Fit
2. Disconnect the intake and pressure lines on the oil the washer and the nut. Tighten the nut to a torque of
pump. 60 Nm.
3. Remove the oil pump and any adjusting disks
between the pump housing and the cylinder block.
4. Release the pump cover and the seal. Remove the
gear wheel fitted on the axle.

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 2002-51
D. Fitting the sump
Fit the sump seal with the silicone strips pointing
towards the cylinder block.

TOP

SS99N126

3. Clamp the pump at the mounting base in a vice

with protected jaws. Check the axial play of the gear SC03G026
wheel (0.03 - 0.11 mm) with a dial test indicator.
Change the number of seals between the cover and
pump body as required. E. Oil cooler
All engine types are equipped with an oil cooler,
which lies between the engine oil filter and the
cylinder block.
1. The coolant must be drained out of the oil cooler
before removing it.

SS99N127

4. Secure the pump in its position below the cylinder

block and use a dial test indicator to check the tooth
play between the crankshaft and pump gear wheels. SS99N129
(0.05 - 0.25 mm). Change the number of shim rings
2. Fit new seals. Mount the oil cooler so that the drain
between the pump base and the cylinder block as
connection points downwards. Secure the coolant
required (shim ring graduation: 0.2 mm). The
hoses in a regular manner.
insertion or removal of a shim ring alters the tooth
play by approx. 0.07 mm. 3. Put some screw locking fluid (e.g. Loctite 243) on
the thread on the engine end of the mounting pipe
127( When measuring the tooth play, the engine
must be in its operating position (cylinders upwards) and tighten it to a torque of 60 Nm.
as the crankshaft bearing play has an effect on the
tooth play.
5. Fix the pump intake and pressure lines, replace
the seals on the mounting flange.
6. Fit the sump and fill the engine with oil.

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2002-52
F. Piston cooling nozzles G. Recommended lubrication oils
The piston cooling nozzles (engine types 620.97, – For engines with a turbocharger
620.98 and 620.99) can be taken out after removing
the sump. The nozzle is equipped with a ball valve. It API CG-4 and CH-4
has an opening pressure of 3±0.25 bar. ACEA E3-96, E4-98, E5-99

°C
40

30

20

SAE 30
10

SAE 20W-20

SAE 20W-40
SAE 15W-40
0

SAE 10W-40
SAE 10W-30
SS99N130
-10
1. Change the valve as required. Unscrew the valve

SAE 5W-30

SAE 5W-40
from the engine and remove the nozzle pipe. Insert
the new valve. -20

-30

-40
SC03G027

SS99N131

2. On assembling the valve, fix the nozzle pipe, as

shown in the figure, at an angle of 90° to the
longitudinal axis of the engine. Tighten the valve to a
torque of 30 Nm. After assembly, check that the
nozzle pipe does not touch the piston or con-rod
when the engine is running.

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 2002-53
10. Cooling system
A. Thermostat
The opening temperature of the smaller, single-
action thermostat is 79 °C.
The opening temperature of the bigger, double-action
thermostat is 83 °C.
If you have doubts about the functionality of the
thermostat, check it as follows:
– place the thermostat in boiling water without it
touching the sides of the vessel.
SS99N140
– the thermostat must start to open within
20 seconds. 4. Pull the impeller off using the 1TSW 662 extractor.

– the thermostat must be fully open after no longer
than 50 seconds. Compare the measured values with
those specified in the technical data.
5. Remove the circlip from the pump body. Use a
hydraulic press, for example, to press the shaft with
the bearing out of the pump body towards the fan.
Clamp the pump body so that the shaft bearing can
be taken out.
6. Remove the axial and shaft seals from the pump
body by means of a mandrel. Clean the parts and
check their condition. Replace worn or faulty parts.
127(If the pump bearings have to be replaced, it is
better to fit the pump repair kit, which also comprises
all seals required for the repair (refer to spare parts
catalogue).

SS00F032

B. Repairing the coolant pump

1. Drain the coolant. Unscrew the thermostat
housing, fan and V-belts.
2. Remove the coolant pump. Take the back plate off
the pump and clean the sealing surfaces.
3. Unscrew the securing nut for the V-belt pulley and
remove the belt pulley. Use the 1TSW 662 extractor,
if required.

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2002-54

1TSW 18390

380000005

SS99N143

SS99N138
7. Use mandrel 380000005 to drive the shaft seal
into the pump body. Mount the bearings and
intermediate sleeves on the shaft. Grease the
bearings with plenty of heat-resistant ball bearing
grease. Fit the shaft and bearings in their place so
that the forces produced by pressing do not act on
the bearing balls. Fit the bearing circlip in its place.
0,8...1,2
10. Fix the back plate using a new seal. To fit the
back plate, use guide pins with a diameter of 8.5 mm
for the bore holes shown in the figure.
C. Coolant quality requirements
– the coolant must conform with quality standard
ASTM D 3306 or BS 6580:1992.
– if there are no frost resistance requirements, a
mixture ratio of 40 % is enough to ensure sufficient
corrosion protection.
– check the coolant (anti-freeze) mixture ratio at
certain intervals. Replace the coolant every two
years.
– the water used must be clean and soft, i.e. it must
not contain any metals and their salts.
,03257$17Never use only water as a coolant.

120 Nm

SC03G028

8. Fit the impeller whilst supporting the other end of

the coolant pump shaft. The clearance (X) between
the pump housing and the impeller is 0.8 - 1.2 mm.
Check that the coolant pump shaft rotates freely.
9. Fix the belt pulley on the shaft and tighten the
securing nut to a torque of 120 Nm.

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11. Intake/exhaust system
An engine equipped with a turbocharger is far more
sensitive to faults and contamination in the intake/
exhaust system than conventional engines. Particular
attention must therefore be paid to the intake/exhaust
system.
A. Checking the air filter
The engine performance and service life are largely
dependent on the condition of the air filter. A faulty air
filter lets dirt particles through, which in the long run
will cause damage to the turbocharger and engine.
A blocked air filter reduces engine performance and
also causes oil leakage through the sealing ring on
the turbocharger shaft.
2002-55
5. Remove the manifold, if necessary. Clean the
sealing surfaces and remove any carbon deposits.
Make sure the sealing surfaces are level. If the
mounting flanges are twisted or the sealing surfaces
scratched, machine the flange or replace the exhaust
manifold.
6. Make sure no loose objects or dirt particles have
ingressed into the exhaust pipe or silencer. Such
loose objects or dirt particles can increase the back-
pressure for the exhaust gases from the turbine
wheel.
C. Checking the boost pressure
The boost pressure should be checked before
removing the turbocharger.

:$51,1* The safety filter located in the main filter

does not have to be cleaned, but must be replaced
as required (refer to operator’s manual).

B. Checking the intake/exhaust system

,03257$17 Leakages in the intake or exhaust
system impair the effect of the turbocharger. Due to
the pressure, even small leaks in the manifold or
turbine inlet flange quickly get bigger. Leakages must
therefore be eliminated without delay.
1. Check the pipes and sealing surfaces between the
air filter and exhaust turbocharger, between the A
exhaust turbocharger and charge-air cooler and
between the charge-air cooler and exhaust manifold.
SC03G033
If the intake manifold is dusty on the inner side, then
there is a leakage in the air filter or in the suction
pipes. Eliminate the leakage. To check the boost pressure, the mini-measuring
connection (380001915) is screwed into the intake
127( Check the condition and tightness of the
manifold instead of screw (A). This applies to all
flexible connection of the charge-air lines to and from
engines. In addition, a mini-measuring line
the charge-air cooler (pivot point) at different pivoting
angles. (380001127) and pressure gauge (380001121) have
to be used.
2. Clean the sealing surface of the intake manifold. Boost pressures see "Engine data", page 9.
Use a straightedge to make sure the sealing surface
is level. If the sealing surface is not level or is
scratched, machine or replace the intake manifold.
Make sure the cylinder heads are parallel to each
other.
3. Insert a new seal and secure the intake manifold.
Tighten the intake manifold securing bolts to a torque
of 30 Nm. Secure the air pipes.
4. Make sure the exhaust manifold does not leak.
Tighten the nuts/bolts to a torque of 50 Nm and
check for damage (cracks, deformation, corrosion,
etc.). Also check the connection between the
turbocharger and exhaust manifold.

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2002-56
D. Checking the turbocharger
If it is assumed that the turbocharger is faulty, the
fault can be determined as follows:
1. Carry out a visual check on the turbine and
compressor wheels. The wings may not show any
signs of damage, deformation or wear caused by
foreign bodies.
2. Check whether oil leaks through the sealing rings
on the shaft in the turbine/compressor housing.
:$51,1* A small amount of oil always comes out
on the compressor side at low idling speeds.
However, there is no need to worry about this unless
a lot of oil is lost.
If the engine does not run properly even though the
turbocharger is not faulty and does not show
excessive wear, the fault could have one of the
following causes:
– a blocked air filter
– a leakage in the intake or exhaust system; a
leaking flange seal
– a faulty or maladjusted injection pump
– faulty or maladjusted injection nozzles
– insufficient fuel pressure (e.g. caused by a blocked
fuel filter)
– weak compression, incorrect valve clearance

SS99N144

3. Check the running play of the turbine shaft. Hold

the probe of a dial test indicator against the shaft and
move the shaft sideways. Also refer to the play
specified under Technical Data.

SS99N145

4. Check the axial play of the shaft. Hold the probe of

the dial test indicator against the end of the shaft
move the shaft axially. Also refer to the play specified
under Technical Data.
If a fault or wear is confirmed, the turbocharger must
be overhauled.

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 2002-57

4
3

1 5

SS99N146

Schwitzer turbocharger S200

1. Compressor housing 5. Bearing bushes
2. Lock nut 6. Turbine housing
3. Compressor wheel 7. Shaft and turbine wheel
4. Bearing housing

E. Fitting the turbocharger 3. Connect the intake/silencer pipe to the

turbocharger.
First, the cause of possible turbocharger damage must
be clarified and eliminated before a new turbocharger 4. Pour clean engine oil into the bearing housing via
is fitted. the oil filler in order to ensure lubrication of the
turbocharger bearings after switching the engine on.
For perfect operation of the turbocharger, it is
important that the engine lubrication oil is changed in 5. Secure the pressure and oil return pipes. Make sure
accordance with the relevant instructions and that the the turbocharger is held completely by the mounting
correct quality class is used. The maintenance flange and that the pipes do not put any strain on the
specifications for the oil and air filters must also be turbocharger.
adhered to. 6. Start the engine and check the line connections for
The injection pump setting, which must correspond the turbocharger lubrication system for leakage.
with the manufacturer’s specifications, has a major
influence on turbocharger operation.
1. Check the fastening and tightness of the exhaust
and intake manifolds. Make sure there are no loose
carbon particles, rust or other foreign bodies on the
exhaust or intake manifolds.
2. Fix the turbocharger onto the exhaust manifold by
means of the flange. Always use new seals.

Sva 6-51250 EN Edition 07/2003

 Chapter
2002A

2002A
ENGINE WORKSHOP MANUAL

with Common Rail Fuel Injection System

CNH Österreich GmbH Sva 6-93080 EN © 2006 CNH Österreich GmbH

Technical Documentation July, 2006
A - 4300 St. Valentin, Steyrer Strasse 32
 2002A-3

CONTENTS
SPECIAL TOOLS .................................................................................................................................................. 7

TO THE USER ...................................................................................................................................................... 9

Engine code and serial number ......................................................................................................................... 9

SAFETY REGULATIONS ................................................................................................................................... 10

ENGINE DATA .................................................................................................................................................... 11

Jumper lead starting and electrowelding ......................................................................................................... 11
Lifting the engine .............................................................................................................................................. 11

TECHNICAL DATA ............................................................................................................................................. 12

Compliance with exhaust standards ................................................................................................................ 12
Cylinder block .................................................................................................................................................. 12
Cylinder liners .................................................................................................................................................. 12
Cylinder head ................................................................................................................................................... 12
Valves, rocker arms and push rods ................................................................................................................. 13
Camshaft .......................................................................................................................................................... 14
Crankshaft ........................................................................................................................................................ 14
Flywheel ........................................................................................................................................................... 15
Gear drive - camshaft and high-pressure pump .............................................................................................. 15
Con-rods .......................................................................................................................................................... 15
Pistons, piston rings and piston pins ................................................................................................................ 16
Lubrication system ........................................................................................................................................... 16
Lubricating oil pump ......................................................................................................................................... 17
Thermostat ....................................................................................................................................................... 17
Coolant temperature - display and monitoring (signal from sensor B22) ......................................................... 17
Coolant pump ................................................................................................................................................... 17
Schwitzer turbocharger S200 ........................................................................................................................... 17
Tightening torques ........................................................................................................................................... 18

CONSTRUCTION ............................................................................................................................................... 19
GENERAL INFORMATION .............................................................................................................................. 19
Cylinder block .................................................................................................................................................. 19
Flywheel casing ............................................................................................................................................... 19
Cylinder head ................................................................................................................................................... 20
Valve mechanism ............................................................................................................................................. 20
Crank drive ....................................................................................................................................................... 21
Vibration absorber ............................................................................................................................................ 22
Timing gears .................................................................................................................................................... 23
Lubrication system ........................................................................................................................................... 24
Cooling system ................................................................................................................................................ 25
Fan ................................................................................................................................................................... 26
Intake / exhaust system ................................................................................................................................... 27

ELECTRONIC ENGINE CONTROL - EEM3 ....................................................................................................... 29

Layout .............................................................................................................................................................. 30
Function ........................................................................................................................................................... 31
Signals ............................................................................................................................................................. 31

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2002A-4
EEM3 in conjunction with the service tool ........................................................................................................ 32
Error codes ....................................................................................................................................................... 32
Replacing the EEM3 box .................................................................................................................................. 36

WORK INSTRUCTIONS ..................................................................................................................................... 37

1. Cylinder block ............................................................................................................................................... 37
A. Measuring wear on cylinder liners ............................................................................................................. 37
B. Removing the cylinder liners ...................................................................................................................... 37
C. Checking the cylinder block ....................................................................................................................... 37
D. Replacing the camshaft bearing bush ....................................................................................................... 38
E. Oversize bearing bushes for the camshaft ................................................................................................ 38
F. Adjusting the plug on rear end
of camshaft ..................................................................................................................................................... 39
G. Adjusting the plug on the rear end of the camshaft after fitting an oversize bearing bush ........................ 39
H. Adjusting the cylinder liner ......................................................................................................................... 39
2. Flywheel casing ............................................................................................................................................ 41
A. Fitting the flywheel casing .......................................................................................................................... 41
B. Replacing the rear crankshaft sealing ring ................................................................................................ 41
3. Cylinder head ............................................................................................................................................... 42
A. Removing the cylinder head ...................................................................................................................... 42
B. Removing the valves ................................................................................................................................. 42
C. Checking the cylinder head ....................................................................................................................... 42
D. Replacing the valve guides ........................................................................................................................ 43
E. Machining the valve seat ........................................................................................................................... 44
F. Replacing the valve seat rings ................................................................................................................... 44
G. Grinding the valves .................................................................................................................................... 44
H. Fitting the valves ........................................................................................................................................ 45
I. Fitting the cylinder head .............................................................................................................................. 45
4. Valve mechanism ......................................................................................................................................... 46
A. Maintenance of the rocker arm system ...................................................................................................... 46
B. Replacing the camshaft / the camshaft gear ............................................................................................. 46
C. Checking and adjusting valve clearance ................................................................................................... 47
5. Crankshaft .................................................................................................................................................... 48
A. Removing the crankshaft ........................................................................................................................... 48
g. Checking the crankshaft ............................................................................................................................. 48
C. Replacing the crankshaft gears ................................................................................................................. 48
D. Fitting the crankshaft ................................................................................................................................. 49
E. Crankshaft hub .......................................................................................................................................... 49
6. Connecting rods and pistons ........................................................................................................................ 50
A. Removing the pistons together with the connecting rods .......................................................................... 50
B. Checking and replacing the connecting rod bearings ................................................................................ 50
C. Checking the connecting rod ..................................................................................................................... 50
D. Checking and replacing the piston rings .................................................................................................... 51
E. Checking the piston ................................................................................................................................... 52
F. Fitting the piston pin ................................................................................................................................... 52
G. Fitting pistons and connecting rods ........................................................................................................... 52
7. Flywheel ....................................................................................................................................................... 53
A. Replacing the starter ring gear on the flywheel ......................................................................................... 53
B. Fitting the flywheel ..................................................................................................................................... 53
8. Control mechanism ...................................................................................................................................... 54
A. Removing the timing gear case ................................................................................................................. 54
B. Replacing the intermediate gear
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 2002A-5
bearing bush .................................................................................................................................................. 54
C. Fitting the timing gear case ....................................................................................................................... 55
9. Lubrication system ....................................................................................................................................... 57
A. Checking the oil pressure valve ................................................................................................................. 57
B. Removing and checking the oil pump ........................................................................................................ 57
C. Assembling and fitting the oil pump ........................................................................................................... 57
D. Assembly of the oil sump .......................................................................................................................... 58
E. Oil cooler ................................................................................................................................................... 58
F. Piston cooling nozzles ............................................................................................................................... 59
G. Recommended lubricants ......................................................................................................................... 59
10. Cooling system .......................................................................................................................................... 60
A. Thermostat ................................................................................................................................................ 60
B. Repairs to coolant pump ............................................................................................................................ 60
C. Coolant quality requirements ..................................................................................................................... 61
11. Air intake and exhaust system ................................................................................................................... 62
A. Checking the air filter ................................................................................................................................. 62
B. Checking the air intake system and exhaust system ................................................................................. 62
D. Checking the turbocharger ........................................................................................................................ 63
E. Assembly of the turbocharger .................................................................................................................... 64

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2002A-6

BLANK PAGE

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 2002A-7
SPECIAL TOOLS
Pressing tool for the front crankshaft Universal pin
shaft sealing ring

SS00B077
1 x 1TSW 18390 M24

SS00B065 Pressing tool for valve guides

1 x 380000002 (1TSW 520)

Pressing tool for the rear crankshaft shaft

sealing ring

SS00B069
1 x 380000007 (1TSW 524)

SS00B066 Valve spring tensioning lever

1 x 380000003 (1TSW 521)

Pressing tool for

camshaft cover

SS00B071
1 x 380000008 (1TSW 014)
SS00B067
1 x 380000004 (1TSW 522) Extractor

Assembly pin for the water pump seal

SS00B070
1 x 1TSW 662 (available from stockists)

SS00B068
1 x 380000005 (1TSW 523)

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2002A-8
Cylinder liner extractor Three-armed puller

SS05N371
1 x 380000329

Key for crankshaft nut

SS00B072
1 x 1TSW 510 (available from stockists)

Extraction plate

SS05N0372
1 x 380002658

Key for Visco fan

SS00B073
1 x 380000011 (1TSW 508)

Dial gauge and holder

SS05N395
1 x 380001791

SS00B075
Key for reverse fan
1 x 380000364 (1TSW 5610) Holder
1 x 380000228 (1TSW 17049-6) Dial gauge

SS05N396
1 x 380002657

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 2002A-9

TO THE USER
The purpose of this manual is to provide basic information required to service and repair CNH diesel engines.
The engines are of the same design. Differences which have an influence on repair work are therefore listed in the
technical data and repair instructions. All dimensions are specified in millimetres and apply at a temperature of +20°C,
unless otherwise specified.
Before starting repair work, make sure all necessary special tools, spare parts and accessories are available. It is not
absolutely necessary to have all the special tools mentioned in this manual. However, they do make it quicker and
easier to carry out the necessary repairs. After carrying out any repair work you must run in the engine as you would
a new engine.
Should any problems arise which are not covered in this manual, please contact the customer service team at CNH
Österreich GmbH in St. Valentin or through the relevant importer.
IMPORTANT: When making any queries, please specify the following engine data and the current operat-
ing hours count.
EEM3 = Electronic Engine Management.

Engine code and serial number

Engine number
(serial number)

SS05N359

NOTE: This label is affixed to the right-hand side of the engine.

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2002A-10
SAFETY REGULATIONS
There is always a risk of injury
when carrying out maintenance
and repair work. Read the
following safety regulations and
information before starting work.
· Never start repair work which you do not fully un-
derstand.
· Make sure that it is possible to work safely at the
location and in the vicinity.
· Make sure that the repair area is clean and well-
maintained.
· Never use incorrect or unsuitable tools.
· Remove all rings, chains and watches before
starting work.
· Use modern safety equipment when working. For
example, protect your eyes when using com-
pressed air for cleaning, grinding, hammering or
similar tasks.
· When lifting or transporting heavy parts (over 20
kg), use lifting equipment. Make sure that hooks
and chains are in good condition and are firmly at-
tached.
· Never work underneath an engine that is freely
suspended from a lifting apparatus or has been
raised by a jack. Always secure the engine with
strong supports before starting work.
· Only use genuine CNH spare parts.
· Only start the engine from the cab using the igni-
tion key.
· Never start the engine when any protective covers
are removed.
CAUTION: The cooling fan is difficult to see when the
engine is running. Loose clothing and long hair may
become caught in rotating engine parts.
· If starting the engine in an enclosed space, make
sure there is sufficient ventilation.
· Never use aerosol-based starting fuels while the
thermal auxiliary ignition system is operating (risk
of explosion).
· Ear muffs must be worn when testing the engine
or working close to the engine to avoid hearing
damage.
· Always switch off the engine before performing
maintenance or repair work.
CAUTION: Never open the connections of high-pres-
sure lines while the engine is running. Always wait at
least 30 seconds after switching the engine off before
opening it. A high-pressure jet of fuel (up to 1100 bar)
can penetrate the skin and cause serious injury. If such
an event occurs, medical attention must be sought im-
mediately.
Sva 6-93080 EN
· Avoid touching the exhaust manifold, turbo charg-
er and other hot engine parts.
· When the engine is hot and the coolant is pressu-
rised, be careful when opening the radiator cap.
Coolant and lubrication oil out of the hot engine
can cause severe injuries if contact is made with
the skin.
· Naked flames and smoking are not permitted in
the vicinity of fuel tanks or batteries. Electrical
sparks should be avoided. (Particularly when
charging the batteries. Explosion hazard!)
· Disconnect the cable at the negative battery pole
before carrying out service or repair work on the
electrical system.
· If the engine gets excessively hot (over 300°C),
for example if it catches fire, the viton seals (e.g.
bottom O-ring on the cylinder liner or the O-ring on
the oil pressure valve) release highly caustic HF
acid. Never touch viton seals which have been
subjected to unusually high temperatures, with
bare hands. Always wear neoprene gloves or thick
working gloves and protective glasses when re-
moving these harmful materials. Wash the seals
and soiled surfaces using a 10% hydroxide solu-
tion or other alkaline solution. Collect the material
in air-tight sealed plastic bags and take it to an au-
thorised collecting depot.
IMPORTANT: Viton seals must never be burned!
· Extended contact with the fuel, lubricant and cool-
ant can irritate the skin.
· Avoid idling the engine unnecessarily.
· When carrying out service work, take measures to
prevent fuel or other fluids from entering the
ground or drains.
· All seals are free of asbestos.
· Be careful when washing the engine using a
washing facility with a high water pressure. For
example, the electrical systems, fuel system and
cooler must not be washed at high pressure be-
cause this could easily cause damage.
Edition 07-2006
 2002A-11

ENGINE DATA
Engine type 620.64
Number of cylinders 6
3
Cubic capacity (dm ) 6.6
Bore (mm) 108
Height of stroke (mm) 120
Nominal power output in kW at 2100 144
rpm in line with ISO 14396
Marker for start of fuel delivery on
set automatically
V-belt disc (° before TDC)
Compression ratio 18.5 : 1
Combustion process direct injection
Injection sequence 1-5-3-6-2-4
1
Compression pressure (bar) 24
Charge-air pressure 2 (bar) 1.45
3
Weight (kg) 515
Direction of rotation of the crank- Clockwise
shaft

1)
Minimum values at operating temperature and starter speed.
Maximum permissible difference between cylinders max. 3 bar.
2)
measured using Service Tool at full load, rated engine speed and maximum fan speed
3)
Without flywheel and electrical equipment.

Jumper lead starting and electrowelding

• Jumper lead starting may only be used with 12V batteries connected in parallel.
• Before performing any welding work, turn the start switch to the „0“ position.
IMPORTANT: Attach the earth terminal of the welding device close to the area to be welded (max. 1m apart).
IMPORTANT: After repairing the fuel system, the system must be vented before attempting to start for the first time
(see Chapter 3001A - Venting the fuel system).

Lifting the engine

The engine can be safely raised using a lifting device where the lifting force acts vertically on the lifting eyes.
(Prepare lifting eyes yourself at the site where repairs are being undertaken)
A = Engine lifting eyes

A A

SS05N281

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2002A-12

TECHNICAL DATA
Compliance with exhaust standards
The engine complies with emissions requirement EU97/68/EC Level 3A.

Cylinder block
Guide pin bores ................................................................................................................. 13.250 - 13.320 mm
Diameter of crankshaft bearing ground bore ...................................................................... 91.000 - 91.025 mm
Diameter of crankshaft bearing ground bore (oversize) ...................................................... 92.000 - 92.025 mm
Bore diameter of cylinder liner:
- top ............................................................................................................................... 124.514 - 124.554 mm
- bottom ......................................................................................................................... 123.000 - 123.040 mm
Diameter of camshaft bearing bush, no. 1 (assembled) ...................................................... 50.040 - 50.060 mm
Diameter of camshaft bearing bush, nos. 2 - 5 (assembled) ............................................... 50.010 - 50.070 mm
Height of cylinder block .................................................................................................. 428.170 - 428.430 mm

Cylinder liners
Height of liners above cylinder block ...................................................................................... 0.030 - 0.080 mm
Max. permissible height difference between cylinder liners (below same head) ................................... 0.02 mm
Diameter of cylinder liner bores in engine block:
- top end of liner ............................................................................................................ 124.475 - 124.500 mm
- bottom end of liner ....................................................................................................... 122.961 - 122.986 mm
Cylinder liner bore ......................................................................................................... 108.010 - 108.032 mm
Height, cylinder liner flange (standard) ....................................................................................... 9.03 - 9.05 mm
Height, cylinder liner flange, oversize 1 ...................................................................................... 9.08 - 9.10 mm
Height, cylinder liner flange, oversize 2 ...................................................................................... 9.13 - 9.15 mm
Height, cylinder liner flange, oversize 3 ...................................................................................... 9.23 - 9.25 mm
Outer diameter of cylinder liner flange ........................................................................... 131.700 - 131.800 mm

Cylinder head
Height of cylinder head .................................................................................................. 104.800 - 105.000 mm
Minimum height of cylinder head after surface grinding (minimum) ................................................ 104.000 mm
Inner diameter of valve guide (not fitted) ................................................................................ 9.000 - 9.015 mm
Outer diameter of valve guide ............................................................................................ 16.028 - 16.039 mm
Diameter of bore for valve guide in cylinder head .............................................................. 16.000 - 16.018 mm
Projection of valve guide above cylinder head surface ............................................................................21 mm
Depth, valve head below cylinder head surface:
- Inlet valve ........................................................................................................0.7 ± 0.05 mm (max. 2.20 mm)
- Outlet valve .....................................................................................................0.6 ± 0.05 mm (max. 2.20 mm)
Valve seat angle:
- Inlet valve ............................................................................................................................................ 35° +20'
- Outlet valve .........................................................................................................................................45° +20'
Valve seat width:
- Inlet valve ....................................................................................................................................2.9 - 3.7 mm
- Outlet valve .................................................................................................................................1.3 - 2.3 mm
Diameter, outlet valve seat ring (standard) ......................................................................... 44.070 - 44.132 mm
Bore in cylinder head for outlet valve seat ring (standard) .................................................. 44.000 - 44.025 mm
Diameter, outlet valve seat ring (oversize) ......................................................................... 44.270 - 44.332 mm
Bore in cylinder head for outlet valve seat ring (oversize) .................................................. 44.200 - 44.225 mm
Diameter, inlet valve seat ring (standard) ........................................................................... 48.570 - 48.632 mm
Bore in cylinder head for inlet valve seat ring (standard) .................................................... 48.500 - 48.525 mm
Diameter, inlet valve seat ring (oversize) ........................................................................... 48.770 - 48.832 mm
Bore in cylinder head for inlet valve seat ring (oversize) .................................................... 48.700 - 48.725 mm

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 2002A-13

Valves, rocker arms and push rods

Valve control times at a valve play of 1.0 mm:
- Inlet valve opens ................................................................................................................ 0° ±2° before TDC
- Inlet valve closes ................................................................................................................ 16° ±2° after BDC
- Outlet valve opens ........................................................................................................... 39° ±2° before BDC
- Outlet valve closes ................................................................................................................ 1° ±2° after TDC
Valve play when engine is cold/hot:
- Inlet valve ......................................................................................................................................... 0.35 mm
- Outlet valve ....................................................................................................................................... 0.35 mm
Valve head angle:
- Inlet valve ............................................................................................................................................ 35° -20'
- Outlet valve .......................................................................................................................................... 45° -20'
Valve head diameter:
- Inlet valve ............................................................................................................................................ 48 mm
- Outlet valve .......................................................................................................................................... 41 mm
Maximum opening travel of valves (with valve play of 0.35 mm):
- Inlet valve ......................................................................................................................................... 10.9 mm
- Outlet valve ....................................................................................................................................... 12.1 mm
Diameter, inlet valve stem ..................................................................................................... 8.960 - 8.975 mm
Diameter, outlet valve stem ................................................................................................... 8.925 - 8.940 mm
Clearance, inlet valve stem (guide fitted in cylinder head) ..................................................... 0.025 - 0.055 mm
Wear limit (inlet valve stem) ................................................................................................................ 0.30 mm
Clearance, outlet valve stem (guide fitted in cylinder head) ................................................... 0.060 - 0.090 mm
Wear limit (outlet valve stem) .............................................................................................................. 0.35 mm
Inner diameter of valve guide (not fitted) ............................................................................... 9.000 - 9.015 mm
Outer diameter of valve guide ............................................................................................16.028 - 16.039 mm
Diameter of bore for valve guide in cylinder head ...............................................................16.000 - 16.018 mm
Projection of valve guide above cylinder head surface ........................................................................... 21 mm
Depth, valve head below cylinder head surface:
- Inlet valve ....................................................................................................... 0.7 ± 0.05 mm (max. 2.20 mm)
- Outlet valve ..................................................................................................... 0.6 ± 0.05 mm (max. 2.20 mm)
Free length of valve spring .................................................................................................................. 69.8 mm
Force of valve spring with pressed length of:
- 48.6 mm ......................................................................................................................................... 327 ± 17 N
- 37.4 mm ......................................................................................................................................... 500 ± 23 N
Diameter, rocker arm shaft .................................................................................................22.970 - 22.990 mm
Diameter of rocker arm bore ...............................................................................................23.000 - 23.021 mm
Permissible radial runout of push rod (free) ........................................................................................... 0.4 mm
Free length of rocker arm spring ............................................................................................................. 80 mm
Force of rocker arm spring with pressed length of 58 mm ................................................................... 70 - 90 N
Outer diameter of pusher ...................................................................................................29.939 - 29.960 mm
Diameter of pusher bores in cylinder block .........................................................................30.000 - 30.043 mm
Length of push rod .........................................................................................................237.000 - 238.300 mm

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Camshaft
Diameter, camshaft bearing journal no. 1 (front) ................................................................ 49.875 - 49.900 mm
Diameter, camshaft bearing journals nos. 2, 3 and 4 .......................................................... 49.865 - 49.890 mm
Diameter, camshaft bearing journal no. 5 ........................................................................... 49.885 - 49.910 mm
Clearance, camshaft bearing no. 1 ........................................................................................ 0.140 - 0.185 mm
Clearance of camshaft bearings nos. 2, 3 and 4 .................................................................... 0.110 - 0.160 mm
Clearance, camshaft bearing no. 5 ........................................................................................ 0.100 - 0.185 mm
Axial play of camshaft (seal 0.5 mm - between cylinder block and
steering housing and between steering housing and cover ............................................................0.5 - 1.0 mm
Cam height (distance between base circle and elevation of cam):
- Inlet valve ........................................................................................................................ 41.987 - 41.487 mm
- Outlet valve ..................................................................................................................... 39.883 - 40.383 mm
Cam stroke:
- Inlet valve .......................................................................................................................................... 7.38 mm
- Outlet valve ....................................................................................................................................... 8.28 mm
Max. permissible radial runout of camshaft .......................................................................................... 0.03 mm

Crankshaft
Diameter of the con-rod bearing journals:
- Standard dimension ......................................................................................................... 67.981 - 68.000 mm
- 1st repair level 0.25 mm .................................................................................................. 67.731 - 67.750 mm
- 2nd repair level 0.50 mm ................................................................................................. 67.481 - 67.500 mm
- 3rd repair level 1.00 mm .................................................................................................. 66.981 - 67.000 mm
- 4th repair level 1.50 mm .................................................................................................. 66.481 - 66.500 mm
Width of con-rod bearing journal ........................................................................................ 40.000 - 40.160 mm
Diameter of the main bearing journals:
- Standard dimension ......................................................................................................... 84.985 - 85.020 mm
- 1st repair level 0.25 mm .................................................................................................. 84.735 - 84.770 mm
- 2nd repair level 0.50 mm ................................................................................................. 84.485 - 84.520 mm
- 3rd repair level 1.00 mm .................................................................................................. 83.985 - 84.020 mm
- 4th repair level 1.50 mm .................................................................................................. 83.485 - 83.520 mm
Diameter, main bearing housing ......................................................................................... 91.000 - 91.025 mm
Thickness of the main bearing shells:
- Standard dimension ............................................................................................................. 2.955 - 2.965 mm
- 1st repair level 0.25 mm ...................................................................................................... 3.080 - 3.090 mm
- 2nd repair level 0.50 mm ..................................................................................................... 3.205 - 3.215 mm
- 3rd repair level 1.00 mm ...................................................................................................... 3.455 - 3.465 mm
- 4th repair level 1.50 mm ...................................................................................................... 3.705 - 3.715 mm
Clearance of main bearings ................................................................................................... 0.050 - 0.127 mm
Width of the journal at the thrust bearing (main bearing at flywheel):
- Standard dimension (2 standard thrust washers) ............................................................. 45.000 - 45.080 mm
- 1st repair level(one standard thrust washer and one with 0.1 mm oversize) ..................... 45.100 - 45.180 mm
- 2nd repair level (one standard thrust washer and one with 0.2 mm oversize) ................... 45.200 - 45.280 mm
- 3rd repair level (one thrust washer of 0.1 mm and one of 0.2 mm oversize) ..................... 45.300 - 45.380 mm
- 4th repair level (two thrust washers with 0.2 mm oversize) .............................................. 45.400 - 45.480 mm
Other crankshaft bearing journals may not be ground wider.
Crankshaft axial play ............................................................................................................. 0.100 - 0.380 mm
Max. permissible ovality of main bearing or con-rod bearing journals ................................................... 0.03 mm
Max. permissible imbalance of crankshaft .................................................................................... 1.0 Ncm max.

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 2002A-15

Flywheel
Cover, starter gear ring on flywheel ....................................................................................... 0.425 - 0.600 mm
Before pressing the starter gear ring on the flywheel, heat up the
gear ring to a temperature of .......................................................................................................... 150 - 200°C
Max. permissible imbalance on flywheel ...................................................................................... 1.0 Ncm max.
max. permissible runout of coupling face, measured on inner edge
of coupling face (diameter 200mm) ..................................................................................................... 0.06 mm

Gear drive - camshaft and high-pressure pump

Tooth flank play:
Crankshaft - intermediate gear .................................................................................................. 0.05 - 0.25 mm
Intermediate gear - camshaft ..................................................................................................... 0.05 - 0.25 mm
Double intermediate gear - high-pressure pump ........................................................................ 0.05 - 0.25 mm
Max. permissible lateral runout of gears .............................................................................................. 0.05 mm
Intermediate gear (with plain bearing, 50.7 mm long):
- Inner diameter, intermediate gear bearing bush (fitted) ....................................................55.200 - 55.230 mm
- Diameter, bearing journal for intermediate gear ................................................................55.151 - 55.170 mm
Inner diameter, intermediate gear .......................................................................................60.000 - 60.030 mm
Timing marks:
The orientation of the timing marks on the gears corresponds to
the upper dead centre of the piston in the first cylinder between the compression stroke and working stroke.
On the crankshaft gear ...................................................................................................... 2 points on the teeth
On the intermediate gear:
- to crankshaft gear ...................................................................................................................1 point on tooth
- to camshaft gear .....................................................................................................................1 point on tooth
On camshaft gear ......................................................................................................... 1 point on the tooth gap

Con-rods
Inner diameter, piston pin bearing bush
(bearing bush pressed into con-rod) ...................................................................................40.025 - 40.040 mm
Outer diameter of piston pin bearing bush (standard) .........................................................44.080 - 44.120 mm
Outer diameter of piston pin bearing bush (oversize) ..........................................................44.580 - 44.620 mm
Cover for bearing seat (press fit) in the con-rod ..................................................................... 0.057 - 0.120 mm
Bore, seat for piston pin bearing bush ................................................................................44.000 - 44.025 mm
Bore, seat for piston pin bearing bush (oversize bush) .......................................................44.500 - 44.525 mm
Bore, con-rod side ..............................................................................................................71.730 - 71.749 mm
Thickness of the con-rod bearing shells:
- Standard ............................................................................................................................. 1.835 - 1.842 mm
- 1st repair level 0.25 mm ...................................................................................................... 1.960 - 1.967 mm
- 2nd repair level 0.50 mm ..................................................................................................... 2.085 - 2.092 mm
- 3rd repair level 1.00 mm ..................................................................................................... 2.335 - 2.342 mm
- 4th repair level 1.50 mm ...................................................................................................... 2.585 - 2.592 mm
Clearance of con-rod bearing ................................................................................................ 0.046 - 0.098 mm
Axial play of con-rod bearing ................................................................................................. 0.200 - 0.410 mm
Alignment of con-rod bearing to bore piston pin bearing ............................................................ within 0.15:100
Parallelism of con-rod bearing bore to bore piston pin bearing .................................................. within 0.05:100
The weight markers are engraved on the lower end of the con-rods
(on the camshaft side)
Max. permissible weight difference between con-rods in same engine ....................................................... 20 g

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2002A-16

Pistons, piston rings and piston pins

Piston diameter (measured 17 mm above
the piston's lower edge .................................................................................................. 107.883 - 107.897 mm
Diameter, piston pin bore in piston ..................................................................................... 40.003 - 40.009 mm
Diameter, piston pin ........................................................................................................... 39.991 - 40.000 mm
Width of the piston ring grooves:
- 1st groove ..................................................................................................................................keystone ring
- 2nd groove .......................................................................................................................... 2.520 - 2.540 mm
- 3rd groove ........................................................................................................................... 4.040 - 4.060 mm
Vertical play of the piston rings in their grooves:
- 1st groove ..................................................................................................................................keystone ring
- 2nd groove ............................................................................................................................ 0.03 - 0.062 mm
- 3rd groove ............................................................................................................................. 0.05 - 0.082 mm
- wear limit ........................................................................................................................................... 0.15 mm
Piston ring height (in direction of cylinder):
- 1st groove ..................................................................................................................................keystone ring
- 2nd groove .......................................................................................................................... 2.478 - 2.490 mm
- 3rd groove ........................................................................................................................... 3.975 - 3.990 mm
End play of piston rings (with piston fitted):
- 1st groove ............................................................................................................................... 0.40 - 0.55 mm
- 2nd groove .............................................................................................................................. 0.60 - 0.80 mm
- 3rd groove ............................................................................................................................... 0.30 - 0.60 mm
- wear limit - rings 1 and 3 .....................................................................................................................1.0 mm
- wear limit - ring 2 .................................................................................................................................1.5 mm
Maximum weight difference between pistons in same engine ......................................................................25 g
NOTE: To assemble the piston pins, heat up the pistons to 100°C!
NOTE: When fitting the pistons, ensure that the piston bowls are on the side of the injectors.

Lubrication system
Oil pressure at normal operating temperature:
- when idling ................................................................................................................................... min. 1.0 bar
- at operating speed ....................................................................................................................... 2.5 - 5.0 bar
Lubricating oil filter - overflow valve opens at pressure difference of .................................................. 2 ±0.5 bar
Oil pressure monitoring .............................................................................................. using oil pressure sensor
Switching pressures for oil pressure sensor .......................................... Speed-dependent from 900 - 2300 rpm
at 900 rpm ........................................................................................................................................... 1.15 bar
at 2300 rpm ......................................................................................................................................... 1.92 bar
Spring in oil pressure valve: free length (identification = yellow point) ........................................ 49.3 - 50.8 mm
Spring length and spring force (with fitted oil pressure valve) ................................................... 28.5 mm / 127 N
±0.25
Overflow valves for the piston cooling nozzles: Opening pressure .................................................... 3 bar

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 2002A-17

Lubricating oil pump

Backlash when the crankshaft is positioned almost against the lower face of the bearing
- between crankshaft gear and oil pump gear .......................................................................... 0.05 - 0.025 mm
- between gears of oil pump ...................................................................................................... 0.16 - 0.26 mm
Diameter of driveshaft in housing and cover .......................................................................17.966 - 17.984 mm
Diameter of bearing bores of driveshaft ..............................................................................18.000 - 18.018 mm
Diameter of fixed shaft in pump gear area ..........................................................................17.966 - 17.984 mm
Diameter of bearing bore in pump gear ..............................................................................18.000 - 18.018 mm
Diameter of fixed shaft in pump housing .............................................................................20.035 - 20.048 mm
Depth of end of driveshaft below surface of housing .............................................................................. 0.5 mm
Thickness of housing seal ......................................................................................................... 0.06 - 0.08 mm
Outer diameter of gears .....................................................................................................55.824 - 55.870 mm
Diameter of housing ...........................................................................................................56.000 - 56.120 mm
Width of gears ....................................................................................................................32.000 - 32.027 mm
Axial play of gears ......................................................................................................................0.03 - 0.11 mm
Depth of housing ................................................................................................................32.000 - 32.043 mm

Thermostat
Type, version ............................................................................................................................ ∅ 54 mm / single-circuit
Starts opening at ................................................................................................................................... 79°C ±2
Fully open at ............................................................................................................................................. 94°C
Max stroke ............................................................................................................................................. 7.5 mm
Type, version ....................................................................................................................................... ∅ 67 / two-circuit
Starts opening at ................................................................................................................................... 83°C ±2
Fully open at ............................................................................................................................................. 95°C
Max stroke ................................................................................................................................................ 8 mm

Coolant temperature - display and monitoring (signal from sensor B22)

Display on ADIC ..................................................................................................................................analogue
Warning on ADIC when temperature ............................................................................................... > 106 ± 3° C
error code EEM112
Acoustic alarm (additional) when temperature ................................................................................. > 113 ± 3° C
error code EEM113

Coolant pump
Outer diameter of bearing ...................................................................................................................... 72 mm
Diameter of bearing housing ..............................................................................................71.961 - 71.991 mm
Diameter for insertion of seal in housing .............................................................................39.981 - 40.019 mm
Diameter of shaft with bearing ............................................................................................30.002 - 30.015 mm
Diameter of shaft with impeller ...........................................................................................15.907 - 15.920 mm
Diameter of impeller bore ...................................................................................................15.876 - 15.894 mm
Gap between impeller and rear face of housing ..................................................................................... 0.7 mm
(must be complied with even when pressing)
Permissible imbalance of fan................................................................................. max. 0.3 Ncm max (30 pcm)

Schwitzer turbocharger S200

Axial play of shaft ........................................................................................................................ max. 0.10 mm
Radial play of shaft (compressor side) ......................................................................................... max. 0.88 mm
Tightening torque of compressor housing screws ............................................................................... 13.60 Nm
Tightening torque of turbine housing screws .......................................................................................21.00 Nm
Tightening torque of nuts on shaft (compressor side) .........................................................................13.60 Nm

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Tightening torques
Cylinder head screws and nuts .................................................................................................80 Nm+90°+90°
Cylinder head pins in the cylinder block .................................................................................................. 30 Nm
Crankshaft bearing screws .................................................................................................................... 200 Nm
Connecting rod bolts (Torx E18) ..................................................................................................... 40 Nm + 90°
Nuts on crankshaft (front face) ............................................................................................................ 1000 Nm
Pulley screws .......................................................................................................................................... 30 Nm
Retaining bolts for flywheel ................................................................................................................... 150 Nm
Retaining bolts for flywheel casing:
- inner bolts M10 ..................................................................................................................................... 80 Nm
- outer bolts M12 ................................................................................................................................... 150 Nm
Retaining screws for intermediate gear (with plain bearing):
- M10 ...................................................................................................................................................... 60 Nm
- M14 .................................................................................................................................................... 200 Nm
Overflow valve - piston cooling nozzle .................................................................................................... 30 Nm
Nuts for lubricating oil pump gear ........................................................................................................... 60 Nm
Retaining screws for lubricating oil pump ................................................................................................ 60 Nm
Connecting part to engine oil cooler ........................................................................................................ 60 Nm
Nuts for coolant pump pulley ................................................................................................................. 120 Nm
Attachment - Visco fan to Visco hub ........................................................................................................ 30 Nm
Screws/nuts on exhaust manifold ............................................................................................................ 50 Nm
Screws on air intake port ........................................................................................................................ 30 Nm
Nuts - Drive gear, high-pressure pump .................................................................................................... 90 Nm
Retaining bolt, injector ............................................................................................................................ 40 Nm
High-pressure line from high-pressure pump to rail ................................................................................. 30 Nm
High-pressure line from rail to injectors ................................................................................................... 25 Nm
Low-pressure line to high-pressure pump ............................................................................................... 25 Nm

NOTE: Use washers for aluminium parts.

If no special tightening torques are given,

always use the values in the table below.

Tightness
Thread size
8.8 10.9
M8 25 Nm 35 Nm
M10 50 Nm 75 Nm

Bolts for the self-supporting oil pan

1 M8 25 Nm
3
2 M10 90 Nm
3 M14 160 Nm
4 M20 600 Nm 4 2
1 SS99N015

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CONSTRUCTION
GENERAL INFORMATION
The 620-series diesel engines described in this manual
are water-cooled four-stroke in-line engines with a
common rail fuel injection system. All models are
equipped with wet, replaceable cylinder liners, an ex-
haust turbocharger and charge-air cooling (air/air). The
engine is controlled by the EEM3 control unit. The en-
gine meets the requirements of the Level 3A exhaust
regulations.

Cylinder block
The rib-reinforced cylinder block forms the main engine
unit, onto which other engine components are mount-
ed.
The wet and interchangeable cylinder liners are sup-
ported in the middle, which has the effect of reducing vi-
bration and making sure that most of the coolant flows
to the upper part of the cylinder liners.
The seal between the lower part of the cylinder liner
and the cylinder block is provided by three O-rings fitted
into the grooves in the cylinder liner. The upper part is
sealed by the cylinder head gasket.
The camshaft is located in the cylinder block. All cam-
shaft bearings are fitted with interchangeable bearing
bushes.
Guide bearings are fitted on both sides of the rear main
bearing of the crankshaft
(crankshaft axial bearings).

Flywheel casing
The flywheel casing is fitted at the rear end of the cylin-
SS05N374
der block. The seal for the rear end of the crankshaft is
inserted in a bore in the casing. The attachment for the
starter is housed in the flywheel casing.
The underside of the flywheel casing serves as a seal-
ing face for the oil sump seal. This means that the lower
face of the cylinder block must stop flush with the fly-
wheel casing. When the flywheel casing is fitted, its po-
sition is determined by sprung dowel pins.

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Valve mechanism
The valve mechanism is activated by the camshaft lo-
cated in the cylinder block. The drive force is trans-
ferred by valve tappets and push rods. The camshaft
wheel is force-fitted on to the camshaft and is radially
fixed with a feather key. The bearings are lubricated
with compressed oil through oil bores in the engine
block.

SS05N284

Cylinder head
The engines have two interchangeable cylinder heads.
Each cylinder has its own intake and outlet duct in the
cylinder head. Between the outlet valves is an inlet
valve to balance out the thermal load.
The cylinder head bolts are high-strength pre-loaded
bolts that are tightened to yield point in line with the
principle of tightening by angle. Due to the high degree
of elongation, the retaining power is kept constant
throughout the entire service life, and the bolts do not
therefore have to be re-tightened.
The injector seats are integrated into the cylinder head
itself. The inlet and outlet valve guides are identical and
can be interchanged. Furthermore, the inlet/outlet
valves are fitted with replaceable valve seat inserts.

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Crank drive The pistons have two compression rings and one oil
The crankshaft is forged from special chrome alloy scraper ring. The upper piston ring, coated with molyb-
steel and the bearing surfaces and sealing faces are in- denum, has a trapezoidal cross-section.
ductively hardened. The bearing points can be re- The middle piston ring is shown as a 'minute ring' (the
ground four times without having to be rehardened. The surface of the outer diameter is conical).
gear wheels are force-fitted at the front end of the The oil scraper ring is sprung and has two chrome-plat-
crankshaft. These serve to drive the camshaft, the high- ed scraping edges.
pressure pump and the oil pump. The front end of the The pistons are ring carrier pistons (the piston has a
crankshaft is also fitted with keyways to hold the drive special cast iron ring carrier cast into it to seat the top
hub. The pulley and rotary vibration absorber (viscous) piston ring). The friction surface of the piston skirt also
are mounted on the hub. The front PTO shaft (if fitted) has a graphite coating to ensure optimal running-in.
is also driven via this hub. An oil repellent ring is insert- The piston base is cooled from below by extra splash
ed between the hub and the gear. The crankshaft car- oil as soon as the oil pressure exceeds 3 bar.
ries the sensor wheel for the engine speed sensor on a
crankweb.
There is a main bearing for the crankshaft on both sides
of each cylinder. Is it therefore supported in seven main
bearings. The crankshaft axial bearings are located on
both sides of the rearmost crankshaft bearing. The fly-
wheel is mounted at the rear end of the crankshaft and
carries a force-fitted crown gear.
The forged con-rods have an I-shaped cross-section.
The con-rod bearing is divided horizontally by 'breaks'.
The bearing cover is held in place by two special
screws. The upper part is fitted with a wedge-shaped
bearing seat in which the piston pin bearing bush is
press-fitted.
The pistons are made of a eutectic aluminium alloy.
There is a combustion space in the piston base. The
shape of the optimised combustion space ensures an
optimal carburetion of air and fuel.

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Vibration absorber
NOTE: When transporting, storing, dismantling or as-
sembling, you must take care to avoid deforming the
3 casing. Any dents made in the casing could trap the
2 otherwise free-moving absorber mass and thus ham-
per the absorber's effectiveness. Damage which re-
sults in the absorber unit becoming non-airtight will
render the absorber ineffective, because the silicon oil
4 will escape. Absorbers with a dented casing must not
be fitted.
NOTE: If indicating marks have to be made on the ab-
sorber casing for certain adjustments, only use a mark-
er pen or an electric engraver. Never make marks
which cause impact on the casing.

1 SS05N324

1. Casing 3. Space for silicon oil

2. Absorber mass 4. Bearing bush

The absorber eliminates rotary vibrations from the

crankshaft, making the engine run more quietly. The
casing is screwed on to the front end of the crankshaft
with the hub. It forms a ring-shaped cavity with a rectan-
gular cross-section. In this cavity is a ring-shaped ab-
sorber mass radially mounted on a bearing bush with
low mounting clearance. The empty space is filled with
viscous, temperature-stable silicon oil. The casing is
hermetically sealed. The absorber requires no mainte-
nance.

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SS03G080

Timing gears
1. Camshaft gear 4. Double intermediate gear
2. Intermediate gear 5. Crankshaft drive gear
3. High-pressure fuel pump drive gear

Timing gears
The gears of the engine control unit are hardened and bevel-toothed when engaged. The gears are located in the
timing gear housing, which is fitted on the front face of the engine.
The timing gears drive the camshaft, high-pressure fuel pump and the oil pump. The high-pressure fuel pump is driven
by the double intermediate gear (4). Like the camshaft, the intermediate gear (2) operates in pressure-lubricated plain
bearings. The bearing journal is attached to the front face of the cylinder block. The double intermediate gear is
mounted with two inclined ball bearings.

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1 4. Turbocharger
Lubrication system
The engine features a lubrication system for which the
oil pump (gear pump) is fitted on the lower face of the
cylinder block. Oil is drawn in by the pump through a
suction filter. From the pump, the oil is conveyed through
an oil line to the oil cooler (heat exchanger) and to the oil
filter. The oil pressure valve is fitted in parallel to this.
The oil is then conveyed into the main oil duct, from
which other oil bores branch off. The oil is conveyed
through these bores to the main bearings and through
the crankshaft to the connecting rods.
From the main oil duct, the compressed oil is then chan-
nelled to the turbocharger and the air compressor (if fit-
ted). The bearing of the intermediate gear, the camshaft
bearings and the valve mechanism are also lubricated
with compressed oil.
The piston bases are sprayed and cooled with oil from
below for as long as the lubricating oil pressure is above
3 bar.
The oil pressure valve regulates the lubrication oil pres-
Sva 6-93080 EN
Lubrication system
7 1. Lubricating oil pump
2. Oil pressure valve
3. Oil filter
5. Main oil duct
6. Oil spray nozzles
7. Oil pressure sensor
SS05N286
sure so that a constant value is maintained regardless of
engine speed. Depending on speed, oil type and tem-
perature, the oil pressure will be between 2.5 - 5bar.
When the engine is at idling speed, the oil pressure must
be at least 1.0 bar.
The oil filter is a one-way main stream filter. An overflow
valve located on the underside of the filter ensures lubri-
cation of the engine after a cold start at extremely low
outside temperatures and also ensures appropriate lu-
brication should the filter become blocked. A non-return
valve prevents the filter being completely drained of oil
when the engine is switched off.
Edition 07-2006
 2002A-25

4 1

Cooling system
1. Coolant pump 5. Expansion tank
2. Thermostats 6. Oil cooler
3. Bypass duct 7. Engine temperature sensor
4. Cooler 05N373

Cooling system
The coolant pump, which is driven by the belt, is fit-
ted at the front end of the cylinder block. The ther-
mostat casing is located above the pump. The
cooling system features two thermostats which reg-
ulate the flow of coolant. The thermostats have dif- C
ferent opening temperatures. If the coolant
temperature is below the opening temperature, the
coolant (A) will circulate back to the coolant pump
via the bypass duct. The smaller, single-action ther-
mostat (1) starts opening at 79°C and allows a quan-
tity of the coolant (B) to flow into the cooler. When B
the temperature inside the engine rises and reaches 1
83°C, the two-circuit thermostat (2) also starts to
open. This closes when the bypass is opened and
conducts the entire flow of coolant (C) into the cool- 2
er.
A

SS05N287

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Fan

VISCO FAN REVERSIBLE FAN

SS03G024 SS05N282

Viscous fan with modulating hub (standard equipment)

For the modulating hub, each incoming air temperature corresponds to a particular slip.
When no cooling or a low level of cooling is required, the fan runs at low speed (= high slip), but the speed is depend-
ent on the engine speed. The flow of air through the cooler pack (air conditioning condenser - charge-air cooler - trans-
mission oil cooler - engine coolant cooler) acts on the front face of the Visco hub. Here there is a bimetallic spring that
continuously measures the discharge air temperature downstream of the coolant cooler. As the discharge tempera-
ture rises (causing an increasing load on the tractor), the control valve reduces the slip and the fan rotates faster ac-
cording to the temperature until the minimum slip of approx. 5% is reached. As the discharge temperature falls
(decreasing load on the tractor), the control valve increases the slip and the fan run more slowly according to the tem-
perature.
The advantages of the Visco fan with modulating hub are: Cooling rating adjusted more accurately to load on tractor,
fan rating required further reduced and reduced noise level.
The Visco fan requires no maintenance.

Reverse fan (optional equipment)

The blades of the reverse fan are arranged on the hub such that they can be twisted. Installed thermo-elements vary
the angle of the blades while the fan is operating and adjust the cooling rating of the fan to suit the cooling require-
ment. Recoil springs hold the blades securely in position.
Touching the 'Reverse fan' button activates the following automated process:
The Electronic Central Control Unit (ECCU2) controls a small air compressor operated by an electric motor and a
solenoid valve. This control unit is fitted on the left of the engine. Compressed air travels via a pressure line and a
special seal to the actuator cylinders, which rotate with the hub and the blades and turn the blades. This causes a
strong current of air to blow in the opposite direction through the coolers and any material which has been sucked in,
such as grass, flowers, insects etc. is removed from the coolers. After 30 seconds the fan blades automatically move
back to their starting position. The driver can also program the fan to reverse automatically, e.g. in conjunction with
automated processes relating to the front or rear power lifts or the AUX additional remote control valves.

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Intake / exhaust system
Compared with aspirated engines, engines with turbo-
chargers are more sensitive to poorly serviced air filters
and leaks in the intake and exhaust system.
You should therefore carry out the specified mainte-
nance and inspection tasks diligently and observe the
maintenance intervals.
Condition of air filter and intake system
To a large extent, the performance and lifetime of the en-
gine are dependent on the condition of the air filter and
intake system.
A very dirty air filter or a buckled intake hose will reduce
the engine's performance and cause engine oil to be
sucked in by the seal on the shaft bearing of the turbo-
charger.
NOTE: A leaky air filter (caused by a damaged filter
cartridge or damaged/missing seal) or leaks in the in-
take system between the air filter and turbocharger al-
lows larger foreign bodies to enter the turbocharger and
from there the engine cylinder.
The filter system for the engine intake air consists of an
upstream cyclonic filter (integrated in the air filter) and a
dry air filter with a safety cartridge. In the upstream cy-
clonic filter, the intake air is induced to rotate. This caus-
es heavy dirt particles to be separated out before being
removed by the dust discharge valve of the upstream cy-
clonic filter.
Sva 6-93080 EN
2002A-27
SS05N357
Ejector
If the tractor is being used in areas where there is a lot of
dust, it can be fitted with an 'ejector system'. The ejector
system features an injector with a hose connection,
where there is a constant suction effect while the engine
is running. The dust particles eliminated by the pre-filter
are continually drawn in through a hose connector and
conveyed to the open air together with the exhaust gas-
es.
Design of filter cartridges
Dirt particles in the air are collected in the main cartridge,
which can be cleaned when required. The safety car-
tridge inside prevents dirt particles from entering the en-
gine in the event of a leak or if the main cartridge is
incorrectly installed. To service the filter cartridges, refer
to the operating instructions.
Filter service indication
A pressure difference switch is located in the filter hous-
ing. This switch turns on an indicator light on the ADIC
when the air filter has reached a certain level of soiling.
The air intake system also contains the air lines between
the air filter and the turbocharger, between the turbo-
charger and the charge-air cooler and between the
charge-air cooler and the intake manifold.
The exhaust manifold is attached to the cylinder head by
special screws without a separate seal. There is no need
to retighten these special screws.
The turbocharger is lubricated and cooled by oil from the
engine lubrication system.
Edition 07-2006
2002A-28

Charge-air cooling
The intake air compressed by the turbocharger can The charge-air cooler is designed for straightforward
reach temperatures of up to 150°C during high utilisa- servicing. It can be folded upwards for effective clean-
tion. It is cooled to 50 - 60°C in a charge-air cooler (air/ ing against the direction of incoming outside air. By
air design) located upstream of the engine cooler. folding up the charge-air cooler, the other coolers are
Cooling of the charge air reduces the thermal and me- easier to access.
chanical stress on the engine and reduces emissions
of nitrogen oxides and soot particles.
Charge-air and charge-air temperature as pa-
rameters for engine control
There is a combined sensor in the air accumulator. It
continually sends information on charge-air pressure
and temperature to the Electronic Engine Management
unit (EEM3). In conjunction with the common rail fuel
injection system, fuel injection is optimised and the dis-
charge of nitrogen oxides and soot particles is signifi-
cantly reduced.

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ELECTRONIC ENGINE CONTROL - EEM3

6 11

12
14

10
7
5

15

8 3

16
13

1
2
SS05N290

1. EEM3 engine control unit (A3) 9. Coolant temperature sensor (B22)

2. Oil pressure sensor (B37)
3. Engine speed sensor (B20)
4. Camshaft position sensor (B40)
5. Rail pressure sensor (B38)
6. Charge-air pressure / temperature sensor (B29)
7. Fuel temperature sensor (B36)
8. Fuel delivery pressure sensor (B39)
10. Fuel delivery pump (M13)
11. Power relay (K8/2)
12. Heating flange (E10/1)
13. ID module (A7)
14. Injector, 1st cylinder (Y21)
15. Solenoid valve, high-pressure pump (Y20)
16. 'Water in fuel' sensor (B23)

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Layout

A7 ID MODULE

CAN H CAN L
Sensor B29
Charge-air pressure A3 Y21 - Injector 1
Charge-air
temperature Y22 - Injector 2

Sensor B40 Y23 - Injector 3

Camshaft position
Y24 - Injector 4
Sensor B39
Fuel delivery pressure Y25 - Injector 5

Y26 - Injector 6
Sensor B36
Fuel temperature
Heating flange E10/1
EEM3 (Jumper lead starting)
Sensor B38
Rail pressure
M13 Fuel
Sensor B23 delivery pump
'Water in
fuel' Solenoid valve Y20
High-pressure pump
Sensor B37
Oil pressure Switch S22
Coolant level
Sensor B22
Coolant temperature Sensor B2/1
Fuel level
Sensor B20
Engine speed
A1
ADIC

Limp home

Warning
Sensor B28 Fuel level
Manual accelerator too low
CAN H

CAN L

ICU Warning
Water in fuel
(optional feature)

ARU
Warning
Coolant level

Indicator
Oil pressure
Potentiometer R8 A4
Accelerator pedal FMGR
Indicator
Cold start aid

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Function
The basic function of the EEM3 engine management system is to continually record and control the engine speed
and fuel injection volume. These two parameters are used to continually calculate the load on the engine.
The central unit of the engine management system receives continuous information (as electronic signals) from var-
ious sensors on physical parameters such as engine speed, coolant temperature, intake air and fuel, charge-air pres-
sure, fuel delivery pressure and engine lubricating oil pressure. The central unit of the engine management system
receives continuous information on the power and speed requirements of the FMGR via the CAN bus (depending on
the position of certain controls in the driver's cab).
The central unit of the engine management system receives the engine identification from the ID module. The EEM3
has an important diagnostic capacity. Errors in the EEM3 system are displayed using codes.

Signals
The EEM3 also receives data in different ways about various parameters which are important to the management of
the engine.

Analogue signals (voltage) Digital signal (Frequency)

· Coolant temperature (from sensor B22)
· Charge-air temperature (from sensor B29)
· Charge-air pressure (from sensor B29)
· Rail pressure (from sensor B38)
· Water in fuel (from sensor B23)
· Nominal engine speed for limp home
(from accelerator pedal sensor R8)
· Engine speed (from sensor B20)
Digital signal (coding)
· Crankshaft position (from sensor B20)
· Camshaft position (from sensor B40)
Digital signal (CAN messages)
· Drive commands (from FMGR)

· Fuel delivery pressure (from sensor B39)

· Fuel temperature (from sensor B36)
· Engine oil pressure (from sensor B37)

Control parameters (which affect fuel injection volumes)

· Torque map
· Coolant temperature
· Charge-air pressure
· Certain errors (e.g. ID module not recognised, error code 453).

Idling speed
The idling speed and final idling speed are electronically regulated and cannot be changed. There is no need to re-
adjust.
Engine protection when limit values are exceeded
If any limit values are exceeded, the engine control system will be activated as a protective measure. The engine pow-
er and/or speed are reduced and if necessary fuel injection is stopped, shutting off the engine.

Fault detection
If an error occurs, an error warning message appears on the ADIC and the corresponding EEM3 error code is shown
on the A-column display.
The error can be pinpointed using the EST (Service Tool) and then remedied. (See Error codes Page 32)
NOTE: Function, removing and fitting the high-pressure pump, checking the delivery pressure: see Chap-
ter 3001A - Mode of operation: Fuel injection system.

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EEM3 in conjunction with the service tool

The following functions are performed with the aid of the service tool:
• Functional test on high-pressure pump
• Functional test on injectors
• Software download
• Software update
• Adjusting engine speed (idling speed and rated speed)
• Correcting current engine operating hours count (only one addition possible)
• Calibrating accelerator pedal sensor
• Calibrating hand throttle
• Analysing errors
• Localising errors
• Show how often a particular error was active
• Read and delete running and shutdown memory (error code)
• Read motor identification and operation memory from ID module

Error codes
Fuel / speed
Error codes

reduction

Error description

Engine sensors
110 FL1 Coolant temperature sensor, signal voltage too low
111 FL1 Coolant temperature sensor, signal voltage too high
112 FLm Coolant temperature too high
113 FLm Coolant temperature alarm
109 FL1 Coolant temperature sensor, no signal
251 FL1 Fuel temperature sensor signal voltage too low
252 FL1 Fuel temperature sensor signal voltage too high
253 FL1 Fuel temperature too high
261 FL1 Fuel temperature sensor, no signal
114 FL1 Charge air temperature sensor, signal voltage too low
115 FL1 Charge air temperature sensor, signal voltage too high
116 FL1 Charge air temperature, value too high
117 FL1 Charge air temperature sensor, no signal
96 FL1 Oil pressure sensor, signal voltage too low
97 FL1 Oil pressure sensor, signal voltage too high
92 FL1/SL1 Oil pressure too high
98 Oil pressure too low
99 Oil pressure too low, alarm
95 FL1 Oil pressure sensor is faulty
93 FL1 Oil pressure sensor, no signal
100 FL1 Boost pressure sensor, signal voltage too low
101 FL1 Boost pressure sensor signal voltage too high
102 FL1/SL1 Charge presure too low
276 Pressure drop in intake system too high during engine start-up
103 FL1/SL1 Boost pressure too high
104 FL1 Boost pressure, no signal
263 FL2/SL2 Rail pressure sensor - signal voltage too low
264 FL2/SL2 Rail pressure sensor - signal voltage too high
265 FL2/SL2 Rail pressure too high

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266 FL2/SL2 Rail pressure, no signal

94 FC Overspeed
269 FL1/SL1 Engine speed, signals faulty
271 FL1/SL1 Engine speed sensor signal faulty
272 FL1/SL1 Faulty engine speed sensor signal
273 FL1/SL1 Engine speed sensor connections reversed
281 FL1/SL1 Faulty camshaft position sensor signal
282 FL1/SL1 Faulty camshaft position sensor signal
283 FL1/SL1 Camshaft position sensor connections reversed
284 FL1/SL1 Camshaft position sensor signal not plausible
121 FL1/SL1 Water in fuel
291 FL1 Fuel delivery pressure sensor, signal voltage too low
292 FL1 Fuel delivery pressure sensor, signal voltage too high
293 FL1 Fuel delivery pressure sensor, no signal
EEM3 diagnosis
22 Temperature sensor in the engine controller, signal voltage too high
20 FL1 Temperature in engine controller too high
21 Temperature sensor in the engine controller, signal voltage too low
23 Temperature sensor in the engine controller, no signal
471 Air pressure sensor in engine controller, signal voltage too low
472 Air pressure sensor in the engine controller, signal voltage too high
473 Air pressure too high
474 Air pressure sensor in the engine controller, no signal
211 FL1 Supply voltage 1 too low
212 FL1 Supply voltage 1 too high
215 FL1 Supply voltage 3 too low
216 FL1 Supply voltage 3 too high
141 A CAN Bus OFF (vehicle bus)
143 CAN bus OFF (ID modules - EEM3)
10 FL2/SL2 EEPROM error
221 FL2/SL2 Engine electronics self-test, internal error 1
222 FL2/SL2 Engine electronics self-test, internal error 2
223 FL2/SL2 Engine electronics self-test, internal error 3
231 Engine controller does not switch off
233 Engine controller switch-off did not function the last time
235 Final stage 1, short-circuit to ground
237 Final stage 3, short-circuit to ground
241 Final stage 1, short-circuit to battery +
245 Engine controller switches off briefly while operating and then functions again
246 Engine controller switches off briefly 3 times while operating and then functions again
248 Water in fuel sensor - supply voltage too low
249 Water in fuel sensor - supply voltage too high
172 Upgrade protective error
EEM3 function monitoring
17 Battery voltage is much too low
18 Battery voltage is much too high
19 Battery voltage, no signal
371 Battery voltage is too low
372 Battery voltage is too high
80 IDLE Accelerator pedal potentiometer, signal voltage too low
81 IDLE Accelerator pedal potentiometer, signal voltage too high
146 A Speed setting through FMGR too low
147 A Speed setting through FMGR too high
381 FL2/SL2 Rail pressure too low
382 Rail pressure too high
383 FL2/SL2 Rail pressure is lower than expected

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2002A-34

384 FL2/SL2 Rail pressure is higher than expected

385 FL2/SL2 Rail pressure, leakage at no-load speed
386 FL2/SL2 Rail pressure, leakage
387 FL2/SL2 Rail pressure signal, leaks during overspeed
391 FL2/SL2 Pressure relief valve open
392 FL2/SL2 Pressure relief valve is stuck
441 Fuel delivery pressure, value fluctuates
442 Fuel delivery pressure sensor, drop-out
445 Fuel delivery pressure, too high
446 FL1/SL1 Fuel delivery pressure, too low
421 High-pressure pump solenoid valve, short-circuit to ground
422 High-pressure pump solenoid valve, short-circuit to +supply
423 High-pressure pump solenoid valve open circuit
424 High-pressure pump solenoid valve, driving circuit overtemperature
Injector function monitoring
311 FL2/SL2 Injector 1 - solenoid valve short circuit to ground
312 FL2/SL2 Injector 1 - solenoid valve short-circuit on +supply
313 FL2/SL2 Injector 1 - solenoid valve open circuit
314 FL2/SL2 Injector 1 - solenoid valve is open too long
315 FL2/SL2 Injector 1 - solenoid valve error
321 FL2/SL2 Injector 2 - solenoid valve short circuit to ground
322 FL2/SL2 Injector 2 - solenoid valve short circuit on +supply
323 FL2/SL2 Injector 2 - solenoid valve open circuit
324 FL2/SL2 Injector 2 - solenoid valve is open too long
325 FL2/SL2 Injector 2 - solenoid valve error
331 FL2/SL2 Injector 3 - solenoid valve short circuit to ground
332 FL2/SL2 Injector 3 - solenoid valve short-circuit on +supply
333 FL2/SL2 Injector 3 - solenoid valve open circuit
334 FL2/SL2 Injector 3 - solenoid valve is open too long
335 FL2/SL2 Injector 3 - solenoid valve error
341 FL2/SL2 Injector 4 - solenoid valve short-circuit to ground
342 FL2/SL2 Injector 4 - solenoid valve short-circuit on +supply
343 FL2/SL2 Injector 4 - solenoid valve open circuit
344 FL2/SL2 Injector 4 - solenoid valve is open too long
345 FL2/SL2 Injector 4 - solenoid valve error
351 FL2/SL2 Injector 5 - solenoid valve short-circuit to ground
352 FL2/SL2 Injector 5 - solenoid valve short-circuit at +supply
353 FL2/SL2 Injector 5 - solenoid valve open circuit
354 FL2/SL2 Injector 5 - solenoid valve is open too long
355 FL2/SL2 Injector 5 - solenoid valve error
361 FL2/SL2 Injector 6 - solenoid valve short-circuit to ground
362 FL2/SL2 Injector 6 - solenoid valve short-circuit on +supply
363 FL2/SL2 Injector 6 - solenoid valve open circuit
364 FL2/SL2 Injector 6 - solenoid valve is open too long
365 FL2/SL2 Injector 6 - solenoid valve error
ID module
451 FLf/SLf Incorrect engine specification
452 FLf/SLf Incorrect serial number
453 FLf/SLf ID module, no communication
454 FLf/SLf ID module, not compatible
455 FLf/SLf ID module, memory 1 faulty
456 ID module, supply voltage too high
457 ID module, supply voltage too low
458 ID module, temperature too high
459 ID module, memory 2 faulty
461 ID module, internal error 1

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 2002A-35

462 ID module, start error

463 FLf/SLf Missing engine specification
464 FLf/SLf Missing serial number
465 Missing ID module, by pass function activated
466 Missing ID module, by pass function deactivated
467 Missing ID module, by pass function time expired

Abbreviations:
FL1 ..................................................................... Fuel injection limit 1 (75% of volume at nominal output)
FL2 ..................................................................... Fuel injection limit 2 (50% of volume at nominal output)
FLm .................................................................... Fuel injection limit through parameters in ignition map
FLf ...................................................................... Fuel injection limit fixed at 50 mg
FC ...................................................................... Fuel injection set to zero
SL1 ..................................................................... Speed limit 1 (max. 1800 rpm)
SL2, SLf ............................................................. Speed limit 2 (max. 1500 rpm)
SLp ..................................................................... Speed limit through parameters in ignition map
A ......................................................................... Analogue speed query is active
SDd .................................................................... Delayed engine shut-off
SDi ..................................................................... Immediate engine shut-off
SNA .................................................................... Starting is not possible

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2002A-36

Replacing the EEM3 box

NOTE: The allocation specification and engine serial number are always given on the type plate of the EEM3 box.
Both of these numbers must be quoted when ordering an EEM3 box.
The EEM3 box is located on the left-hand side of the engine. It is mounted on a bracket fitted with a vibration absorber.
1. Turn the ignition switch to the OFF position. Turn the
main battery switch (if present) to the OFF position.
2. Remove the outer plastic cover. Disconnect the plug
connection. Remove the inner plastic cover.
IMPORTANT: You must not touch the contacts on the open
plug connection.
3. Remove the box from the bracket. Check the condition
of the rubber absorbers on the bracket. Replace the rub-
ber absorbers if necessary. The tightening torque of the
retaining bolts is 30 Nm.

4. Put the new EEM3 box in position.

Tightening torque ............................................. 10 Nm
NOTE: Tighten the retaining bolts in the sequence given
(see diagram).
5. Fit the inner plastic cover. Connect the plug connection. SS05N363

Fit the outer plastic cover.

6. Link up the Service Tool and the current software and transfer the memory data file in the ID module to the new
EEM3 box.

SS05N362

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WORK INSTRUCTIONS
1. Cylinder block
A. Measuring wear on cylinder liners
1. Set the dial gauge to zero using a micrometer
screw or a new cylinder liner, (initial dimension
108.00 mm).
2. Thoroughly clean the inner surface of the cylinder
liner before the measurement.
SS05N289
3. Measure cross-wise at the top end, bottom end and
in the middle of the cylinder liner.
4. Check the indicated value for maximum wear and
ovality (compare with nominal values).
Sva 6-93080 EN
2002A-37
B. Removing the cylinder liners
1. If the cylinder liners are to be re-used, they must be
marked so they can be re-fitted in the same posi-
tions.
2. Remove the cylinder liners using the 380000011
and 1TSW 510 extraction tools.
1TSW 510
380000011
SS99N037
C. Checking the cylinder block
1. Clean the cylinder block and all oil lines.
2. Check the coolant ducts and remove any scale and
deposits of dirt from the engine to make sure the
engine cooling system functions correctly.
3. Check that the shell plugs and thread plugs in the
cylinder block are secure and examine the cylinder
block and sealing faces to make sure they are in
serviceable condition.
4. Measure the wear on the camshaft bearings (com-
paring it with the nominal values).
NOTE: If the upper face of the cylinder block needs to
be machined, the pistons must be shortened by the
same amount. Pay attention to the valve disk clear-
ance at the top surface of the piston.
Edition 07-2006
2002A-38
D. Replacing the camshaft bearing bush
1. Pull out the bearing bush with an inner extraction tool.
Once the rear end connection of the camshaft is re-
moved, push out the bearing bush with a long mandrel.
2. Clean the bush seat.
3. Press in a new bearing bush. Pay attention to the posi-
0.1 - 0.4 mm tion of the oil bore. The bearing bush does not need to
be worn down because if it is correctly fitted it will have
the correct inner diameter.
SS05N361

NOTE: All camshaft bearing points have a separate bearing bush. Observe the various outer diameters when re-
moving and adjusting bearing bushes.

SS05N292

The numbering starts at the front end of the engine.

Bore diameter Bore diameter
1. 55.62 - 55.65 4. 55.42 - 55.45
2. 55.42 - 55.45 5. 55.64 - 55.67
3. 55.22 - 55.25

E. Oversize bearing bushes for the camshaft

If the seat of the camshaft bearing bush (front bearing) is damaged, a bearing bush with an oversize outer diameter
of 0.4 mm can be adjusted. The machining dimensions for the seats of the bearing bushes are shown in the illustra-
tion.
CAUTION: Pay attention to the position of the bearing bush oil bores. (see step A-A)
After adjusting, the bearing bushes do not need to be worn down.

SS05N293

Camshaft oversize bearing bushes

Bore diameter Bore diameter
1. 56.02 - 56.05 4. 55.62 - 55.65
2. 55.62 - 55.65 5. 55.84 - 55.87
3. 55.42 - 55.45

The numbering starts at the front end of the engine.

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 2002A-39
F. Adjusting the plug on rear end H. Adjusting the cylinder liner
of camshaft 1. Clean the cylinder liner and the liner recess in the
cylinder block. Once fitted the liner must be able to
rotate freely without the O-ring.
2. Apply a thin coat of marker paint to the underside
of the cylinder liner flange. Fit the cylinder liner
without the O-rings and rotate backwards and for-
wards. Remove the cylinder liner and check that
the paint has been transferred to the whole of the
contact surface.
3. Clean the contact surfaces.

0.03 - 0.08 mm

SS05N295

1. Clean the plug seating.

2. Apply sealant (e.g. Loctite 572) to the contact sur-
face of the plug.
3. Drive in the plug with pressing tool
380000004.
NOTE: Do not drive the plug in too far, because this
could affect the axial play of the camshaft.

G. Adjusting the plug on the rear end of SS99N048

the camshaft after fitting an oversize bear-

ing bush 4. Fit the cylinder liners and attach each liner with two
clamping devices. Measure the height of the cylin-
der liners using a dial test indicator and holder
O - ring 380000364. Set the dial gauge to zero on a flat sur-
face, e.g. the cylinder block. Measure each cylinder
liner at four points. The projection of the cylinder
liner above the surface of the cylinder block should
be between 0.03 - 0.08 mm.
The height difference between the cylinder liners
below a cylinder head must not exceed 0.02 mm.
In addition, a middle cylinder liner must not be low-
er than one of the outer ones.

Plug
SS00F003

Upon completion, the rear camshaft end plug is re-

placed by the plug and the O-ring.

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2002A-40
5. If the height of one cylinder liner is too low, one liner
must be fitted with a higher flange.

BLACK

GREEN

SS05N294
SS99N050

7. Fit the O-rings in the grooves on the lower part of

Height Marker the cylinder and lubricate with liquid soap (not with
(H) grooves engine oil).
(number) NOTE: When tightening on to the cylinder liners,
9.03 +0.02
(standard) stretch the O-rings as little as possible.
The maximum permissible elongation is 6%.
9.08+0.02 1

9.13+0.02 2

9.23+0.02 3
The oversize of the cylinder liner (higher flange) is indi-
cated on the outer circumference by one or more mark-
er grooves as follows:

1st oversize, 0.05 mm = 1 marker groove

2nd oversize, 0.10 mm = 2 marker grooves

3rd oversize, 0.20 mm = 3 marker grooves

6. If the height of a cylinder liner is not even across the
whole breadth, you must check the cylinder liner
flange and the depth of the recess in the cylinder
block. Replace any cylinder liners with misshapen
flanges. If necessary, machine the bush seat in the
cylinder block with a reamer.

SS05N291

8. Press the cylinder liners into the cylinder block. You

should be able to press them in to their starting po-
sition without difficulty. Ensure that the cylinder lin-
ers no longer move upwards after being fitted.

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 2002A-41
2. Flywheel casing
A. Fitting the flywheel casing
The flywheel casing is centred on the cylinder block us-
ing two dowel pins. The casings for the flywheel, which Spacer ring
are available as spare parts, feature ready-made bores
for the dowel pins.
1. Clean the sealing faces between the cylinder block
and the flywheel casing.

SS05N297

NOTE: If the crankshaft shows signs of wear on the

seal seating, a 2 mm spacer ring (available as a spare
part) can be fitted between the flywheel casing and the
crankshaft sealing ring.
5. Carefully press in the sealing ring using installation
tool 380000003 and 1TSW 662 until it reaches the
base of the flywheel casing.

1TSW 662
SS05N296

2. Apply the sealant (e.g. silicone) to the areas shown

in the illustration.
3. Lift the flywheel casing into the correct position and
fit all screws.
4. Centre the casing and adjust the dowel pins with a
mandrel.
5. Tighten the screws on the inner ring to a tightening 380000003
SS99N056
torque of 80 Nm and the screws on the outer ring
to a tightening torque of 150 Nm.
NOTE: The sealing ring must be fitted dry and free of
oil.
B. Replacing the rear crankshaft sealing
ring
1. Separate the tractor between the engine and power
unit.
2. Remove the flywheel.
3. Remove the sealing ring, making sure you do not
damage the crankshaft.
4. Clean the seal seat and grind down any burrs.

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3. Cylinder head
A. Removing the cylinder head B. Removing the valves
1. Clean the engine on the outside. Ensure that valves which are to be reused are marked
appropriately so that they can be replaced in their orig-
inal position.

SS99N057

Drain plug
1. Screw a nut on to a stud bolt for the rocker arm
mechanism. There is no stud bolt for the valves on
the central cylinder. Instead, use a bolt of the ap-
SS05N360
propriate length.
2. Press together the valve springs with lever
Drain off the coolant at the engine drain plug and the 380000008. Remove the valve spring seat retain-
drain cock on the lower side of the cooler. Disconnect ers, the spring guide and the spring. Remove the
the coolant hoses from the cylinder head and the ther- valves.
mostat housing.
2. Remove the intake lines between the exhaust tur- C. Checking the cylinder head
bocharger and the air filter and the charge-air lines 1. Remove carbon deposits from the outlet ducts,
from the turbocharger and the intake manifold. clean the seal surfaces and wash the cylinder
3. Remove the oil lines from the exhaust turbocharg- head.
er. 2. Check the cylinder head for cracks and any other
4. Unscrew the screw connections on the electrical damage.
wires from the injectors.
5. Remove the high-pressure lines and oil leakage
lines. Remove the injectors. Fit seal caps on all
open connections.
6. Remove the intake and exhaust manifolds and the
thermostat housing.
7. Remove the valve cover and the vent hose.
8. Remove the rocker arm mechanism and the push
rods.
9. First loosen all the cylinder head screws by a quar-
ter-turn and then unscrew them. Remove the cylin-
der head.

SS05N299

3. Check the evenness of the cylinder head using a

straight edge. An uneven or bent surface must un-
dergo surface grinding. After grinding, the height of
the cylinder head must not be less than 104.00
mm. The depth of the valve disk below the cylinder
head surface must be 0.60 mm for outlet valves
and 0.70 mm for inlet valves.

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D. Replacing the valve guides

SS99N061

SS05N300
1. Press or force out the old guides using a mandrel.
Clean the valve guide seats.
4. If necessary, clean the bearing surface of the injec-
2. Fit the new guides using pressing tool 380000007,
tor in the cylinder head using a reamer.
which is used to ensure the right installation height
(21 mm above the plane face of the spring).

380000007

SS05N304

SS05N301
3. The same guides are used for both inlet and outlet
valves. Ensure that the steepest chamfer on the
5. Measure the amount of play between the valve
guide points towards the valve spring. Ensure that
stem and the valve guide with a dial gauge. Lift the
the valves do not jam in the guides.
valve so that the valve disk juts out of the surface
of the cylinder head by 15 mm and measure the
clearance. For the inlet valves, this must not ex-
ceed 0.30 mm and for the outlet valves, must not
exceed 0.35 mm. To determine whether the valve
guide is worn, a new valve must be used for the
measurement.

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2002A-44
E. Machining the valve seat Inlet valve

SS05N306

3. Clean the valve seat. Cool the new valve seat ring
in dry ice or liquid nitrogen.
4. Fit the valve seat ring with a suitable pressing tool.
Machine the seat.
NOTE: If required, the valve seat rings can be re-
SS05N302
placed by oversize valve seat rings. If this is the case,
A damaged valve seat must be machined using a mill- the cylinder head will need to be reworked. (see Tech-
ing cutter. If the width of the seat exceeds 2.3 mm at the nical Data Page 12)
outlet valve or
3.7 mm at the inlet valve, it must be reduced, particu- G. Grinding the valves
larly at the outer edge. To ensure there is an adequate seal around the valves,
The angle of the valve seat is 45° +20' at the outlet there is a difference between the angles of the sealing
valve and 35°+20'at the inlet valve. faces. There is an especially narrow sealing face that
guarantees an effective seal even after extended peri-
ods of use.
F. Replacing the valve seat rings
The outlet valves have separate valve seat rings. If the
sealing face is so heavily soiled that it cannot be re-
paired by machining, the valve seat rings must be re-
placed.
1. Grind the valve disk on a discarded valve so that it
fits snugly in the valve seat. Fit the valve and weld
correctly on to its seat. Cool with water.
2. Rotate the cylinder head and knock out the valve
together with the seat.

Outlet valve

SS05N307

A B C [mm]
INLET 35° -20'
35° 0.7 ±0.05
+20'
(max. 2.20)
OUTLET 45° -20'
45° 0.6 ±0.05
+20'
(max. 2.20)
1. Machine the damaged valve disk with a valve
SS05N305 grinder. Adjust the angle for the outlet valves to 45°-
20'
and for the inlet valves to 35°-20'.
2. If the height of the edge of the valve disk is less
than 1.5 mm after grinding, or if the valve stem is
bent, the valve will need to be replaced.
3. Grind the valves using a grinding paste and exam-
ine the contact surface using marker paint.

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 2002A-45
4. Clean the grinding paste off the cylinder head and 5. Tighten the screws in phases as follows:
valves.
1. Pre-tension of 80 Nm
H. Fitting the valves 2. Tighten by 90°
1. Use a spring tester to check that the valve springs 3. Tighten by 90°
show the correct straightness, length and tension. 4. Adjust valve clearance (see Page 47).
Compare the measured values with the technical 5. Sub-assemble the engine and fill up the coolant
data. and
2. Oil the valve stems and fit the valves in the cylin- engine oil.
ders in the correct sequence.
NOTE: The cylinder head screws do not need to be
3. Fit the valve springs, spring disks and valve spring
retightened after this procedure has been carried out.
seat retainers in the cylinder head using lever
380000008.
4. After inserting the valves, tap the ends of the valve
stems, e.g. with a plastic hammer, to make sure the
valve spring seat retainers are sitting correctly.

I. Fitting the cylinder head

1. Measure the length of the cylinder head screws.
The length should lie within the limit values shown
in the diagram. Replace any screws which vary
from these limit values.

SS05N310

Tighten the retaining bolts / nuts on the exhaust mani-

fold to a tightening torque of 50 Nm.
IMPORTANT: Do not over-tighten the nuts.

SS05N308

2. Screw the cylinder head stud bolts into the cylinder

head with a tightening torque of 30 Nm. Fit any
valve tappets which were removed.
3. Ensure that the sealing faces are clean and fit the
cylinder head seal. Use a ruler to check that the cyl-
inder heads are parallel to each other. Clean, oil
and fit the screws.

SS05N309

4. The illustration shows the order in which the screws

should be tightened. The correct sequence is also
cast on the cylinder heads.

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2002A-46
4. Valve mechanism
A. Maintenance of the rocker arm system
1. Examine the valve tappets, particularly the guide
face on the camshaft. Replace any worn or twisted
valve tappets.
SS05N311
2. Examine the push rod to make sure it is straight. Al-
so check the condition of the spherical surfaces on
the end of the push rod.
3. Dismantle the rocker arm mechanism and clean
the individual parts. Check the level of wear on the
rocker arm shaft and the condition of the oil lines.
SS05N312
4. Check the diameter of the bore in the rocker arm
(23.000 - 23.021) and replace if necessary. If the
pressure face of the rocker arm is worn, grind it to
the correct shape. Do not grind down more than
necessary, because the pressure surface is sur-
face-hardened.
SS99N072
Sva 6-93080 EN
SS05N313
5. Attach a flange fastening to one end of the rocker
arm shaft. Apply oil to the shaft and assemble the
parts in the correct sequence. Pay attention to the
correct position of the bearing holders and the
shaft. The divided side of the holder and the oil
bores in the shaft must point towards the valve face
as shown in the illustration. Attach the other flange
fastening.
SS05N314
B. Replacing the camshaft / the camshaft
gear
1. Remove the intake pipe between the turbocharger
and the intake manifold. Remove the cover of the
valve mechanism and the venting pipe. Remove
the rocker arm mechanism.
2. Remove the cooler unit, the fan, the generator and
the belt.
3. Remove the pulley and the vibration absorber.
4. Undo the crankshaft nut and remove the hub.
5. Remove the cover from the timing gear case.
Edition 07-2006
 2002A-47
C. Checking and adjusting valve
clearance

SS05N315

6. Lock the valve tappets so that they do not come off
when the camshaft is removed and do not hinder
installation of the camshaft. Raise the valve tappet
push rods by bending two at a time slightly to-
wards each other, working with pairs positioned
alongside each other. Clamp the push rods to-
gether (e.g. with an O-ring), working with pairs po-
sitioned alongside each other, so that they are
slightly tensioned, keeping the tappets in the up-
per position.
CAUTION: Applying too much tension to the push
rods will cause them to distort.
7. Rotate the crankshaft until the position markers on
the camshaft gear and intermediate gear are
aligned with each other. Pull out the camshaft.
8. Remove the camshaft gear wheel from the cam-
shaft.
9. If you will be refitting the used camshaft or cam-
shaft gear later, clean the parts before assembling
them.
10. Slide the feather key into the appropriate groove
on the camshaft and fit the camshaft gear wheel.
Tighten the nut to 200 Nm.
11. Lubricate the bearing faces and slide the shaft into
the cylinder block, noting the position marks on
the camshaft gear.
12. Fit the cover of the timing gear case and the pulley
with the hub. (see Page 49)
13. Lower the push rods and fit the rocker arm mech-
anism. Adjust the valves. Then screw the valve
cover and venting hose on to the cylinder head.
Also fit the intake pipe that goes between the tur-
bocharger and intake manifold.
14. Fit the generator and the belt. Tension the belt to
the correct level of tension. Fit the cooler unit.
SS05N314
The clearance of the inlet and outlet valves is 0.35
mm. You can carry out this check when the engine is
hot or cold. Check and adjust the the valve clearance
of one cylinder while the piston is positioned at the up-
per dead point of the compression stroke. Proceed fol-
lowing the engine's fuel injection sequence.
If the valve clearance deviates from the specified val-
ue, loosen the lock nut and adjust the valve clearance
using the adjustment screw. The 0.35 mm thickness
gauge must fit snugly between the rocker arm and
the end of the valve stem.
E A E A E A E A E A
E A
I = INLET
O = OUTLET SS05N317
- Turn the crankshaft in running direction until the
valves of the 6th cylinder overlap. (Outlet valve is
closed, inlet valve is opened). Check the valves on the
first cylinder.
- Rotate the crankshaft by 1/3 of a turn in running di-
rection until the valves of the 2nd cylinder overlap.
Check the valves on the 5th cylinder.
- Continue working, following the fuel injection se-
quence:
Fuel injection sequence: 153624

Valve overlap: 624153

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2002A-48
5. Crankshaft
A. Removing the crankshaft
1. Unscrew the oil sump.
2. Remove the retaining bolts of the lubricating oil
pump pressure line from the cylinder block. Re-
move the oil sump, suction lines and pressure
lines.
3. Remove the flywheel casing.
4. Remove the pulley, vibration absorber and hub
from the front end of the crankshaft (see Page 54).
5. Remove the con-rod bearing covers and push the
con-rods up so they are not in the way when re-
moving the crankshaft.
6. Remove the crankshaft bearing covers and lift the
crankshaft out.
g. Checking the crankshaft
SS05N318
1. Clean the crankshaft. Don't forget to clean the oil
bores as well.
2. Measure the amount of wear at different points on
the crankshaft bearing journal. Ovality, conicity or
other forms of wear must not exceed 0.03 mm.
SS05N319
3. Refit the bearing caps with new bearing shells and
tighten to the correct tightening torque. Measure
the internal diameter using a dial gauge which has
been zeroed using the values obtained in step 2.
The display will then show the actual bearing play.
Sva 6-93080 EN
If a bearing housing which exhibits wear is not
round, take the measurements at several different
points.
4. If the bearing play exceeds 0.18 mm on the main
bearings or 0.14 mm on the con-rod bearings with
new bearing shells, the bearing journals on the
crankshaft must be ground.
Refer to the Technical Data for the correct under-
size and corresponding bearings. Ensure that the
radii do not change when ground.
NOTE: If the ground bores of the crankshaft bear-
ing are damaged or worn as a result of damage
to a bearing, main bearings with an oversize of
1.0 mm (external) and an undersize of 0.5 mm
(internal) are also supplied as spares. The cylin-
der block must now be machined down to a di-
mension of 92.000 - 92.025 mm. The crankshaft
must be machined down to a dimension of 84.485
- 84.520 mm. The bearing shell with a groove
and an oil bore is fitted in the cylinder block, and
the bearing shell without an oil bore is fitted in
the bearing cap.
C. Replacing the crankshaft gears
380000329
SS05N320
1. Use the extractor tool for the crankshaft gears and
remove both gears.
2. Clean the seat on the crankshaft, e.g. using a wire
brush.
3. Heat up the new gears to 200°C. Knock the gear
wheels on to the shaft using a suitable sleeve or
soft mandrel. Pay attention to the position of the
feather key and ensure that the orientation marks
on the front gear wheel are clearly visible. Allow the
parts to cool down.
Edition 07-2006
 2002A-49
D. Fitting the crankshaft 4. Insert the main bearing covers by number. Behind
1. Clean the oil lines, bearing shells and seats. Make them fit axial bearings with guide lugs. Lubricate
sure the crankshaft is clean. the screws and tighten to a tightening torque of
200 Nm.

SS05N323

SS05N321 5. Ensure that the crankshaft can rotate unhindered

and without jamming. Check the axial play with a
2. Position one bearing shell (A) with an oil bore and dial gauge. The correct axial play is 0.10-0.38 mm.
oil groove into the cylinder block and one bearing If the axial play is too great, you must insert axial
shell (B) without an oil bore into the bearing cover. bearings with oversize.
Ensure that the lugs of the bearing shell engage
with the corresponding notches and that the shells NOTE: Never abrade or machine the bearing shells
to be fitted in the cylinder block have an oil bore that and never file the sides of the bearing covers.
matches the oil bore in the cylinder block.
3. Oil the bearing faces and fit the crankshaft. E. Crankshaft hub
NOTE: When fitting the crankshaft, make sure the
sensor wheel of the speed sensor is not damaged.
Insert the axial bearings of the crankshaft such that the
lubrication grooves point towards the crankshaft.

SS05N325

When mounting the hub at the front end of the crank-

shaft, pay attention to the correct position (injection
marker on vibration damper). The hub features markers
to help with fitting -- the two lines on the hub must be
SS05N322 positioned to the side of the points marked • on a tooth
of the crankshaft.

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2002A-50
6. Connecting rods and pistons
A. Removing the pistons together with the
connecting rods
1. Loosen the oil sump and the pressure and suction
lines for the lubricating oil.
2. Loosen the cylinder head.
3. Scrape off the carbon deposits in the cylinder liner.
If necessary, scrape away the sharp wearing edge
in the reverse point of the piston ring.
4. Remove the con-rod bearing cover and the con-rod
bearing shells. If the bearing shells are to be re-
used, you will need to number them in sequence.
5. Slide the piston and con-rod upwards using the
shaft of a hammer or a similar tool.
6. Remove the circlips from the piston rings. Slide out
the piston rings.
NOTE: If the piston pin cannot be moved by pressing SS05N327

it with a finger, the piston must be heated up evenly to

100°C.
B. Checking and replacing the connecting
rod bearings
1. Clean the con-rod and bearing shells. Fit the bear-
ing shells and tighten the 'used' screws to a tighten-
ing torque of 40 Nm + 90°.
NOTE: The connecting rod bolts must only be used
once.
4. Force-fit the new bush. The oil duct in the bush
must match the corresponding duct in the con-rod.
After adjusting, machine the new bush with the
reamer to the specified dimensions.
NOTE: If necessary, an oversize bush can be fitted in
the connecting rod. In this case, the ground bore of the
connecting rod must be reworked (see Technical Da-
ta).
C. Checking the connecting rod
Clamp the con-rod in a suitable test apparatus and
check it. (For test values, refer to Technical Data
Page 15)
The con-rods are divided into weight groups of
20 g. The weight group is indicated by a letter. This is
marked on the side face of the con-rod. All the con-rods
in an engine must belong to the same weight group, i.e.
the permissible difference in weight is 20 g.

SS99N090

2. Measure the internal diameter with a plug gauge

that has been zeroed to the diameter of the rele-
vant bearing journal. If the clearance of the new
bearing shells is greater than 0.14 mm, the con-rod
bearing journals must be ground and the next un-
dersize (repair level) bearing shell fitted.
3. If the piston pin bush is worn, it must be driven out
using a suitable mandrel.
SS05N328

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 2002A-51
The letters represent the following weights: 3. Position the piston ring in the cylinder and measure
Weight [g] the distance between the ends of the ring. For the
1st and 3rd rings the distance must not exceed 1
F 1935 - 1954 mm and for the 2nd ring it must not exceed 1.5
V 1955 - 1974 mm.
X 1975 - 1994 4. Re-insert the piston rings with the aid of the piston
ring pliers. Make sure that the rings are in the cor-
Y 1995 - 2014 rect position and the letters TOP on the rings or the
W 2015 - 2034 manufacturer's name point upwards.
Z 2035 - 2054
G 2055 - 2074

D. Checking and replacing the piston

rings
1. Loosen the piston rings using piston ring grippers.
Do not stretch the rings any more than is necessary
to loosen them. If the same rings are to be fitted
back in the pistons, set them aside in their correct
sequence.

SS05N331

SS05N329

2. Clean the piston ring groove carefully and then

measure the play of the piston ring in the groove.
The play must be less than 0.15 mm. Check wheth-
er the play was created by wear in the ring groove.
Then replace either the rings or the pistons as ap-
propriate.

SS05N330

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2002A-52
E. Checking the piston
Visually examine the pistons and piston pins. In partic-
ular, look out for any cracks on the edge of the combus-
tion chamber or the upper part of the piston pin bore.
Measure the diameter of the piston at the point shown
in the diagram and compare the result with the given
value. If necessary, replace the piston.
∅ 107.883 -
107.897
17 mm
SS05N332
F. Fitting the piston pin
1. Insert the con-rod into the piston and slide the pis-
ton pin into place.
SS05N333
CAUTION: The combustion chamber in the piston and
the letter indicating the weight class of the con-rod can
be found on the side.
2. Then fit the circlips of the piston pin, making sure
that the ends of the circlips point upwards.
Sva 6-93080 EN
G. Fitting pistons and connecting rods
1. Insert the bearing shells into the con-rods. Make
sure that the fitting surfaces are clean and the bear-
ing shells are sitting correctly.
2. Grease the piston, piston rings and cylinder with
engine oil. Rotate the piston ring gap on different
sides of the piston.
SS05N334
3. When fitting, use a piston ring tension band or in-
sertion cone. Insert the piston and the con-rod such
that the combustion space of the piston and the in-
jector in the cylinder head are on the same side
(the arrow on the piston must point forwards).
4. Grease the con-rod journals and bearing shells
with oil and slide the pistons downwards. Fit the
bearing cover such that the guide lugs of the bear-
ing shells are on the same side. Then tighten the
screws to a tightening torque of 40 Nm+90°.
5. Check that the lower con-rod bearing has sufficient
axial play on the crank pin.
Edition 07-2006

7. Flywheel
A. Replacing the starter ring gear on the
flywheel
The ring gear cannot be reworked because the teeth on
the starter side are bevelled and hardened.
1. Release the old ring gear by tapping with a man-
drel. Clean the ring gear seat on the flywheel with
a steel wire brush.
2002A-53
B. Fitting the flywheel
1. Clean the contact surfaces on the rear crankshaft
flange and the flywheel.
2. Bolt the flywheel on to the crankshaft. Two M12
grub screws, which fit into the securing holes in the
flywheel, should be used as guide pins.
3. Tighten the screws on the flywheel evenly to a tight-
ening torque of 150 Nm.

SS05N335

2. Heat up the new ring gear to 150 - 200°C. Fit the

ring gear, making sure the bevelled inner edge fac-
ing the flywheel and the bevelled teeth point to-
wards the starter.
IMPORTANT: Allow the ring gear to cool in the air.
Do not use coolant.

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2002A-54
8. Control mechanism
A. Removing the timing gear case B. Replacing the intermediate gear
The timing gear case acts as a seal to the sump. bearing bush
NOTE: The timing gear case can only be removed If the intermediate gear bearing bush is to be replaced,
once the oil sump has been removed. force-fit a new bearing bush
such that 0.1 - 0.25 mm of its rear edge is inside the
1. Drain off the engine oil and remove the sump. rear
2. Remove the fan, generator, pulley and belt. If the edge of the gear wheel (see illustration).
tractor has air conditioning or a compressed air
system, the compressor must also be removed.
Key for Visco fan ....................................... 380001791 1
Key for reverse fan .................................... 380002598 2
IMPORTANT: Do not disconnect coolant lines!
Just pivot the compressor backwards with the
lines connected and suspend to relieve strain on
the lines.
3. Remove the pulley and vibration absorber.
4. Remove the crankshaft nut using key 380002658.
5. Remove the retaining bolt on the double intermedi-
ate gear bearing.
6. Take the cover off the timing gear case and remove
the oil repellent ring from the crankshaft.
7. Remove the high-pressure fuel pump (see Chapter
3001A).
8. Remove the double intermediate gear.
9. Unscrew the intermediate gear bolts. Remove the 1. Lathe chuck
flange, gear wheel and bearing journal. 2. Roller ø=5 mm SS05N336
10. Pull out the camshaft.
NOTE: If the cylinder head and valve mechanism are After fitting, machine the inner diameter of the interme-
not dismantled, the valve tappets must be prevented diate gear bearing bush to the correct dimension. Cen-
from falling off (see Page 46). tre the intermediate gear as shown in the diagram
above such that the tooth play stays uniform.
11. Unscrew the bolts on the timing gear case and re-
move the case. If a soft wedge needs to be driven
between the engine block and the wheel arch,
make sure you do not damage the sealing faces in
the process!
12. Loosen the front crankshaft sealing ring from the
wheel arch and clean all dismantled parts.

SS05N337

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 2002A-55
C. Fitting the timing gear case
The position of the timing gear case and cover is deter-
mined by two sprung dowel pins. For this reason, cen-
tring should not be done as part of the fitting process.
However, the play between the different gear teeth
must be checked. The timing gear case and cover sup-
plied as spare parts also feature holes already ma-
chined for the dowel pins.
1. Use a 2-dimensional sealing compound to seal the
timing gear case and fit on cylinder block. Drive in
the dowel pins with a mandrel. Tighten the screws
and nuts.
2. Oil the camshaft bearing and insert the shaft in the
cylinder block. If the push rods and valve tappets SS05N338
are still attached, remove them.
5. Check the tooth play.
It must be 0.05 - 0.25 mm.

SS05N339

6. Attach the oil repellent ring to the crankshaft and fit

the wheel arch cover using a new seal. Drive in the
SS05N365 dowel pins using a mandrel (connect the pipe pin
around the stud bolt). Tighten the bolts and nuts to
3. Fit the intermediate gear with the shaft stud bolt the correct tightening torque.
and ensure that the markers are correctly aligned.
Insert the washer and tighten the bolts to the cor-
rect tightening torque.

SS05N364
SS99N114

4. Pre-fit the angled ball bearings in the double inter- 7. Insert the protective ring correctly into the seal seat
mediate gear. Fit the intermediate gear in the timing (see sectional drawing) and use special tool
gear case using the retaining bolt. 380000002 to insert the front crankshaft sealing
NOTE: Use new O-rings! ring fully home.

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2002A-56
SS05N340
8. Oil the sealing faces on the sealing ring and crank-
shaft and the profile for holding the hub.
9. Line up the marker on the hub with the marker on
the crankshaft (see diagram).
Sva 6-93080 EN
SS05N325
10. Slide the hub on to the crankshaft profile.
11. Apply a thin coat of oil to the thread of the crank-
shaft nut. Fit the nuts and tighten with key
380002658.
Tightening torque .......................................... 1000 Nm
12. Fit the vibration damper and the V-belt pulley on the
hub. Tighten the bolts to the correct tightening
torque.
13. Refit the other dismantled parts.
Edition 07-2006

9. Lubrication system
A. Checking the oil pressure valve
Check the function of the oil pressure valve if the en-
gine's oil pressure is insufficient or if it fluctuates notice-
ably. First make sure, however, that there is enough oil
in the engine.
25 Nm
Loctite 638
SS05N341
1. Remove the cover from the oil pressure valve and
the spring underneath it. Pull the valve cone out of
the cylinder block.
2. Clean the parts. Check that the valve cone can
move easily in the valve insert. If the valve cone
sticks, remove any dirt which has accumulated. If
necessary, rub down the parts using fine sanding
wool or else use new parts. Clean the sealing sur-
faces between the cylinder block and the cover.
3. Apply Loctite 638 to the outer circumference of the
cylindrical part of the valve insert. Drive the valve
insert into the engine block using a suitable tool. In-
sert the valve cone into the valve insert. Fit the
spring and the cover, using a new seal for the cov-
er.
NOTE: The spring must be fitted with the largest di-
ameter facing the cover.
B. Removing and checking the oil pump
1. Drain off the engine oil and remove the sump.
2. Release the intake and pressure line from the oil
pump.
3. Remove the oil pump and any regulating washers
between the pump housing and the cylinder block.
4. Release the pump cover and seal. Remove the
gear wheel on the axle.
Sva 6-93080 EN
2002A-57
5. Clamp the pump on the pump gear wheel into a
vice with protective jaws and release the nuts on
the drive gear. Drive out the pump driveshaft from
the gear wheel using a plastic hammer. Pull the
driveshaft gear wheel out of the pump body.
6. Wash the parts and check the level of wear. Com-
pare the actual measurements with the given di-
mensions in the Page 17'Lubricating oil pump'
section. Replace any worn parts and all the seals.
60 Nm
+Loctite 243
SS05N342
7. The bearing points on the oil pump are fitted with
separate bearing bushes. If the bearing bushes are
replaced, machine them after installation to a di-
mension of 18.000 - 18.018 mm.
C. Assembling and fitting the oil pump
1. Fit the gear wheels in the recess located in the
pump body. Position a new seal (if required) be-
tween the pump body and the cover. Tighten the re-
taining bolts slightly. Rotate the shaft and tap the
cover laterally into the position in which the shaft
rotates most easily. Firmly tighten the retaining
bolts on the cover and check that the shaft can still
turn slightly.
2. Fit the drive gear on to the pump shaft. Apply Loc-
tite 243 screw locking fluid into the nut thread. Fit
the washer and nut. Tighten the nuts to a tightening
torque of 60 Nm.
Edition 07-2006
2002A-58
D. Assembly of the oil sump
Fit the seal for the sump using silicone strips facing the
cylinder block.

SS05N343

3. Clamp the pump on the mounting bracket into a

vice with protective jaws. Use the dial gauge to
check the axial play of the gear wheel (0.03 - 0.11
mm). If necessary, change the number of seals be-
tween the cover and the pump body.
SS05N345
E. Oil cooler
All engine types are fitted with an engine oil cooler that
is housed between the engine oil filter and the cylinder
block.
1. Before removing the oil cooler, drain off the coolant.

SS05N344

4. Fix the pump in place below the cylinder block and

use the dial gauge to check the tooth play between
the gears of the crankshaft and the pump. (0.05 -
0.25mm). If necessary, change the number of com- SS05N346
pensation washers between the pump base and
the cylinder block (the compensation washers are 2. Fit new seals. Fit the oil cooler such that the drain
graded in steps of 0.2mm). Inserting / removing a nozzle points downwards. Attach the coolant hoses
compensation washer alters the tooth play by correctly.
around 0.07 mm. 3. Put some screw locking fluid (e.g. Loctite 243) on
NOTE: When measuring the tooth play, the engine the thread on the engine end of the retaining tube
must be in operating position (cylinder pointing up- and tighten it to a tightening torque of 60 Nm.
wards) because the tooth play is affected by the bear-
ing play of the crankshaft.
5. Attach the intake and pressure line of the pump and
replace the seals on the retaining flange.
6. Fit the oil sump and fill with engine oil.

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 2002A-59
F. Piston cooling nozzles G. Recommended lubricants
The piston cooling nozzles can be removed after taking
out the oil sump. The nozzle is equipped with a ball - For engines with a turbocharger
valve. This has an opening pressure of 3±0.25 bar. API CI-4

ACEA E7

SS05N347

1. If necessary, replace the valve. Remove the valve

from the engine and remove the nozzle pipe. Fit the
new valve.

SS05N349

SS05N347

2. When assembling the valve, attach the nozzle pipe

to at an angle of 90 ° to the longitudinal axis of the
engine as shown in the illustration. Fix the valve in
place with a tightening torque of 30 Nm. After as-
sembling, check that the nozzle pipe does not
touch either the piston or the con-rod when the en-
gine is running.

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2002A-60
10. Cooling system
A. Thermostat
The opening temperature of the smaller, single-action
thermostat is 79 ° C.
The opening temperature of the larger, double-action
thermostat is 83 ° C.
If you have any doubts as to whether the thermostat is
functioning correctly, inspect it as follows:
· Place the thermostat in boiling water, making sure
it does not touch the sides of the container.
· The thermostat must start opening within 20 sec-
onds.
· It must be fully open within 50 seconds. Compare
the measurements obtained with the specifica- SS99N140

tions in the Technical Data.

4. Pull out the impeller with the aid of extraction tool
1TSW 662.
5. Remove the circlip from the pump body. Press the
shaft out of the pump body together with the bear-
ing, for example using a hydraulic press, pressing
towards the fan. Clamp the pump body such that
the shaft bearing can be taken out.
6. Use a mandrel to remove the axial and shaft seals
from the pump body. Clean the parts and check
their condition. Replace any worn or defective parts
with new ones.
NOTE: If the pump bearings need to be replaced, it is
more cost-effective to fit the pump repair kit, which al-
so includes all the seals needed for repairs (see spare
parts catalogue).

SS05N350

B. Repairs to coolant pump

1. Drain the coolant. Unfasten the thermostat casing,
fan and belt.
2. Remove the coolant pump. Remove the rear plate
of the pump and clean the sealing faces.
3. Release the retaining nuts of the pulley and remove
the pulley. Use an extraction tool if required.

Sva 6-93080 EN Edition 07-2006


380000005
SS05N351
7. Use mandrel 380000005 to tap the shaft seal into
the pump body. Fit the bearings and the intermedi-
ate sleeves on the shaft. Lubricate the bearings
with plenty of heat-resistant ball bearing grease.
Mount the shaft and bearing in position such that
the force created when they are pressed does not
affect the bearing balls. Fit the bearing circlip in its
place.
SS05N352
8. Fit the impeller, supporting the other end of the
coolant pump shaft. The clearance between the
pump housing and impeller is 0.8 - 1.2 mm. Check
that the coolant pump shaft can rotate freely.
9. Attach the pulley to the shaft and tighten the retain-
ing nuts to a tightening torque of 120 Nm.
Sva 6-93080 EN
2002A-61
SS05N353
10. Attach the rear plate using a new seal. To fit the
rear plate for the bores shown in the diagram, use
guide lugs with a diameter of 8.5 mm.
C. Coolant quality requirements
· The coolant must fulfil quality standard
ASTM D 3306 or BS 6580:1992.
· If no frost resistance requirements are specified, a
mixture ratio of 40% is sufficient to protect against
corrosion.
· Check the coolant (anti-freeze) mixture ratio at
certain intervals. Replace the coolant every two
years.
· The water used must be clean and soft, i.e. it must
contain no metals or their salts.
IMPORTANT: Never use water on its own as a
coolant.
Edition 07-2006
2002A-62
11. Air intake and exhaust system
An engine fitted with a turbocharger is much more sen- 5. If necessary, remove the manifold. Clean the seal-
sitive to malfunctions and contamination in the intake ing faces and remove any carbon deposits. Ensure
and exhaust system than a conventional aspirated en- that the sealing faces are even. If the retaining
gine. You should therefore be particularly careful when flanges are twisted or there are scratches on the
working with the intake and exhaust system. sealing faces, machine the flanges or replace the
exhaust manifold.
A. Checking the air filter 6. Ensure that no loose objects or dirt particles have
Engine performance and service life are highly depend- made their way into the exhaust pipe or silencer.
ent on the condition of the air filter. A defective air filter Any such loose objects or particles may increase
allows in dirt particles that cause lasting damage to the the counter-pressure for exhaust gases from the
turbocharger and the engine. A blocked air filter im- turbine wheel.
pedes the engine's performance and may also allow oil
to escape through the sealing ring on the shaft of the
exhaust turbocharger.
CAUTION: The safety filter located inside the main fil-
ter does not require cleaning, but must be replaced
when necessary (see operating instructions).

B. Checking the air intake system and ex-

haust system
IMPORTANT: Any leaks which develop in the in-
take or exhaust system seriously affect the effec-
tiveness of the turbocharger. Because of the
pressure levels present, even small leaks in the
manifold or turbine inlet flange become bigger
very quickly. You must therefore repair any leaks
as soon as you discover them.
1. Examine the pipes and sealing faces between the
air filter and the exhaust turbocharger, the exhaust
turbocharger and the charge-air cooler, and the
charge-air cooler and the intake manifold. If the in-
side of the intake manifold is dusty, there is a leak
either in the air filter or in the intake pipes. Repair
the leak.
NOTE: You should check the condition of the flexible
connection on the charge-air lines to and from the
charge-air cooler (swivel point) for leaks at different
swivel angles.
2. Clean the sealing face of the intake manifold. Use
a straight edge to make sure the sealing surface is
level. If the sealing face is uneven or scratched, ei-
ther machine the intake manifold or replace it. En-
sure that the cylinder heads lie parallel to one
another.
3. Fit a new seal and secure the intake manifold.
Tighten the retaining bolts on the intake manifold to
a tightening torque of 30 Nm. Secure the air pipes.
4. Make sure the exhaust manifold does not leak.
Tighten the screws / nuts to a tightening torque of
50 Nm and check for damage (cracks, deformation,
corrosion etc.). Also check the connection between
the turbocharger and the exhaust manifold.

Sva 6-93080 EN Edition 07-2006


D. Checking the turbocharger
If you believe there is a malfunction in the turbocharger,
you can identity it as follows:
1. Carry out as visual inspection of the turbine and
compressor wheels. The blades should exhibit no
damage, deformation or wear caused by foreign
particles.
2. Check whether any oil is escaping through the
sealing rings on the shaft in the turbine and com-
pressor casing.
CAUTION: At low idling speed, some oil will always
escape on the compressor side. This should not give
rise to undue concern unless a great deal of oil is be-
ing lost.
SS05N354
3. Check the running play of the turbine shaft. Hold
the probe of a dial gauge against the shaft and
move the shaft sideways. Refer to the play speci-
fied in the Technical Data.
Sva 6-93080 EN
2002A-63
SS05N355
4. Check the axial play of the shaft. Hold the sensor of
the dial gauge at the end of the shaft and move the
shaft in an axial direction. Refer to the play speci-
fied in the Technical Data.
If you discover a defect or worn-out part, the turbo-
charger will need to be overhauled.
If the engine's performance and response are not sat-
isfactory even though there are no apparent faults with
the turbocharger, the reason may lie in the following
faults:
· Air filter too heavily soiled
· Leak in intake and/or exhaust system, leaky
flange seals
· Fuel delivery pressure too low
· Unsuitable fuel type (e.g. summer diesel instead
of winter diesel when the weather is cold)
· Injector(s) defective or incorrectly adjusted
· High-pressure pump malfunction
· EEM3 engine control unit malfunction
· ID modules malfunction
· Compression pressure of one or all cylinders too
low (wear on piston rings, cylinder bushes, pis-
tons, leaking valves, valve stroke too narrow be-
cause of worn cam on camshaft)
Edition 07-2006
2002A-64
E. Assembly of the turbocharger
Pinpoint the cause of the malfunction in the turbocharg-
er. If the cause is outside the turbocharger, remedy the
problem before fitting a new or repaired turbocharger. To
make sure the turbocharger operates satisfactorily, you
must use the engine oil specified by the manufacturer.
The air filter and engine oil filter must be serviced or re-
placed regularly (see operating manual). The fuel injec-
tion system must be in perfect working order if the
turbocharger is to function well. The fuel injection sys-
tem must be correctly calibrated (see Service Tool).
1. Check the attachment of the intake and exhaust
manifold. Check that screws and nuts are tightened
to the specified tightening torque. Ensure that there
are no rust particles or other loose foreign bodies in
the intake or exhaust manifold. Remove any loose
soot from the exhaust manifold.
2. If using a new flange seal, mount the turbocharger
on the exhaust manifold.
3. Connect up the intake line, line to the charge-air
cooler and the exhaust pipe. Avoid creating torsion
on the fitted pipe, or remedy it if it does occur.
Sva 6-93080 EN
SS99N146
4. If using a new seal, fit the waste pipe for the turbo-
charger lubricant to the turbocharger. Avoid creating
torsion on the fitted pipe, or remedy it if it does oc-
cur.
5. Add approx. 0.1 litres of pure engine oil to the bear-
ing casing of the turbocharger through the connec-
tion opening of the pump-fed lubrication system.
This is the only way to ensure that the turbocharger
is sufficiently lubricated the first time the engine is
started.
6. If using a new seal, connect the line for the pump-
fed lubricant to the turbocharger. Avoid creating tor-
sion on the fitted pipe, or remedy it if it does occur.
7. Start the engine. Check the lubrication, intake and
exhaust systems for leaks.
Edition 07-2006
 3001
Section
3001

FUNCTIONAL DESCRIPTION INJECTION SYSTEM

CNH Österreich GmbH Sva 6-51300 EN © 2003 CNH Österreich GmbH

Technische Dokumentation April, 2003
A – 4300 St. Valentin, Steyrer Straße 32
 3001-3

TABEL OF CONTENS

SPECIAL TOOLS .................................................................................................................................................. 5

GENERAL INFORMATION ................................................................................................................................... 7
SAFETY REGULATIONS ..................................................................................................................................... 7
TECHNICAL DATA ............................................................................................................................................... 8
Injection pump ............................................................................................................................................. 8
Type of pump ( related to engine type) ....................................................................................................... 8
Sequence of injection .................................................................................................................................. 8
Fuel supply .................................................................................................................................................. 8
Fuel filters ................................................................................................................................................... 8
Injectors and Nozzles .................................................................................................................................. 8
Tightening torques ...................................................................................................................................... 8
FUEL SYSTEM ..................................................................................................................................................... 9
Function .................................................................................................................................................... 10
Safety measures ....................................................................................................................................... 10
Electronically controlled fuel injection system ................................................................................................ 11
Solenoid-Valve-Controlled Axial-Piston Distributor Pump ............................................................................ 12
General ..................................................................................................................................................... 13
Parameters affecting the injection timing .................................................................................................. 13
Parameters affecting the maximum quantity of fuel injected .................................................................... 13
Emergency operation and emergency engine stop .................................................................................. 13
Signal „engine speed“ faulty: .................................................................................................................... 13
Idle speed ................................................................................................................................................. 13
Electronic control ...................................................................................................................................... 14
Injection Pump - Operating Principle ............................................................................................................. 15
Operating Principle ................................................................................................................................... 16
IAT Sensor - Commencement of Delivery and Pump Speed ......................................................................... 17
Bleeding the fuel system ................................................................................................................................ 18
General ..................................................................................................................................................... 18
Automatic bleeding during operation ........................................................................................................ 18
Bleeding after changing the fuel filter ........................................................................................................ 18
Bleeding after fuel has been used up ....................................................................................................... 18
Bleeding after a new or an overhauled injection pump has been fitted .................................................... 18
Fuel feed pressure ......................................................................................................................................... 19
Testing the fuel feed pressure .................................................................................................................. 19
Removal of the fuel injection pump ................................................................................................................ 20
Fitting the fuel injection pump ........................................................................................................................ 21
Static pump timing .................................................................................................................................... 21
Updating pump serial numbering in EEM ................................................................................................. 21
Final jobs ................................................................................................................................................... 21
Injectors and nozzles ..................................................................................................................................... 22
Removing the injectors ............................................................................................................................. 22
Checking the nozzles ................................................................................................................................ 22
Overhauling injectors ................................................................................................................................ 23
Fitting the injectors .................................................................................................................................... 23
Assembly of the injection lines .................................................................................................................. 23
Fuel quality requirements ............................................................................................................................... 24
Directives to run on biological fuel (RME)
(RME = Rape oil-Methyl-Ester Bio - Fuel) ................................................................................................ 24
Service intervals ........................................................................................................................................ 24

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 3001-5

SPECIAL TOOLS

Timing pin Mini-measuring line

SS03D046 SS98J030

1 off 380001487 1 off 380001127 (1TSW 635)

Pressure gauge and connection Mini-measuring connection

SS00B076 SS98J031

1 off 380001129 (1TSW 645) Connection 1 off 380001486 (1TSW 641) M14x1,5
1 off 380001121 (1TSW 5002) Pressure gauge

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 3001-7

GENERAL INFORMATION
This manual only contains general instructions for repairing and servicing the injection system. This applies to the
injection pump in particular, as specially trained personnel with special tools and measuring instruments are required
to repair it. All service and repair work on the injection system requires particular care and cleanliness.
Boost start and arc-welding
• Only 12V Batteries must be connected in parallel. As soon as the supply voltage will raise > 17V, the EEM
will interrupt the electrical supply to the PCU. The engine will not start (zero delivery).
• Prior to arc-welding turn the starter key to position "0". At the PCU, the connector must get unlocked and
disconnected. Do not touch the pins of either side.
IMPORTANT: In the case of fuel systems with Bosch VP 30 injection pump, it is important that the fuel system is
bled of air before starting the engine for the first time (see page 19 , bleeding the fuel system).
ATTENTION: Never wash the area of the injection pump with high pressure (electrical connection)

PCU = Pump Control Unit

EEM = Electronic Engine Management

SAFETY REGULATIONS
There is always a risk of getting injured
when performing service and repair
work. Before commencing work,
the following safety regulations
and instructions must be read.
•) Never start repair work which you do not fully
understand.
•) Make sure that it is possible to work safely at the
location and in the vicinity.
•) Make sure the location is clean and in a good state.
•) Never use wrong or unsuitable tools.
•) Remove all rings, chains and watches before
commencing work.
•) Use state of the art safety equipment. For example,
wear goggles when using compressed air for
cleaning.
•) Only use original CNH spare parts.
•) Only start the engine from the cab, using the
ignition key.
•) Never start the engine with the protective covers
removed.
•) It is difficult to see the radiator fan when the engine
is running! Baggy clothes and long hair can get
caught in rotating engine parts!
•) If the engine is started in a confined space,
sufficient ventilation must be provided.
•) Never use auxiliary starting fuels on an aerosol
basis whilst the pre-glow starting facility is in
operation (explosion hazard).
•) Ear muffs must be worn when testing the engine or
working close to the engine.
•) Always switch the engine OFF before carrying out
repair work.
•) Naked flames and smoking are not permitted in the
vicinity of fuel tanks or batteries. Electric sparks
should be avoided.
•) Disconnect the cable at the negative battery pole
(–) before carrying out service or repair work on the
electrical system.
•) When checking the injection nozzles, never touch
the fuel, which is ejected under high pressure. The
jet will penetrate the skin and cause serious
poisoning. If contact is made with the skin, consult
a doctor without delay!
•) Fuel and lubrication oil can cause skin irritations if
contact is made over a longer period.
•) Avoid running the engine in idle unnecessarily.
•) When carrying out service work, take measures to
prevent fuel or other fluids from entering the ground
or drains.
•) Be careful when washing the engine using a
washing facility with a high water pressure. Do not
wash, for example, the electrical and fuel systems
under high pressure as they can easily be
damaged.
•) Never wash the area around the injection pump
when the engine is running.

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TECHNICAL DATA
Injection pump
Manufacturer and series.......................................................................................................................Bosch VP 30
Design ..............................................................................Solenoid-valve-Controlled Axial Piston Distributor Pump
Pump control ..................................................................................electronically by PCU (in connection with EEM)
Control of fuel quantity ........................................................................................... solenoid valve (PCU controlled)
Injection timing (dynamic)...............................................................................electronic/hydraulic/mechanic control
Speed control ............................................................................................electronically by the EEM (via CAN bus)
Electrical supply to PCU (from EEM) ..................................................................................................12V (min. 7V)
Current draw of the PCU (constant) ............................................................................................................ max. 8A
Direction of rotation (to be seen from pump drive) .................................................................................... clockwise
Pump setting (static)...........................................................................................................................with timing pin

Type of pump ( related to engine type)

620.95 to 620.99 .......................................................................................................................VP30 0470 006 004

Sequence of injection
620.95 to 620.99 ...........................................................................................................................1 - 5 - 3 - 6 - 2 - 4

Fuel supply
Fuel feed by.............................................................................................................................. electrical feed pump
Position of fuel feed pump..................................................... in the head of the sedimenter/primary filter assembly
Electrical supply (Fuse F29, 7,5A, +15/2) .......................................................................................................... 12V
Current draw................................................................................................................................................ max. 6A
Feed pressure - at low idle speed (past the fuel filter) ........................................................................ 1,0 to 1,3 bar
Feed pressure - at rated power (past the fuel filter) ............................................................................ 1,0 to 1,1 bar
Control of feed pressure (past the fuel filter) ................................................... pressure control switch and warning
Feed pressure warning activated when pressure......................................................................... < 0,05 bis 0,2 bar

Fuel filters
Sedimenter/primary filter (with water drain plug)................................................................................................ 30µ
Fuel filter (with water drain plug) .......................................................................................................................... 5µ
Indicator „water in fuel“ (standard) ................................................................................ sedimenter on primary filter
Indicator „water in fuel“ (option)............................................................ sensor in sedimenter and warning on ADIC

Injectors and Nozzles

With the engines 620.95 to 620.99, producer, type and opening pressure of the nozzles is equal.
Producer, type ...............................................................................................................Stanadyne M - Typ M35927
Number of spray holes ............................................................................................................................................5
Opening pressure.............................................................................................................................270 bis 280 bar
Pressure setting ...............................................................................................................................270 bis 280 bar
System of pressure adjustment....................................................................................................................... shims
Graduation of the adjusting shims...............................................................................................................0.05 mm
Change in opening pressure per graduation ............................................................................................... 5.00 bar
Range of adjusting shims (refer to spare parts catalogue)..............................................................1.00 to 1.90 mm
Periode for nozzle check or re-adjustment..............................................................................................2000 hours

Tightening torques
Pump retaining nuts (M8) ............................................................................................................................... 30 Nm
Pump drive gear retaining screws .................................................................................................................. 40 Nm
Banjo bolt with overflow orifice (pump-fuel return line)................................................................................... 27 Nm
Injection pipe union nut .................................................................................................................................. 25 Nm
Bracket for retaining the injector (retaining nut) ............................................................................................. 15 Nm
Injector nozzle sleeve..................................................................................................................................... 60 Nm

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 3001-9

FUEL SYSTEM

19
18

17
7

17
13 3
14

15
5

12 9
10 8

4
6

11
16

17

SS03D002

SS03D002

1. Fuel tank 11. Injection pump

2. Fuel gauge 12. Pump Control Unit (PCU)
3. Gravity valve (tank vent) 13. Delivery line
4. Suction line 14. Injector (with nozzle)
5. Sedimenter/primary filter assembly 15. Overflow valve (fitted into filter housing)
6. Sensor "water in fuel" 16. Overflow valve (screw-mounted)
7. Electrical feed pump 17. Overflow line
8. Fuel filter (with water drain) 18. EEM (Electronic Engine Management)
9. Feed pressure - control switch 19. ADIC (Analog Digital Instrument Cluster)
10. Feed line

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3001-10

Function
The electrical fuel feed pump (7) draws fuel from the tank (1) through the sedimenter/primary filter assembly (5) and
passes fuel through the fuel filter (8) to the injection pump (11).
NOTE: The electrical fuel feed pump starts operating at the moment the starter key is turned to position "1". If the
engine is not started within one minute, the EEM will cut out the feed pump. As soon as the engine will be started,
the EEM will cut in the feed pump.
The injection pump forces the fuel into the injector (14) that feeds the fuel into the combustion space via the nozzle
in a fine spray. An overflow line (17) leads from the fuel filter to the tank, passing-by the injectors (14) and the injection
pump (11). At the fuel filter (8), an overflow valve with a throttle (15), located in the filter housing, allows a constant
bleed of the filters. At the injectors, the leak-off will join the overflow line (17) and finally, the overflow valve (16) allows
a certain overflow for the purpose of pump bleeding and pump cooling. The injection pump is lubricated by the fuel
only. As an option, the prefilter (5) can carry a transparent sedimenter equipped with a sensor (6) that triggers an
alarm on the ADIC (19) if a certain amount of water has collected in the bowl.
The quantity of fuel to be injected is controlled by the PCU (12) and metered by the fuel-quantity solenoid valve inside
the injection pump (11). When the engine is in operation, a number of parameters are fed continuously to the EEM
(Electronic Engine Management) (18) from different sensors. Concerning the quantity of fuel to be injected and the
timing advance, the EEM (18) constantly gives the needed information to the PCU (12) via CAN Bus.

Safety measures
Fuel level in the tank below minimum
If the fuel level in the tank is going below a certain limit, an alarm will be activated on the ADIC (19).
Fuel feed pressure to low
If the fuel feed pressure will drop below 0,05 to 0,2 bar between fuel filter and injection pump, the control switch (9)
will trigger an alarm on the ADIC (19). Additionally, fault code EEM 122 will be stored and displayed. Possible causes
for low feed pressure see page 20, „testing the fuel feed pressure“.
NOTE: When the fault code 122 is active, the EEM does not apply any active restrictions on engine operation.

Reasons for fuel cut off (to stop running engine)

• Low engine oil pressure: fuel cut off after 30 seconds delay.
Fault code EEM 99 will be stored and displayed.
• Engine overheating : fuel cut off after 30 seconds delay.
Fault code EEM 113 will be stored and displayed.
• Engine overspeed (> 3000 rpm): fuel cut off immediately.
Engine operation returns to normal as soon as engine speed is < 2700 rpm.
Fault code EEM 94 will be stored and displayed.
• Upgrade protection:
Fault code EEM 172
• Power "on" - self test:
Fault code EEM 10
• Pump map defect:
Fault code EEM 33
• PCU - internal CAN bus defect:
Fault code EEM 34
• Wrong pump CAN interface configuration:
Fault code EEM 37
• Solenoid valve final defect:
Fault code EEM 40
• Injection control pulse width defect:
Fault code EEM 5
• Pump speed deviation:
Fault code EEM 55
• Pump supply voltage too high (>17,0V):
Fault code EEM 57
Reason for reduced quantity of fuel injected (reduction of engine power)
Injection pump - serial number mismatch
Fault code 175

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 3001-11

Electronically controlled fuel injection system

Solenoid valve
IAT Sensor A2/2
Fuel quantity
Timing advance PCU
Commencement
Solenoid valve
of delivery
Timing device
Pump speed
(proportional)

CAN H

CAN L
DZG
Signal
Engine
emergency stop
Switch S6
A2
Engine oil pressure
DZG = Signal, crankshaft position
(top dead centre)
Sensor B29
Boost pressure
Sensor B29
Starting aid E10/1
Boost air-temperature
(Grid heater)

Sensor B22
Coolant temperature

EEM M13
Control switch B21 Fuel feed pump
Fuel feed pressure

Sensor B23
"Water
in fuel"
Sensor B2/1
Fuel level
Sensor B20
Engine speed and
crankshaft position

Limp home
A1
(engine speed)
ADIC

Sensor B28
Hand throttle
CAN H

CAN L

Warning
Fuel
level
too low
ARU
P8
Warning
DISPLAY Fuel feed
pressure
too low
Sensors R8 A4
Drive pedal FMGR Warning
Water
in fuel

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Solenoid-Valve-Controlled Axial-Piston Distributor Pump

10

17

11

16

13

SS03D037
12
15 5 6 7 14 8 9

1. Drive shaft 10. PCU (Pump Control Unit)

2. Housing 11. IAT sensor
3. Vane pump 12. incremental wheel
4. Bearing ring 13. Fuel-quantity solenoid valve
5. Roller ring 14. Proportional solenoid valve (timing device)
6. Lift disc 15. Timing device
7. Axial piston 16. Connector
8. Delivery valve 17. Conductive foil
9. Delivery port

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General
The injection system consist of a mechanical distributor pump with electro-hydraulic actuators. Further an electronic
Pump Control Unit (PCU) (10), which communicates with the Electronic Engine Management (EEM) via CAN Bus.
The fuel supply is done by an electrical feed pump. A warning is activated on the ADIC if the feed pressure drops
below 0,05 - 0,2 bar, or the feed pump ceases.
• The EEM gets supplied with 12V (Fuse F30, 5A, +15/2) and ground. The PCU gets supply (12V and ground)
by the EEM only.
• The PCU (10) controls the actuators responsible for commencement of delivery and quantity of fuel injected.
• High pressure and delivery is performed by a mechanical pump with a concentrically arranged piston (7).
The piston simultaneously moves axialy to deliver fuel with high pressure and rotates to distribute the fuel to
the delivery valves (8) and delivery ports (9) of the very cylinders.
• To control the timing advance dynamically, a hydraulically controlled piston in the timing device (15) positi-
ons the bearing ring (4) together with the roller ring (5). The required pressure is delivered by an internal
vane pump (3) and gets controlled by means of a proportional pressure control valve (14).
• Engine-related parameters get changed into electrical signals by sensors. The signals are fed to the EEM.
The electronic makes use of the value of the signals.
• The IAT sensor (11) (Incremental Advance Time System), which is fixed to the bearing ring (4) inside the
injection pump, delivers the "incremental angle/time" signal to the PCU (10) by means of the conductive foil
(17). The electronic is drawing three different informations out of this signal. Details see page 14 (Electronic
control).

Parameters affecting the injection timing

• Engine speed
• Engine load
• Engine coolant temperature

Parameters affecting the maximum quantity of fuel injected

• Torque map
• Engine coolant temperatue
• Boost pressure
• Certain fault conditions (e.g. fault code 175, injection pump - serial number mismatch)

Emergency operation and emergency engine stop

CAN failure between EEM and PCU:
The additional signal line „emergency engine stop“ will be activated by the EEM. Immediately, the PCU will cease to
energise the fuel-quantity solenoid valve. As a result, fuel injection will be interrupted and the engine will stop. In cer-
tain cases, the EEM will even interrupt the electrical supply to the PCU. Again, there is no fuel injection and the engine
will stop.

Signal „engine speed“ faulty:

Via CAN bus communication, the EEM permanently receives information of the current speed of the injection pump
from the PCU. Thus, the electronic will calculate the engine speed. For the moment, there is no reason to stop the
engine. Fault code EEM 66 will be stored and displayed.

Idle speed
The low idle speed as well as the high idle speed are controlled electronically and cannot be altered.
There is no re-adjustment necessary.

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Electronic control
• No mechanical connection (rod or cable) exists between the engine and the controls in the cabine. The para-
meters supplied by the electronic drive pedal or the electronic hand throttle are conducted as electrical
signals to control units like FMGR (Vehicle Control Unit) and ARU (Arm Rest Unit). There, these signals get
converted into CAN messages, thus being transmitted to the EEM too.
• Messages related to engine and fuel injection are transmitted between EEM and PCU by CAN Bus.
• Taking in account the coming-in parameters and the momentary engine requirements, the EEM determines
CAN messages to control injection timing and the quantity of fuel to be injected.
• The PCU (10) controls the proportional solenoid valve (14) of the hydraulic-mechanically controlled timing
device (15) by means of PCC (Pulsed Current Control).
• In the injection pump, at the circumference of the rotating incremental wheel (12), there are six notches (18)
arranged by symetrical division (see page 17). At the moment a notch will pass the IAT sensor (11), the
signal generated will trigger the PCU (10) to energise the solenoid of the fuel-quantity solenoid valve (13).
Thus the valve needle will close a port leading to the barrel. Pressure will build up and fuel, displaced by the
piston(7), gets delivered to the injector (21) via delivery valve (8) and delivery port (9) to the injector.
• By CAN message, the PCU (10) gets informed for how many degrees of rotation of the incremental wheel
(12) and rotating pump drive shaft (1) the pump should deliver to the very injector (this will represent a cer-
tain distance of the effective lift of the pump piston (7). After completing the desired angle, the PCU (10) will
de-energise the fuel-quantity solenoid valve (13). The valve needle will open the port, as a result delivery
will be stopped. The angle run through between closing and opening the valve needle will determine the
quantity of fuel injected.
• The incremental wheel rotating with the crankshaft of the engine is provided with a notch too. The signal
generated at this point by the engine speed sensor serves as an electronic (virtual) reference marking (e.g.
Top Dead Center). In connection with the signal of the IAT sensor (11) in the injection pump, the electronic
will calculate the real timing advance. Additionally, the signal of the PCC (Pulsed Current Control) to control
the solenoid valve of the timing device will be altered if required.

Cam angle
Cam lift of delivery

Effective lift

Control pulse

Lift of valve
needle

IAT-Signal

SS03D036

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 3001-15

Injection Pump - Operating Principle

27

28 26
10

23 25

2 17 22
11

3 12 6
24

5
1
13
20

18 7 8 9

15
21
14
SS03D035

1. Drive shaft 14. proportional solenoid valve (timing device)

2. Housing 15. Timing device
3. Vane pump 17. Conductive foil
4. Bearing ring 18. Notch (missing tooth)
5. Roller ring 20. Pressure valve (flow controlled)
6. Lift disc 21. Injector (with nozzle)
7. Axial piston 22. Overflow valve (screw-mounted)
8. Delivery valve 23. Overflow valve (located in fuel filter housing)
9. Delivery port 24. Tank
10. PCU (Pump Control Unit) 25. Sedimenter/Pre-filter
11. IAT sensor 26. Electrical fuel feed pump
12. Incremental wheel 27. Fuel filter
13. Fuel-quantity solenoid valve 28. Feed pressure-control switch

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Operating Principle
Latest technology used with the injection pump VP30 results in a compact construction, fulfilling the emission stan-
dards, developing the whole potential of engine power, at the same time ensuring low fuel consumption.
An electrical feed pump (26) supplies fuel to the injection pump. An overflow valve (22) ensures permanent bleeding
and cooling of the injection pump.
High pressure delivery is produced mechanically by means of the cam lobes of the roller ring (5), the lift disc (6) in
connection with the axial piston (7). An integrated vane pump (3) creates a pressure, which, on the one hand ensures
proper feeding of the high pressure element and, on the other hand serves as a control pressure for the hydraulic/
mechanically controlled timing device (15). The injection pump as a whole is lubricated by the fuel only. In connection
with fitting the injection pump to the engine, static timing is part of the procedure (see page 22).
The electronic Pump Control Unit (PCU) (10) is attached to the upper side of the pump. The electrical supply to the
PCU comes from the Electronic Engine Management (EEM). With the exception of an extra line for „emergency en-
gine stop“, all signals and parameters are sent by a series of numeric values by means of CAN communication (Con-
troller Area Network) between the EEM and PCU.
The PCU (10) controls the proportional solenoid valve (14) by means of PCC (Pulsed Current Control). Valve (14)
vary a control pressure. This control pressure moves a piston in the timing device (15), positioning the bearing ring
(4) together with the roller ring (5) dynamically.
The IAT sensor (11), attached to the bearing ring (4) signals the real angle of timing advance as well as the pump
speed and triggers the commencement of delivery. Taking in account various parameters, the EEM determines the
timing advance, transmitting the message to the PCU (10) by CAN Bus. In case the signal of the engine speed sensor
is faulty, the EEM makes use of the pump speed signal to calculate the engine speed.
The fuel-quantity solenoid valve (13) is positioned concentrically around the distributor body. When the PCU (10) en-
ergises the valve, it‘s needle will close a port and delivery commences. As the valve get‘s de-energised, delivery cea-
ses. Within the periode the fuel-quantity solenoid valve (13) is energised the piston (7) moves a certain distance of
its total stroke. This again determines the quantity of fuel delivered to the injector (21). During one revolution of the
pump drive shaft (1), the fuel-quantity solenoid valve (13) runs through six cycles of closing and opening the needle.

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 3001-17

IAT Sensor - Commencement of Delivery and Pump Speed

10
10

17

17 11
2 11 5

12
6
3

7
12
19

18 4
SS03D033

15
SS03D034

1. Drive shaft 10. PCU (Pump Control Unit)

2. Housing 11. IAT sensor
3. Vane pump 12. Incremental wheel
4. Bearing ring 15. Timing device
5. Roller ring 17. Conductive foil
6. Lift disc 18. Notch (missing tooth)
7. Axial piston 19. Guide

• The incremental wheel (12) rotates together with the pump drive shaft (1). The IAT sensor (11) moves toge-
ther with the bearing ring(4) and the roller ring (5).
• When in the timing device (15) the timing advance is altered by the proportional solenoid valve , the bearing
ring (4) together with the roller ring (5) and the IAT sensor (11) is moved in the direction „advance“ or „retard“
either.
• At the circumference of the incremental wheel (12), there are six notches (18) (one notch for each cylinder of
the engine), arranged by symetric division. The sequence of teeth and notches is scanned by the IAT sensor
(11).
• The signal is transmitted to the PCU (10) by means of a conductive foil (17). The signal is utilised as follows:
- to determine the present angle position
- to determine the present timing advance in connection with the engine speed signal
- to sense the speed of the pump drive shaft
• The present angle position determines the trigger point for energising the fuel-quantity solenoid valve (13)
by the PCU (10). This will ensure the correct timing for closing and opening of the valve needle (valve lift) in
accordance with the cam lift (see page 14).

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Bleeding the fuel system Bleeding after a new or an overhauled
injection pump has been fitted
General • Ensure adequate fuel in the tank.
With this fuel system, bleeding screws are not requi- • Crack the union nuts of the six injection pipes at
red. Due to the configuration of this fuel system, the their connection to the injector open.
procedure of bleeding depends on the very situation.
• Turn starter key to position „1“ (electric fuel
feed pump will run).
Automatic bleeding during operation
This fuel system automatically removes air bubbles
• Keep fuel feed pump running for 30 to 45
seconds.
from the filters and injection pump when the engine is
running. Further, constant bleeding during operation NOTE: If the engine will not be started after one
provides also cooling of the pump. minute, the EEM will cut off the fuel feed pump. As
soon as the engine get‘s started, the fuel feed pump
NOTE: Due to the electric fuel feed pump, will start to operate automatically.
automatic bleeding starts already at the
moment the starter key is turned to position „1“. • Crank the engine for about 5 seconds, until fuel
(engine is not running). comes out from every loosened connection.
Retighten connections with 25 Nm. Clean off
the over flown fuel and start the engine.
Bleeding after changing the fuel filter
NOTE: If no fuel will reach the opened connections
• Ensure adequate fuel in the tank.
of the injection pipes, a faulty gravity valve (tank
• Turn starter key to position „1“ (electric fuel vent, see page 9) may be the reason. To prove this,
feed pump will run). Provisions for overflow on open the tank cover and repeat the bleeding proce-
fine filter and injection pump ensure automatic dure.
bleeding. There are no bleeding screws to be
opened!
• Keep fuel feed pump running for about 30
seconds before you make the first attempt to
start the engine.
NOTE: If the engine will not be started after one
minute, the EEM will cut off the fuel feed pump. As
soon as the engine get‘s started, the fuel feed pump
will start to operate automatically.

Bleeding after fuel has been used up

IMPORTANT: Drivers have to be instructed in
advance to avoid "using fuel up"!
Supposed the engine was stopped in time after signs
of power loss, the engine will run again if you comply
with the following steps:
• Add fuel into the tank.
• Turn starter key to position „1“ (electric fuel
feed pump will run).
• Keep fuel feed pump running for about 30
seconds before you make the first attempt to
start the engine.
NOTE: If the engine will not start, keep to the blee-
ding procedure as you apply after fitting an injection
pump.

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Fuel feed pressure
At any condition of engine load and engine speed,
sufficient feed pressure is essential that the injection
pump will deliver the demanded quantity of fuel to be
injected.
NOTE: If the warning „fuel filter blocked“ is aktiv, the
function of the electric fuel feed pump is to be chek-
ked prior to a change of the fuel filter or testing the
feed pressure.
Supply voltage ................................................. 12V
(at the pump while engine is running)
(Fuse F29, 7,5A, +15/2)
Current draw ............................................. max. 6A
3001-19
Disconnect the wiring at the feed pressure - control
switch. Unscrew the control switch.
Fit adapter 380001486 (thread M14 x 1,5), using a
copper seal . Connect mini-test tube 380001127 and
pressure gauge 380001121.
Feed pressure and capacity (after fuel filter):
Engine at low idle speed ................... 1,0 to 1,3 bar
Engine at rated power ....................... 1,0 to 1,1 bar
If the pressures demanded are not reached, there can
be various causes:
• blocked fuel filter
• blocked primary filter
• feed pump defective (worn)
• gravity valve defective
• leaking primary filter
• blocked, kinked or leaking suction lines
• wrong diesel fuel (e.g. not suitable for winter)
If the gravity valve will be suspected, the steps of
testing the feed pressure may be repeated with par-
tially opened tank cap.

SS03D001

NOTE: If the electrical supply exists but the pump

cannot be heard running, this indicates that the pump
is sticking. The pump will need replacing.
If there is a fault in the electrical supply, see service
manual chapter 04, wiring diagram.
NOTE: If the engine will not be started after one
minute, the EEM will cut off the fuel feed pump. As
soon as the engine get‘s started, the fuel feed pump
will start to operate automatically.

Testing the fuel feed pressure

Clean the fuel filter outside and the connec-
tions.Make sure that adequate fuel is in the tank.

SS03C027

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3001-20
Removal of the fuel injection pump
Prior to removing the pump, disconnect the battery or
switch OFF the battery master switch (if fitted) in order
to prevent inadvertent starting.

SS03C029

NOTE: Never loosen the retaining nut of the

hub! There is no key to locate the hub to the
pump drive shaft. The hub is accommodated by
the cone of the shaft only. Refitting the hub is
only possible on a pump test bench.

SS00E039

Turn the crankshaft until the beginning of compressi-

on stroke of cylinder No. 1 (front). Gradually turn the
crankshaft in the direction of rotation until the marking
of the belt pulley matches with the reference marking.
Carefully clean the pump and the surrounding com-
ponents. Remove the injection pipes, the supply line
as well as the overflow line. Fit protective caps to the
delivery ports, to the feed- and overflow connection.

SS03C030

Unscrew the three nuts retaining the pump. Take the

pump off the timing housing by keeping the pump
drive gear engaged in the intermediate gear.
ATTENTION: Once the pump has been removed,
the crankshaft must not be turned! The loose gear
SS03C028
could damage the timing drive and (or) the timing
housing.
Pull up the lock () of the connector and disconnect the Clean the sealing surfaces.
connector () on the pump control unit (PCU).
NOTE: The pins of either side of the connector
must not be touched with fingers!
Remove the cover on the engine timing housing to
make the pump drive gear accessible.
Unscrew the four retaining screws of the pump drive
gear. The gear is centered (loose) by the hub.

Sva 6-51300 EN Edition 05-2003


Fitting the fuel injection pump
ATTENTION: The starter of the engine must never
be operated prior to air bleeding after an injection
pump was fitted (damage to the injection pump due
to lack of lubrication).
Ensure that the crankshaft is still in the position as it
was turned to prior to removing the pump. If the mar-
kings do not match, adjust accordingly.
NOTE: If the crankshaft needs to be turned, the
loose pump drive gear must be supported to avoid
damage.
SS03C030
Ensure clean contacting surfaces at timing housing,
spacer and pump flange. Place new seals to spacer
and pump flange. Push the pump to the correct posi-
tion on the timing housing, at the same time hold the
pump drive gear in position to allow the hub to slip into
the gear. Attach the washers, fit the pump retaining
nuts and tighten them only hand-tight for the moment.
Static pump timing
380001487 SS03C032
Turn the pump drive shaft clockwise by means of ap-
plying a wrench to the hub retaining nut until the in-
spection holes of gear, hub and pump housing will
match and the timing pin 380001487 will easely enter.
Fit the retaining screws of the pump drive gear by
hand. Remove the timing pin. Tighten the drive gear
retaining screws to 40 Nm.
Sva 6-51300 EN
3001-21
Tighten the pump retaining nuts finally to 30 Nm.
Fit the cover on the engine timing housing with a new
seal.
Remove the protective caps and fit the pipes. Tighten
the union nuts of the injection pipes only at the pump
delivery ports (25 Nm). Use new sealing rings for the
banjo bolts. Tighten the overflow valve at the overflow
port of the pump to 27 Nm.
Fit the connector of the harness to the pump control
unit and push in the lock.
NOTE: The pins of either side of the connector
must not be touched with fingers!
Updating pump serial numbering in EEM
• Connect the CNH service tool to the diagnosis
connector.
• Go to the screen
"CONFIGURATION ITEM SELECTION" .
• Select the menu "ENGINE - FUEL INJECTION
PUMP CONFIGURATION".
• Execute updating of pump serial numbering in
the sequence as indicated on this screen.
• Disconnect the CNH service tool.
Final jobs
• Make sure there is adequate fuel in the tank.
• Perform bleeding according to paragraph
„Bleeding after a new or an overhauled
injection pump has been fitted“ (see
page 19).
• Tighten the union nuts of the injection pipes at
the injector connections to 25 Nm.
• Clean off spilled fuel. Start the engine, check for
leaks and see the engine performance.
• Take a test ride with the tractor.
Edition 05-2003
3001-22
Injectors and nozzles – opening pressure

– buzzing sound and spray pattern

1 – tightness

1.Fuel inlet
2.Leakage oil port
3. Adjusting shim
4.Pressure spring 3
5.Thrust bolt
6.Nozzle body
4
7.Pressure chamber
5
8. Needle
9.Spray orifice 6
7
8
9 Increase the pressure in the injector until the buzzing
SS99N149
The injectors are equipped with a five-hole nozzle.
The small amount of leakage fuel used to lubricate the
needle is returned to the fuel tank via the overflow li-
ne.
Removing the injectors
1. Clean the injectors and the surrounding area. Dis-
connect the pressure lines and the leakage oil line.
NOTE: Keep in mind the assignment of the injection
lines to the connections at the pump and notice how
the injectors are fitted (direction of leakage oil port).
2. Unscrew the nuts of the injector retaining brackets.
Remove the brackets and then the injectors from the
cylinder head. Seal off all connecting points by fitting
protective caps.
3. Remove the sealing washers from the injectors
seating in the cylinder head, if they have not already
been taken out together with the injectors.
Checking the nozzles
IMPORTANT: When checking the nozzles on the
test stand, it is not permitted to remain in the vicinity
of the nozzle outlet (e.g. with one’s hands). The fuel
jet, which is ejected at high pressure, can easily
penetrate the skin and cause serious injuries. Brea-
thing-in fuel spray is detrimental to health.
1. Clean the injectors using cleaning fluid and a soft
brush. The carbon deposits must not be knocked off
or removed in such a way that the nozzle can be da-
maged.
2. Mount the injectors on the test stand and check the
following points:
Sva 6-51300 EN
SS99N147
Opening pressure
To fill the injector, pump the system a few times.
is audible. Check the opening pressure. If the opening
pressure deviates from the specified value (see
page 8), the injector must be dismantled to adjust the
opening pressure.
An adjustment is made by means of altering the adju-
sting shim. The thickness of the adjusting shims va-
ries between 1.00 and 1.90 mm and they are
available in graduations of 0.05 mm. A thicker adju-
sting shim increases the opening pressure, a thinner
one reduces the opening pressure. Changing the
thickness of the shim by 0.05 mm changes the ope-
ning pressure by approx. 5.0 bar. Because the ope-
ning pressure of the nozzle drops slightly after being
adjusted, it should be set approx. 10 bar higher than
the value specified in the technical data. This value is
valid for both new and used nozzles.
Buzzing properties
Testing by means of the hand pump does not fully cor-
respond to the conditions that the nozzle is subject to
in the engine. The test results are only reliable for new
nozzles. Used nozzles do not buzz at certain pump
speeds, which is due to the design of the nozzle.
When pumping quickly, however, the buzz is audible
and/or a fine jet of atomised fuel is visible. The jet is
thicker and less defined in the buzz-free zone.
Tightness of the nozzle
Press the test pump lever slowly, until the pressure
increases to approx. 20 bar below the setting value.
Maintain this pressure for approx. 10 seconds. If no
drops of fuel form at the tip of the nozzle, the nozzle
seals correctly. When the nozzle does not perform as
demanded, see page 24, chapter "Overhauling injec-
tors".
Edition 05-2003

Overhauling injectors
1. Mount the injector in such a way in a fixture that it
will not be damaged.
2. Unscrew the nozzle tensioning nut. Remove the
nozzle and the parts inside the injector body.
3. Clean the nozzle, both inside and outside, in cle-
aning fluid.
4. Steep blocked spray orifices or clean them using a
cleaning needle.
5. Check the movement of the needle as follows:
SS99N148
Rinse the parts out with fuel or test fluid. Pull the
needle out off the nozzle body by one third of the slide
face length. The needle must be able to slide into the
valve seat by its own weight. Turn the needle a little
and repeat the test. The needle must not stick in any
position. If it does, rinse the parts and repeat the test.
If the needle sticks again, the nozzle must be repla-
ced.
6. Before assembly, all parts must be carefully clea-
ned in clean fuel or test fluid.
7. Insert the adjusting shim in the injector body. Bear
in mind that the opening pressure may require adjust-
ment. Assemble the injector, making sure the thrust
bolt and intermediate washer are in the correct positi-
on.
8. Tighten the nozzle tensioning nut by hand and then
to a torque of 60 Nm.
Fitting the injectors
1. Clean the injectors seating in the cylinder head. If
necessary, smoothen the surface by using a reamer.
Sva 6-51300 EN
3001-23
1
2
1. Sealing washer
2. Rubber ring
3. Sealing ring
3
SS99N150
2. Fit the injector in its place in the cylinder head. Use
a new sealing washer.
IMPORTANT: The spraying directions of the injec-
tion nozzle are not symmetrical. It is therefore
important that the injector is fitted into the cylinder
head correctly.
3. Fit the bracket and tighten the nuts evenly to a tor-
que of 15 Nm.
4. Connect the leakage oil line and the injection line.
Use new seals where required.
ATTENTION: Always make sure the correct type of
nozzle is used. Incorrect nozzles impair engine ope-
ration and will cause engine damage.
Assembly of the injection lines
1. Check the state of the lines before fitting them. If
the lines show signs of kinking, breakage or abrasion,
or the sealing olive is damaged, replace the line with
a new one.
2. When connecting the line, make sure that the union
nut is not cross threaded, otherwise the olive will be
damaged.
Tighten the union nut of the line to a torque of 25 Nm.
3. Secure the injection lines by refitting all the holders.
Edition 05-2003
3001-24
Fuel quality requirements
This fuelsystem can be run on diesel fuel which will
meet the standard ÖNORM EN 590, but also biologi-
cal fuel (RME), standard ÖNORM C 1190, can be
used.
Running on RME, a reduction of engine output up to
7% must be taken in account.
RME is known by the trade marks „BIO-DIESEL“ and
„ÖKO-DIESEL“.
NOTE: For different seasons as summer or winter,
different diesel fuels are recommended.
For suitable diesel fuel in the winter season, special
info will be available with the fuel dealers.
Service intervals
Reduction of running hours recommended in the ope-
rators handbook for periodical change of engine oil
and engine oil filter:
• Limited by 50% if engine is low loaded (easy
work).
• Limited by 25% if engine is high loaded (hard
work).
NOTE: In case the engine oil level would raise by
more than one inch, the engine oil must be changed.
For further details about alteration of service intervals
see the „Operator‘s maual“.

Directives to run on biological fuel (RME)

(RME = Rape oil-Methyl-Ester Bio - Fuel)
The diesel engines 620.95, 620.96, 620.97, 620.98
and 620.99 can be run on RME fuel without requiring
technical modifications. The only one requirement is
to meet the Austrian standard ”C 1190”.
IMPORTANT: To ensure smooth run on RME, the
operator should obey the following recommendati-
ons.
• To store RME correctly, keep to the recommen-
dations of the fuel supplier. Seal tanks to avoid
entering of air and water, for RME is hygrosco-
pical.
• Do not take fuel from the lowest point of the
tank (danger of water collection).
• When the starting temperature will be < -10 °C,
do not use RME. Other recommendations from
the fuel suppliers are excepted.
• Do not run on RME if longer periodes of vehicle
standstill (> 3 months) will be ahead. Otherwise
there would be danger of a sticking axial plun-
ger and sticking delivery valves in the injection
pump, as well as sticking nozzles.
• Do not run on RME if longer periodes of low
engine load are expected. Since the boiling
point of RME is remarkable higher compared to
diesel fuel, RME which will not combust will
enter the oil sump, thus diluting the engine oil.
Additionally, not combusted RME will exit the
exhaust and will soil the cabine, engine hood,
windscreen and other parts.

Sva 6-51300 EN Edition 05-2003

 &KDSWHU
$

$
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)8(/,1-(&7,216<67(0
&RPPRQ5DLO6\VWHP

CNH Österreich GmbH Sva 6-93150 EN © 2006 CNH Österreich GmbH

Tecnical Documentation Januar, 2006
A - 4300 St. Valentin, Steyrer Straße 32
 3001A-3

&217(176

SPECIAL TOOLS .................................................................................................................................................. 5

GENERAL ............................................................................................................................................................. 7

SAFETY REGULATIONS ..................................................................................................................................... 7

TECHNICAL DATA ............................................................................................................................................... 8

High-pressure pump ........................................................................................................................................ 8
Injectors ........................................................................................................................................................... 8
Fuel .................................................................................................................................................................. 8
Fuel filter .......................................................................................................................................................... 8
Tightening torques ........................................................................................................................................... 8

JUMPER LEAD STARTING AND ELECTROWELDING ...................................................................................... 8

FUEL SYSTEM ..................................................................................................................................................... 9

Function ......................................................................................................................................................... 10
Safety equipment ........................................................................................................................................... 11
Diagram - Electronically controlled injection system ...................................................................................... 12
Venting the fuel system .................................................................................................................................. 13
Checking the fuel delivery pressure ............................................................................................................... 13
Checking the injectors .................................................................................................................................... 14
Removing the injectors .................................................................................................................................. 14
Assembly of injectors ..................................................................................................................................... 14
High-pressure pump ...................................................................................................................................... 15
Removing the high-pressure pump ........................................................................................................... 15
Assembly of high-pressure pump ............................................................................................................. 16
Final work .................................................................................................................................................. 16
Fuel quality requirements ............................................................................................................................... 17

Sva 6-93150 EN Edition 01-2006

3001A-4

BLANK PAGE

Sva 6-93150 EN Edition 01-2006

 3001A-5

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3UHVVXUHJDXJHDQGFRQQHFWLRQ 0LQLPHDVXULQJFRQQHFWLRQ

SS00B076 SS98J031
[76: Connection [76: 0;
[76: Pressure gauge

0LQLPHDVXULQJOLQH

SS98J030
[76:

Sva 6-93150 EN Edition 01-2006

3001A-6

BLANK PAGE

Sva 6-93150 EN Edition 01-2006

 3001A-7

*(1(5$/,1)250$7,21
The engines are equipped with a FRPPRQUDLO fuel injection system. This system is controlled by the electronic en-
gine management system EEM3. The engines meet Tier 3 emissions standards.
To make sure that the engine continues to meet these emissions standards over its entire service life, the stipulated
periodic service and maintenance work must be carried out with the necessary diligence. Only genuine CNH service
material (filters) may be used.
The stipulated periodic functional check of the injectors should be carried out every 2000 operating hours using the
EST (Service Tool).
Calibration of the fuel injection system should be undertaken using the EST (Service Tool).
Only genuine CNH spare parts may be used to carry out repairs. Maintenance and service work which is not carried
out with due diligence or is not carried out in time and/or the use of any parts which are not genuine spare parts or
service material will result in the manufacturer’s guarantee of the fulfilment of emissions standards becoming void.
127( 7KLVPDQXDOFRQWDLQVLQVWUXFWLRQVRQKRZWRUHSODFHWKHIXHOILOWHUHOHFWULFDOIXHOGHOLYHU\SXPSVKLJKSUHV
VXUHSXPSLQMHFWRUVDQGUDLO
This work may only be undertaken by trained personnel using the required special tools and testing and calibration
equipment.
((0 = Electronic Engine Management. German: Electronic engine management

6$)(7<5(*8/$7,216
7KHUHLVDOZD\VDULVNRILQMXU\ZKHQ •) Always switch the engine off before performing re-
FDUU\LQJRXWPDLQWHQDQFHDQGUHSDLU pair work.
ZRUN5HDGWKHIROORZLQJVDIHW\
$77(17,211HYHURSHQWKHFRQQHFWLRQVRIKLJKSUHV
UHJXODWLRQVDQGLQIRUPDWLRQEHIRUH
VXUHOLQHVZKLOHWKHHQJLQHLVUXQQLQJ$OZD\VZDLWDW
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•) Never start repair work which you do not fully under-
stand.
•) Make sure that it is possible to work safely at the lo-
cation and in the vicinity.
•) Make sure the repair area is clean and in good con-
dition.
•) Never use incorrect or unsuitable tools.
•) Remove all rings, chains and watches before start-
ing work.
•) Use modern safety equipment when working. For
example, protect your eyes when using compressed
air for cleaning.
•) Only use JHQXLQH&1+VSDUHSDUWV.
•) Never wash the components of the fuel injection sys-
tem while the engine is running.
•) Only start the engine from the cab using the ignition
key.
•) Never start the engine when protective covers are
not in place.
•) The cooling fan is difficult to see when the engine is
running! Loose clothing and long hair may become
caught in rotating engine parts.
•) If the engine is being started in an enclosed space,
make sure there is sufficient ventilation.
•) Ear muffs must be worn when testing the engine or
working close to the engine to avoid hearing dam-
age.
Sva 6-93150 EN
RSHQLQJLW$KLJKSUHVVXUHMHWRIIXHOXSWREDU
FDQSHQHWUDWHWKHVNLQDQGFDXVHVHULRXVLQMXU\,IVXFK
DQHYHQWRFFXUVPHGLFDODWWHQWLRQPXVWEHVRXJKWLP
PHGLDWHO\
•) Naked flames and smoking are not permitted in the
vicinity of fuel tanks or batteries. Electrical sparks
should be avoided.
•) Disconnect the cable at the negative battery pole (-)
before carrying out service or repair work on the
electrical system.
•) Extended contact with fuel or lubricant
can irritate the skin.
•) Avoid running the engine in idle unnecessarily.
•) When carrying out service work, take measures to
prevent fuel or other fluids from entering the ground
or drains.
•) Be careful when washing the engine using a wash-
ing facility with a high water pressure. Do not wash,
for example, the electrical and fuel systems under
high pressure as they can easily be damaged.
•) Never use auxiliary starting fuels on an aerosol basis
whilst the pre-glow starting facility is in operation (ex-
plosion hazard).
Edition 01-2006
3001A-8

7(&+1,&$/'$7$
+LJKSUHVVXUHSXPS
Type .............................................................................................................................................................. CP 1H
Design .................................................................................................................... Radial piston pump, 3 cylinders
Lubrication .........................................................................................................................................................Fuel
Max. injection pressure ..............................................................................................................................1100 bar
Transmission ratio of drive gears ......................................................................................................................4 : 3
Injection sequence .................................................................................................................................1-5-3-6-2-4

,QMHFWRUV
Type ..................................................................................................................................................... CRIN 2 - 2V
Number of blowholes...............................................................................................................................................5

)XHO
Required fuel quality ......................................................................................................................EN 590 standard
Fuel supply temperature, max. .............................................................................................................. 70° Celsius

)XHOILOWHU
Pre-filter .......................................................................................................................................... 30 µ Stanadyne
Fine filter ........................................................................................................................................... 5 µ Stanadyne
Delivery pump ................................................................................................................. electric, fitted on pre-filter
Supply voltage ....................................................................................................................................... 12 volts DC
Max. current. ............................................................................................................................................6 amperes
Delivery pressure when engine idling, min. ................................................................................................ 0.75 bar

7LJKWHQLQJWRUTXHV
,QMHFWRUV
Retaining bolt ................................................................................................................................................ 40 Nm
Retaining nuts - cable connection ................................................................................................................ 1.5 Nm
+LJKSUHVVXUHSXPS
Retaining nuts - drive gear wheel (M14) ....................................................................................................... 70 Nm
Retaining bolts ............................................................................................................................................... 30 Nm

)XHOOLQHV
High-pressure line from high-pressure pump to rail ...................................................................................... 30 Nm
High-pressure line from rail to injectors ......................................................................................................... 25 Nm
Low-pressure line to high-pressure pump ..................................................................................................... 25 Nm

-XPSHUOHDGVWDUWLQJDQGHOHFWURZHOGLQJ
‡ Jumper lead starting may only be used with 12V batteries connected in parallel.
‡ Before performing any welding work, turn the start switch to the „0“ position.
,03257$17 $WWDFKWKHHDUWKWHUPLQDORIWKHZHOGLQJGHYLFHFORVHWRWKHDUHDWREHZHOGHGPD[PDSDUW
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Sva 6-93150 EN Edition 01-2006

 3001A-9

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SS05M991

1. Fuel tank 9. Fuel delivery pressure sensor

2. Level sensor 10. Fuel temperature sensor
3. Gravity valve (tank venting) 11. High-pressure pump
4. Suction line 12. Rail
5. Electric delivery pump 13. Overflow valve
6. Pre-filter 14. Injector
7. ’Water in fuel’ sensor 15. High pressure sensor (pressure in rail)
8. Fuel filter

Sva 6-93150 EN Edition 01-2006

3001A-10

)XQFWLRQ
The electric delivery pump (5) draws fuel from the tank through the pre-filter (6). It conveys the fuel through the fuel
filter (8) to the high-pressure pump (11).
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WKHHQJLQHLVVWDUWHG
The high-pressure pump pumps fuel into the rail (12) (storage area). When the engine is running, fuel is stored at high
pressure (up to 1100 bar) in the rail and the high-pressure lines, as far as the injectors (14). Electronically controlled
injectors inject the fuel, finely atomised, into the combustion chambers of the cylinders.
The timing of the injection and the volume of fuel injected are controlled by the electronic engine management unit,
the EEM3. The injection volume is determined by both the current pressure in the rail and the time during which an
injector is activated by the EEM3.
The common rail injection system significantly optimises the fuel injection process. This is due to a number of advan-
tages of the common rail injection system:
‡ Fuel is injected at high pressure (up to 1100 bar) through five-hole injector nozzles
‡ The fuel is injected in up to three part-volumes
‡ Key physical parameters are processed by the EEM3 to determine the number, volume and timing of inject-
ed part-volumes:
- Output requirements through FMGR via CAN bus, engine speed
- Engine temperature (coolant), intake air and fuel
- Charge-air pressure, high pressure in rail, fuel delivery pressure, engine oil pressure

7KHUHDUHPDQ\DGYDQWDJHVWRWKLVW\SHRIIXHOLQMHFWLRQ
‡ Reduction in harmful emissions
‡ Reduction in specific fuel consumption
‡ Reduction in engine noise
‡ Automatic venting (starting from driver’s seat) without opening the line system

)XHOUHWXUQHGWRWDQN
‡ by pressure control valves on high-pressure pump
‡ by overflow valve in rail
‡ as leaked oil from the injectors
‡ from the overflow connection on the fuel filter (this also aids automatic venting of the fuel system after a filter
change or when the fuel tank is empty).

Sva 6-93150 EN Edition 01-2006

 3001A-11

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)XHOOHYHOLQWDQNEHORZPLQLPXP
If the fuel level falls below the minimum, a warning message is displayed on the ADIC.

)XHOGHOLYHU\SUHVVXUHWRRORZ
If the delivery pressure between the fuel filter and the high-pressure pump is insufficient, the fuel delivery pressure
sensor (9) activates a warning message on the ADIC. For possible causes of low delivery pressure, refer to Seite 13,
’Checking the fuel delivery pressure’.

(QJLQHLVVKXWRIILPPHGLDWHO\
‡ Rail pressure too high:
Error code EEM3 - 382 is stored and displayed.

(QJLQHVKXWVGRZQZLWKGHOD\
‡ Engine oil pressure too low: Zero delivery after 30-second delay.
Error code EEM3 - 99 is stored and displayed.
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‡ Coolant temperature too high: Zero delivery after 30-second delay.
Error code EEM3 - 113 is stored and displayed.

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‡ Engine speed too high (> 3000 rpm): Zero delivery cuts in immediately.
Error code EEM3 - 94 is stored and displayed.

6WDUWLQJLVQRWSRVVLEOH
‡ Upgrade protection error
Error code EEM3 - 172 is stored and displayed.
‡ Self-test for shut-off, hardware error
Error code EEM3 - 221, 222, 223 is stored and displayed.

Sva 6-93150 EN Edition 01-2006

3001A-12

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Sva 6-93150 EN Edition 01-2006

 3001A-13

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There is no need to vent the engine specially after changing the fuel filter or if the fuel tank has run empty. It is sufficient
to turn the start switch to the ON position and allow the electric delivery pump to run for at least 30 seconds. Then
activate the starter (max. 10 seconds). If the engine still will not start, activate the electric delivery pump for at least
another 30 seconds and then attempt to start the engine again.

&KHFNLQJWKHIXHOGHOLYHU\SUHVVXUH
1. Clean both filter casings and the line connections.

2. Disconnect the plug connection on the delivery pressure

sensor. Detach the delivery pressure sensor (9) from the fil-
ter head of the fuel filter. Attach measurement connection
with sealing ring (thread M14 x 1.5).
Connect up mini measurement line and pressure
gauge 
127( $IWHUHQJLQHLVVWDUWHGHUURUFRGH((0LVDF

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3. Start the engine and allow to idle. The delivery pressure
should reach 0.75 bar. If this nominal value is not reached, SS05M992
one of the following causes may be responsible:
‡ Too little fuel in tank.
‡ Fuel filter heavily soiled.
‡ Leak between fuel tank and electric delivery pump (air ingress).
‡ Fuel unsuitable for season (e.g. summer diesel in freezing temperatures).
‡ Suction line crimped (clamped), buckled or blocked.
‡ Supply voltage to electric delivery pump too low.
‡ Electric delivery pump malfunction.
If you suspect that a tank venting valve is malfunctioning, you can repeat the steps of the test while the tank lock is
partly open and compare the pressure values.
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If the power supply fails, refer to the workshop manual, chapter 04: Circuit diagram.
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VWDUWVLWLVDXWRPDWLFDOO\VZLWFKHGRQ

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3001A-14

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FDXVHVHULRXVLQMXU\,IVXFKDQHYHQWRFFXUVPHGLFDODWWHQWLRQPXVWEHVRXJKWLPPHGLDWHO\
The function of the injectors must be checked every 2000 operating hours using the EST (Service Tool) (’run-up’ test).
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WKHVNLQDQGFDXVHVHULRXVLQMXU\,IVXFKDQHYHQWRFFXUVPHGLFDODWWHQWLRQPXVWEHVRXJKWLPPHGLDWHO\
1. Clean the injectors, line connections, lines and immediate surroundings.
2. Disconnect the electrical connection, high-pressure line and oil leakage line.
3. Undo the retaining bolt. Remove the retaining bolt and washer, noting the position in which the washer is fitted.
4. Remove the injector and the bracket. Immediately seal the connection openings on the injector with plastic plugs.
5. Remove the injector seal from its seat in the cylinder head if it was not removed along with the injector.

$VVHPEO\RILQMHFWRUV
1. Clean the bore in the cylinder head and the sealing face. If necessary, clean the seat in the cylinder head with a
reamer.
2. Ensure that the sealing face in the cylinder head is clean. Fit a new sealing ring.
3. Fit the injector. Put the bracket in position, aligning the injector to the bracket.
4. Attach the washer with the spherical surface to the brack-
et. Screw in the retaining bolt.
Anzugsdrehmoment ..................................................40 Nm
5. Connect the high-pressure line to the injector.
Anzugsdrehmoment .................................................. 30 Nm 

6. Connect the oil leakage line to the injector.

127( $IWHUWLJKWHQLQJWKHIXHOOLQHVPXVWEHIUHHRIGLVWRU
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7. Connect the electrical cables to the injector.
Anzugsdrehmoment .................................................1.5 Nm
8. Fit the protective cap.
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LQJWKH(676HUYLFH7RRO

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1. Electrical connection
2. Washer with spherical surface
3. Bracket
4. Sealing ring

 SS05M993

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 3001A-15

+LJKSUHVVXUHSXPS
The high-pressure pump is mounted on the engine control housing on the left-hand side of the engine. It is driven by
gear wheels. The high-pressure pump is a radial piston pump with three cylinders. The high-pressure pump is lubri-
cated by the fuel.
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FUDQNVKDIW
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If necessary the function of the high-pressure pump can be checked using the (67 (Service Tool).

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WKHVNLQDQGFDXVHVHULRXVLQMXU\,IVXFKDQHYHQWRFFXUVPHGLFDODWWHQWLRQPXVWEHVRXJKWLPPHGLDWHO\
127( 7KHSRVLWLRQRIWKHFUDQNVKDIWGRHVQRWQHHGWREHWDNHQLQWRFRQVLGHUDWLRQZKHQUHPRYLQJWKHKLJKSUHV
VXUHSXPS
1. Turn the start switch to the OFF position. Turn the main battery switch (if present) to
the OFF position.
2. Clean the high-pressure pump, the area around it and the line connections.
3. Disconnect the plug connection. Disconnect the fuel lines and immediately seal the connection openings with
plastic plugs.
4. Unscrew the retaining bolts. Remove the high-pressure pump, being careful with the guide ring.
5. Unscrew the retaining nut of the drive gear from the pump shaft, fixing the drive gear using a suitable tool. Use a
suitable extractor to pull the drive gear off the pump shaft.
127( :KHQGRLQJWKLVWKHH[WUDFWRUPXVWEHVXSSRUWHGDJDLQVWWKHSXPSVKDIW
6. Remove the guide ring from the pump flange.

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KLJKSUHVVXUHSXPS
1. Clean the guide ring (A) and the drive gear (B). Check
the mounting flange on the high-pressure pump you plan 1P
to install. Check the O-ring grooves on the pump flange
and on the guide ring. They must be clean and free from
burrs or foreign material. Check the outer cone of the
pump shaft and the inner cone of the drive gear. They 1P
must be dry, free of oil and grease and must not show
any signs of burrs.
$ 1P
2. Attach an O-ring to both the pump flange and the guide
ring. Apply a thin coat of oil to the O-ring on the pump %
flange. Fit the guide ring. Manually slide the drive gear on
1P
to the pump shaft. Fit the nut. Fix the drive gear in place
with a suitable tool. Tighten the nut.
Anzugsdrehmoment ..................................................70 Nm
SS05M994

3. Clean the flange face and the bore for inserting the high-
pressure pump on the control unit casing. Apply a thin
coat of oil to the O-ring on the guide ring. Hold the high-
pressure pump in its installation position. Align the guide
ring radially on the pump flange such that the bore (see
arrow) is in line with the bore on the control unit casing.
4. Slide the high-pressure pump into the control unit casing
together with the guide ring. Screw on and tighten the re-
taining bolts (with shim).
Anzugsdrehmoment ................................................. 30 Nm
5. Connect the fuel lines to the high-pressure pump and
tighten them.
Anzugsdrehmoment Low-pressure lines .................. 25 Nm
High-pressure line (pump to rail) .............................. 30 Nm SS05M995

6. Connect the plug connection.

127( $IWHUWLJKWHQLQJWKHIXHOOLQHVPXVWEHIUHHRIGLVWRUWLRQ

)LQDOWDVNV
‡ Ensure that the tank contains sufficient fuel.
‡ Vent the fuel system (see Seite 13).
‡ Start the engine, check the fuel system for leaks and observe how the engine runs.
‡ Carry out a test drive.

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)XHOTXDOLW\UHTXLUHPHQWV

5HTXLUHPHQW 7HVWPHWKRG
3
Density at +15 °C 0.82...0.84 kg/dm EN ISO 3675:1998, EN ISO 12185
2
Viscosity at +40 °C 2.0...4.5 mm /s EN ISO 3104
Sulphur content max. 350 mg/kg EN ISO 14596:1998
Cetane rating min. 51 EN ISO 5165:1998
Water content max. 200 mg/kg prEN ISO 12937:1996
Lubricity max. 460 microns ISO 12156-1

The diesel fuel used must satisfy the EN 590 standard.

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'HSHQGHQFHRIHQJLQHRXWSXWRQIXHOTXDOLW\
Various physical parameters relating to fuel quality, such as temperature, density and viscosity, have an impact on
engine output.
The output of the engines is given at a density of 0.84 kg/dm³, a specific heat capacity of 42.7 Mj/kg and a fuel tem-
perature of +15 °C.
The diagrams below show the change in engine output as a percentage when one physical parameter is changed.
'LDJUDP$
Engine output is dependent on the fuel temperature. The refer-
ence temperature is +35 °C (correction factor 0%). The fuel tem-
perature not only depends on the ambient temperature but also
varies according to factors in the fuel system such as the volume
and position of the tank, the return volume, position of the lines
and filter and the material from which the lines are made.

'LDJUDP%
Engine output is dependent on the density of the fuel used. The
standard value is 0.84kg/dm³ at +15 °C.

'LDJUDP&
Engine output is dependent on the viscosity of the fuel used. The
standard value is 3 cSt at +20 °C.
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DEOHIURPWKHPDQXIDFWXUHURUGHDOHU

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Add together the correction values (in %) of diagrams A, B and

C. Correct the manufacturer's specified rated engine output us-
ing the percentage calculated.

SS05M996

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BLANK PAGE

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 Chapter
4002

4002
FUNCTIONAL DESCRIPTION OF
THE CAN BUS
(Basics)

CNH Österreich GmbH Sva 6-51350 EN © 2003 CNH Österreich GmbH

Technical Documentation May, 2003
A – 4300 St. Valentin, Steyrer Straße 32
 4002-3
TABLE OF CONTENTS
INTRODUCTION ................................................................................................................................................... 5

DIGITAL TECHNOLOGY ...................................................................................................................................... 6

Advantage of digital message transmission ..................................................................................................... 6
Ranges for 1 and 0 .......................................................................................................................................... 7
Parallel Data Transmission .............................................................................................................................. 8
Serial Data Transmission ................................................................................................................................. 8

DATA BUS ............................................................................................................................................................ 9

Function ......................................................................................................................................................... 10
Can bus line ................................................................................................................................................... 11
Can high – Can low ........................................................................................................................................ 12
CAN High Speed Signal Level ....................................................................................................................... 13
Topology ........................................................................................................................................................ 14
Data Transmission ......................................................................................................................................... 14

DATA PROTOCOL ............................................................................................................................................. 15

Structure of the CAN Data Frame – Standard Identifier (11 bits) CAN V2.0A ............................................... 15
Structure of the CAN Data Frame – Standard Identifier (29 bits) CAN V2.0B ............................................... 17
Structure of the CAN Remote Frames Identifier ............................................................................................ 19

ERROR DETECTION ......................................................................................................................................... 20

Mechanisms on the Data Frame level ........................................................................................................... 20
Mechanisms of the Bit Level .......................................................................................................................... 20

TROUBLESHOOTING ........................................................................................................................................ 21
Interrupting the Transmission ........................................................................................................................ 21
Resumption of the Transmission ................................................................................................................... 21
Realtime Transmission .................................................................................................................................. 21

TRANSMISSION SPEED .................................................................................................................................... 22

TELEGRAM LENGTH ......................................................................................................................................... 23

CENTRAL GATEWAY ........................................................................................................................................ 25

SERVICE TOOL .................................................................................................................................................. 25

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INTRODUCTION
There is a clear trend in automobile and farm implement technology towards an increasing replacement of mechanical
components by electronic components.
This thereby allows the maker to provide the customer with more comfort and more safety inside the vehicle.
However, this also means that vehicle electronics are becoming ever more complex and are equipped with a growing
number of sensors and actuators.
In the future, these increased requirments can no longer be implemented by autonomous control devices.
The solution to the problem lies in the networking of various electronic modules with a data bus.
The simple motto is: "Less hardware, and more software".
This provides many advantages, which will be described in detail in this document.

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DIGITAL TECHNOLOGY
There are only two conditions in digital technology (lat. digitus >finger<). Both of these conditions are defined exactly.
They are termed logical zero and logical one.

Lamp lights Lamp does not light

Both conditions (logical one and logical zero) are mutually exclusive, i.e. both conditions can never be present
simultaneously.
There are no intermediate values (e.g. lamp lights weakly).
One single such condition is termed within digital technology as a bit (BInary digiT ).
Therefore, using one bit (Bi = 2), exactly two different conditions can be described (e.g. switch closed or switch
open).

Condition Electrical Magnetic Light

Logical zero No current Not magnetized Dark

Logical one Current present Magnetized Bright

One BIT therefore represents the smallest amount of information.

In control units, a voltage of 3.5 volts is defined with logical one.

Advantage of digital message transmission

The great advantage is that the "quality" of a single bit is insignificant. The only fact that is decisive is whether or not
a bit is set (logical one) or not (logical zero).
If the requirements for the correct type and installation of the lines are met and the limit values for the line length and
transmission speed (see page 22) are observed, then there are no losses of quality during data transmission by
means of digital technology.
127( Repairs to CAN bus lines must be carried out in such a way that the EMC* requirements are met again
(screening and transposition must be restored).
* EMC = electro-magnetic compatibility

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Ranges for 1 and 0

Voltage


Time

Assigned areas that are defined by one and zero.

1 Bit = 2 possible states
.

State of the bits PTO state State of the seat switch

0 0 OFF OPEN

1 0 ON OPEN

0 1 OFF CLOSED

1 1 ON CLOSED

This information could be used, e.g. in FMGR control units for recognising the working mode or at the seat switch for
safety conditions.
Possibilities in relation to the number of bits
A single bit has a low data content. Several bits are therefore used in practice.

Number of BITs Possibilities

1 2

2 4

3 8

4 16

5 32

6 64

7 128

8 256

The number of possibilities increases exponentially.

Number of possibilities = 2 n (n = number of BITs).
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4002-8
Therefore, using eight BITs, 256 (2 8 = 256) various conditions can be shown.
There are eight BITs to a BYTE (BY eighT).
Using one BYTE, 28 = 256 various conditions can be shown.
Often, one byte (eight bits) is used in the electronic systems of farm implement technology.
In this way, e.g. the engine temperature of -20 °C to +120 °C can be "digitized" to one BYTE. This in turn means that
the temperature difference of 140 °C is divided into 256 steps or levels.
This means that a resolution of 0.546 875 °C per BIT is achieved.
0000 0000 ...................................................................... corresponds to -20 °C
1111 1111 ........................................................................ corresponds to 120 °C
If a higher resolution is required then a (phsical) signal can also be "digitized" with two (or more) bytes. In principle,
there are no limits to this.

Parallel Data Transmission

The transmision of the single bytes can be made in such a way that each bit has its own line.
This means that eight lines are required. This procedure is suitable when large amounts of data have to be
transmitted. The large amount of cable required for this is, however, somewhat disadvantageous.

E\WH

1 1 0 0 0 1 1 0

OLQHV

Serial Data Transmission

If the single bits are transmitted one after the other using just a single line then this procedure is referred to as serial
data transmission. Using this method, however, only relatively short transmission paths can be bridged. The greater
the rate of transmission, the shorter the line length (1 Mbit/s up to 40 m and 50 Kbit/s up to 1000 m).

0 E\WH
1
1
0
0 OLQH
0
1
1

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DATA BUS
The term CAN (= Controller Area Network) originates from computer technology and, when related to tractors,
means the electronic coupling (i.e. networking) of control units.
Within a data bus system, individual control units are linked to each other in a network can therefore exchange data.
As all control units connected to the bus participate in the data exchange, the control units in such a system are
also called bus users.
Note:
‡ The bus users are connected in parallel to the data bus.
‡ Data transmission is effected serially.

EEM

CAN Data Bus

ARU FMGR MONITOR

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4002-10

Function
The CAN data bus is a bi-directional bus.
This means that every control unit which is connected can transmit and receive.
Conditioning an analogue signal
‡ A sensor transmits an analogue signal, e.g. engine coolant temperature (the voltage is the signal value), to an
assigned control unit
‡ In the control unit, the analogue signal is conditioned (digitalised) by an AD converter and converted into
a numeric code
‡ A data telegram is also created in the control unit
‡ The signal value is a part of the data telegram
Conditioning a digital signal
‡ A sensor transmits a digital signal, e.g. engine speed (the frequency is the signal value), to an assigned control
unit
‡ In the control unit, the digital signal is converted into a numeric code by a code converter
‡ A data telegram is also created in the control unit
‡ The signal value is a part of the data telegram
Forwarding the data telegram
The data telegrams are sent to the data bus. Every control unit connected to the data bus can read and process the
signal value in the data telegram as required.

Message-related addressing
This means that every message is assigned one fixed address (identifier) that identifies the contents of the message
(e.g. engine speed).
The CAN protocol can allow up to 2048 messages in the case of an 11-bit identifier and up to 500 million for a 29-bit
identifier. The data capacity per message is up to 8 bytes.
A receiver evaluates only those messages (data telegrams) that are stored in its list of messages to be received
(acceptance test).
Advantages:
‡ Sensor lines must be led to the nearest control unit. This results in much less cable being used with a
concomitant reduction in plug connections and thereby a reduced number of possible error sources.
‡ Improved EMC (= electromagentic compatibility) and therefore less trouble-prone.
‡ Multiple use of signals and thereby less sensors.
‡ Better and more exact diagnosis possibilities using the CNH Service Tool.
‡ Control units can be programmed when assembled in the vehicle (flashing).

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Can bus line

Design
The CAN data bus is a special twisted two-wire line. The users (control units) are connected in parallel to this line.
Data transmission is made redundantly via both lines, whereby the bus levels are mirrored (i.e. if the level at one line
is 0 then the other line transmits level 1, and vice versa).
Dual-line mode
Dual-line mode is used for several reasons:
‡ Bus systems with a higher clock frequency work in dual-line mode (for physical reasons)
‡ In conjunction with the transposition, there is a (partial) compensation of the electro-magnetic interference
caused by the clock mode
‡ As a security concept
‡ For error recognition.
Screening of the CAN line
The screening is run parallel to the two-wire CAN line. The overal line is thus four-wire.
The screening comprises two wires. The ground potential is carried in one. The second wire carries a plus potential
of 12 V. The CAN line is twisted together with the screening. In some cases, the two-wire screening ends directly in
front of the casing of a bus user.
127( When looking for faults in the CAN cabling, bear in mind that in some cases the 12 V potential of the
screening is supplied by its own fuse. For details, refer to Chapter 4010, "Circuit Diagram" / "Diagram of CAN Bus" in
the CNH Service Tool.
Bus user screening
In addition to the integrated protective measures in their electronic circuits, the bus users are protected against
external electro-magnetic interference by a metal casing. Such interference occurs especially when operating radio
equipment, mobile phones, GPS, etc.
The carrier waves of these systems have a high frequency. The closed metal casing forms a "Faraday cage".
127( In the case of certain bus users, e.g. EEM, the metal casing is connected to the ground supply for the
electronics circuit (refer to Chapter 4010, "Circuit Diagram" / "Diagram of CAN Bus" in the CNH Service Tool).
These electrical connections must also be checked when looking for faults in the CAN cabling.

Standardised representation of a twisted line in the circuit diagram

CAN high

CAN low

+12 V

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4002-12

Can high – Can low

One bus line is theoretically enough for bus systems with a low clock frequency. High-speed bus systems must
always have 2 lines as the voltage level will otherwise be too low.
The data is transmitted redundantly via both lines, whereby the signal is mirrored. Data transmission errors are
thereby reliably recognised (e.g. checksum test).
Data signal on the CAN-high line (example)

Bit 3

Bit 4

Bit 5

Bit 7

Bit 8
Bit 2

Bit 6
Bit 1

Logical 1

Logical 0

0 1 1 0 1 0 0 1

Mirrored signal on the CAN-low line

Bit 3

Bit 4

Bit 5

Bit 7

Bit 8
Bit 2

Bit 6
Bit 1

Logical 1

Logical 0

1 0 0 1 0 1 1 0

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CAN High Speed Signal Level

Voltage

5
CAN_H

4
CAN_H
CAN_L / CAN_H
3 CAN_H
CAN_L / CAN_H

2 CAN_L
CAN_L / CAN_H
CAN_L
1
CAN_L
0
Time
Recessive Dominant Recessive

min
nom
max

CAN Recessive Dominant

High Speed min nom max min nom max

CAN H 2.0 V 2.5 V 3.0 V 2.75 V 3.5 V 4.5 V

CAN L 2.0 V 2.5 V 3.0 V 0.5 V 1.5 V 2.25 V

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Topology
"Series" system

HI

LO

FMGR EEM ECCU

Data Transmission
Transmission Protocol
All details of a data transmission are regulated in a transmission protocol.
Data telegrams can only be transmitted when the CAN data bus is free (i.e. when, after the last data telegram, there
is a 3 bit space and no control unit starts transmitting). The bus level is thereby logical one.
Arbitration
If several control units start transmitting simultaneously, then a procedure is introduced in which the message with
the highest priority wins through without any time or bit loss ensuing.
Every control unit that looses the arbitration automatically becomes a receiver and repeats its attempt to transmit as
soon as the CAN data bus is free.
Apart from data telegrams, there are also request telegrams for particular messages. Every control unit that is able
to provide the required data telegram then reacts to this request.
If a voltage peak only occurs at one line (e.g. due to EMC problems) then the receivers can recognise this as an
error and ignore the voltage peak.

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DATA PROTOCOL
Structure of the CAN Data Frame – Standard Identifier (11 bits) CAN V2.0A

Arbitration

IFS Start Identifier IDE DLC Data CRC ACK EOF IFS
3 Bit 1 Bit 11 Bit 1 Bit 4 Bit 0-8*8 Bit 15 Bit 2 Bit 7 Bit 3 Bit
Bus idle RTR r0 CRC DEL
1 Bit 1 Bit 1 Bit

Start of Frame (1 bit)

Start bit = Low (dominant). The negative flank is used for phase synchronization of the receivers.

Arbitration Field (12 bits)

Identification of the address (ID 0-ID 10)
The smaller the numerical value in the address, the higher the priority. The highet value 7 bits must not all be
recessive.
Remote Transmission Request – RTR (last bit of the Arbitration Field)
RTR = LOW – Telegram contains data
RTR = HIGH – Telegram contains request to send data

Control Field
ldentifier Extension – IDE (1 bit)
IDE = LOW – Standard Identifier – there are no further Identifier bits
r0 = 1 reserved bit for subsequent extensions

Data length Code – DLC (4 bits)

Identifies the number of data bytes in Data Field

Data Field
0 - 8 byte data can be transmitted per Data Frame.

CRC Field (15 bits)

Cyclic Redundancy Code – CRC
‡ The CRC sequence is formed (on the transmission side) from the data flow (without stuff bits) from Start of Frame
+ Arbitration Field + Control Field + Data Field (if available).
‡ The CRC Check recognises up to 5 individual errors per message, up to 15 burst errors per message (errors that
directly follow each other), all errors with an uneven number per message
CRC Delimiter (1 bit – recessive)

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4002-16

Acknowledge Field (2 bits)

‡ 1st. bit (ACK slot) is transmitted recessively by the transmitter. Receivers that have received a valid message
acknowledge receipt with a dominant bit.
‡ 2nd. bit is transmitted recessively as an ACK delimiter.

End of Frame – EOF "Data/Remote Frame" (7 bits – recessive)

A stuff bit is not generated; normally a stuff bit is added after five bits of the same level.

lnter Frame Space – IFS (3 bits – recessive)

Identifies the period of time between a correctly received telegram and transfer into the respective
message buffer.

Bus Idle (recessive)

‡ Bus is not assigned
‡ Every bus user can start the transmission of a new frame by means of a Start bit

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 4002-17

Structure of the CAN Data Frame – Standard Identifier (29 bits) CAN V2.0B

Arbitration

IFS Start Identifier Data CRC ACK EOF IFS

IDE Identifier r1 DLC
3 Bit 1 Bit 11 Bit 0-8*8 Bit 15 Bit 2 Bit 7 Bit 3 Bit
1 Bit 18 Bit Bit 4 Bit
Bus idle SRR RTR r0 CRC DEL
1 Bit 1 Bit Bit 1 Bit

Start of Frame
Start bit = Low (dominant). The negative flank is used for for phase synchronization of the receivers.

Arbitration Field
Identification of the address (ID18-ID28)
The smaller the numerical value in the address, the higher the priority. The highet value 7 bits must not all be
recessive.
Substitute Remote Request – SRR (1 bit)
Replacement for the RTR bit from the standard CAN (CAN V2.0A); otherwise meaningless
ldentifier Extension – IDE (1 bit)
IDE = HIGH – there are further 18-bit identifiers in the 2nd. Identifier Field (ID 17-ID 0)
Remote Transmission Request – RTR (last bit of the Arbitration Field)
RTR = LOW – Telegram contains data
RTR = HIGH – Telegram contains request to send data

Control Field
r1 / r0 = 2 reserved bits for subsequent extensions

Data length Code – DLC (4 bits)

Identifies the number of data bytes in Data Field

Data Field
0 - 8 byte data can be transmitted per Data Frame.

CRC Field (15 bits)

Cyclic Redundancy Code – CRC
‡ The CRC sequence is formed (on the transmission side) from the data flow (without stuff bits) from Start of Frame
+ Arbitration Field + Control Field + Data Field (if available).
‡ The CRC Check recognises up to 5 individual errors per message, up to 15 burst errors per message (errors that
directly follow each other), all errors with an uneven number of errors per message
CRC Delimiter (1 bit – recessive)

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4002-18

Acknowledge Field (2 bits)

‡ 1st. bit (ACK slot) is transmitted recessively by the transmitter. Receivers that have received a valid message
acknowledge receipt with a dominant bit.
‡ 2nd. bit is transmitted recessively as an ACK delimiter.

End of Frame – EOF "Data/Remote Frame" (7 bits – recessive)

A stuff bit is not generated; normally a stuff bit is added after five bits of the same level.

lnter Frame Space – IFS (3 bits – recessive)

Identifies the period of time between a correctly received telegram and transfer into the respective message buffer.

Bus Idle (recessive)

‡ Bus is not assigned
‡ Every bus user can start the transmission of a new frame by means of a Start bit

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Structure of the CAN Remote Frames Identifier

Data frame (CAN 2.0A with 11-bit identifier)

IFS Start Identifier IDE DLC CRC ACK EOF IFS IDLE/
3 Bit 1 Bit 11 Bit 1 Bit 4 Bit 15 Bit 2 Bit 7 Bit 3 Bit Next telegram
Bus idle RTR r0 CRC DEL
1 Bit 1 Bit
1 Bit

Remote Frame (CAN 2.0B with 29-bit identifier)

IFS Start Identifier CRC ACK EOF IFS

IDE Identifier r1 DLC
3 Bit 1 Bit 11 Bit 15 Bit 2 Bit 7 Bit 3 Bit
1 Bit 18 Bit Bit 4 Bit
Bus idle SRR RTR r0 CRC DEL
1 Bit 1 Bit Bit 1 Bit

CAN Remote Frame

Receivers of a message can:
‡ Wait for a Data Frame triggered by the Transinit job in the corresponding transmitter
‡ Request a transmitter with a Remote Frame to transmit the current data
Independent of the Data Length Code (DLC), a Remote Frame does not contain any data (RTR bit is recessive).
Depending on the priority of the Remote Frame, the answer can be delayed by higher priority telegrams.
All nodes (bus users) at the CAN bus can receive the requested data telegram, whereby data consistency is ensured
in the network.

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ERROR DETECTION
Faults can result in errors during data transmission. Such transmission errors must be detected and rectified. In the
CAN protocol, there are two different error-detection levels:
1 Mechanisms on the Data Frame level
2 Mechanisms on the Bit level

Mechanisms on the Data Frame level

Cyclic Redundancy Check
The transmitter calculates check bits from the message to be transmitted; these check bits are transmitted along
with the message in the "CRC field" of the data telegram. The receiver re-calculates these check bits from the
received message and compares them with the received check bits.
Frame Check
This mechanism checks the structure of the transmitted frame by checking the bit fields with a pre-determined fixed
format as well as the frame lengths. The errors detected by the Frame Check are called format errors.

Mechanisms of the Bit Level

Monitoring
Each station observes the bus level when transmitting and thereby recognises differences between the transmitted
bit and the received bit. This allows global and local bit errors at the transmitter to be reliably detected.
Bit Stuffing
In every data telegram, a maximum of 5 consecutive bits can have the same polarity between "Start of Frame" and
the end of the "CRC Field". After each 5 identical consecutive bits, the transmitter attaches a bit of the opposite
polarity into the bit stream. The receivers remove these bits after receiving the message.

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TROUBLESHOOTING
Interrupting the Transmission
If any station on the CAN bus detects an error then it interrupts the current transmission by transmitting an error
message. The error message consists of 6 dominant bits.
The error message informs all connected control units of a locally occurring error; these then ignore the
subsequently transmitted messages.

Resumption of the Transmission

After a short pause, all control units are then once more able to transmit, whereby the message with the highest
priority once again wins out.
The control unit whose message has caused the error also begins to re-transmit its message (automatic repeat
request).

Realtime Transmission
To be able to process data in realtime, the data must be transmitted quickly. This not only presupposes a fast
physical data transmission path, but also requires a fast allocation on the bus if several control units want to transmit
simultaneously.
To take into account the various levels of urgency of messages that are transmitted via the bus, there are various
priorities for the single messages. The advance angle (hydrostat) has, e.g. very high priority, the oil temperature
value medium priority and the service message low priority.
Example:
If several control units want to transmit simultaneously then the bus access conflict is triggered by the respective
identifier via "bit arbitration".
On transmitting the Arbitration Field, the transmitter checks after every bit whether it is still authorized to transmit or
whether another control unit is transmitting a message of higher priority. When a recessive bit transmitted by the first
transmitter is overwritten by a dominant bit from another transmitter then the first transmitter loses its authorization to
transmit (arbitration) and becomes a receiver.
The first control unit (N2) loses the arbitration with bit 3. The third control unit (N3) loses the arbitration with bit 7. The
first control unit (N1) retains access to the bus and can transmit its message.

User 1
Node 1
High priority

User 2
Node 2
Receive only Low priority

User 3
Node 3
Receive only Medium Priority

CAN Bus CAN Bus

Recessive
Line
Dominant

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TRANSMISSION SPEED
Different CAN data busses are used. They are mainly differentiated by their various transmission speeds. If one bit
per second is transmitted on a line then the transmission speed is one baud (Jean Maurice Baudeot – French
lineman)
1 baud (Bd) ........................................................................................................................... 1 bit/sec.
1 kbaud (kBd)..................................................................................................................1024 bits/sec.

Data bus systems currently in use

125 kBd................................................................................................................... Å125,000 bits/sec.
250 kBd......................................................................................................................250,000 bits/sec.
500 kBd......................................................................................................................500,000 bits/sec.
5,785.6 kBd (optical data bus) .................................................................................5,785,600 bits/sec

A maximum of 135 bits (11-bit identifier) and 160 bits (29-bit identifier) are transmitted for a data telegram.
The number of data telegrams that can be transmitted per second can be calculated from these values as follows:

125 kBd (11-bit ID) .............................................................................................. 925 telegrams / sec.

125 kBd (29-bit ID) .............................................................................................. 781 telegrams / sec.
250 kBd (11-bit ID) ............................................................................................ 1851 telegrams / sec.
250 kBd (29-bit ID) ............................................................................................ 1562 telegrams / sec.

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TELEGRAM LENGTH
Maximum length of a telegram for standard frames (11-bit identifier) = 135 bits.
The transmission time for a telegram is 540 µs at 250 kBd.
Sections Number of bits
Start ............................................................................................................................................................. 1
Identifier ......................................................................................................................................................11
RTR ............................................................................................................................................................. 1
Contrl ........................................................................................................................................................... 6
Data ........................................................................................................................................................... 64
CRC ........................................................................................................................................................... 15
CRC Dlimiter ................................................................................................................................................ 1
Staff .................................................................................................................................................. max. 24
ACK ............................................................................................................................................................. 2
EOF ............................................................................................................................................................. 7
IFS ............................................................................................................................................................... 3

Maximum length of a telegram for standard frames (29-bit identifier) = 160 bits.
The transmission time for a telegram is 640 µs at 250 kBd.
Sections Number of bits
Start ............................................................................................................................................................. 1
Identifier ......................................................................................................................................................11
SRR ............................................................................................................................................................. 1
IDE ............................................................................................................................................................... 1
Identifier ..................................................................................................................................................... 18
RTR ............................................................................................................................................................. 1
Contrl ........................................................................................................................................................... 6
Data ........................................................................................................................................................... 64
CRC ........................................................................................................................................................... 15
CRC Dlimiter ................................................................................................................................................ 1
Staff .................................................................................................................................................. max. 29
ACK ............................................................................................................................................................. 2
EOF ............................................................................................................................................................. 7
IFS ............................................................................................................................................................... 3

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SGR
VP30

Sva 6-51350 EN
Transmision bus
Getriebe Bus
AUX
1
Service

29 bit ID 250 kBaud

Tool FMGR AUX
11 bit ID 500 kBaud
2
AUX
3
EEM ICU FSS
AUX
4
AUX
Vehicle bus
Fahrzeug Bus
5
29 bit ID 250 kBaud

EDC
ADIC KPAD TC ECCU ARU
Gerät
ISO Bus

29 bit ID 250 kBaud ISO

Bus
= Matching resistor Virtual GPS
SC03E068

Edition 05-2003
 4002-25

CENTRAL GATEWAY
Efficient data bus systems are used in automotive engineering for the communication between individual control
units. However, it has become apparent that it is not useful to connect all control units to the same (common) data
bus.
Different function areas, such as the gearbox management, operating management and engine management, as
well as the distribution of the data bus load, result in bus systems that work parallel. These differ through the
transmission speed, transmission protocol and transmission medium.
The gateway is the connecting link between the data bus systems located in the vehicle. However, a gateway can
also assume additional tasks of a control unit (e.g. operation).
Gateways: FMGR, ECCU and EEM.

SERVICE TOOL
The existence of a common interface between the various data bus systems allows important functions to be
implemented. For example, the various data bus systems can be accessed via a common diagnostics interface for
the CNH SERVICE TOOL. In addition, in the event of a data bus failure, certain important tests are easily accessible
and can thus be carried out in a short time via the diagnostics interface when looking for the fault in the CAN bus
line.

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 )81&7,21$/'(6&5,37,21$1'
7528%/(6+227,1*±$',&



CNH Österreich GmbH Sva 6-91700 EN © 2004 CNH Österreich GmbH

Technical Documentation March 2004
A – 4300 St. Valentin, Steyrer Straße 32
 4003-3

TABLE OF CONTENTS
TABLE OF CONTENTS .........................................................................................................................................3

SPECIAL TOOLS ...................................................................................................................................................5

GENERAL DESCRIPTION ....................................................................................................................................6

GENERAL NOTES ................................................................................................................................................7

Handling plug-in connections ............................................................................................................................7
Regulations for using jumper cables for starting ...............................................................................................7
Regulations for carrying out electro-welding work on the tractor or on an implement ......................................7

ANALOG AND DIGITAL DISPLAYS ......................................................................................................................8

WARNING AND INDICATOR LAMPS ...................................................................................................................9

ANALOG DISPLAY INSTRUMENTS ...................................................................................................................10

Engine speed display ......................................................................................................................................10
Coolant temperature display ...........................................................................................................................10
Fuel level indicator ..........................................................................................................................................10

DIGITAL DISPLAY INSTRUMENTS ....................................................................................................................11

Display 1 .........................................................................................................................................................11
Display 2 .........................................................................................................................................................11
Display 3 .........................................................................................................................................................11

ADJUSTMENT BUTTONS ...................................................................................................................................12

DMD (DOT MATRIX DISPLAY) ...........................................................................................................................13

Warnings .........................................................................................................................................................13
Information ......................................................................................................................................................13
Service ............................................................................................................................................................14

KEYPADS ............................................................................................................................................................15
Service interval key .........................................................................................................................................15
Odometer key .................................................................................................................................................15
Hectare counter key ........................................................................................................................................16
Hectare performance / hour key .....................................................................................................................16
Menu up scroll key ..........................................................................................................................................16
Enter / Save key ..............................................................................................................................................16
Menu down scroll key .....................................................................................................................................16
Escape key without saving ..............................................................................................................................16
Key for displaying 3-point hitch position front / rear ........................................................................................17
Key for displaying PTO shaft speed front / rear ..............................................................................................17
Wheel slip key .................................................................................................................................................17
Battery voltage key .........................................................................................................................................17
Engine operating hours key ............................................................................................................................17
Key for tractor RESET ....................................................................................................................................18
Key for compressed air trailer braking system ................................................................................................18
Changeover key for driving strategy and speed range display .......................................................................18

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MENU SETTINGS ............................................................................................................................................... 19
Setup menu 1 ................................................................................................................................................. 19
Setup menu 2 ................................................................................................................................................. 21
Plugs on the ADIC .......................................................................................................................................... 23

TROUBLESHOOTING USING THE DIAGNOSTIC SYSTEM ............................................................................ 24

TEST VALUES FOR SPEED DISPLAYS ............................................................................................................ 29

TEST VALUES FOR ANALOG DISPLAYS AND WARNING .............................................................................. 29

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SPECIAL TOOLS

SD00C040 SD00D003

MULTIMETER (Fluke 79 or similar) DIAGNOSTIC BOX, 100-POLE

(1TSW 516-1) 380000058 (1TSW 528-1)
380000061 (1TSW 528-44)

SD00C038

SD04A006
MEASURING CABLES (pin diameter - 4 mm)
(1TSW 528-11) "Y" ADAPTER, 26-POLE (ADIC) 38000149226

SD04A002

TEST LAMP (with 21 W bulb)

1TSW 528-2

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GENERAL DESCRIPTION
ADIC = Analog-digital instrument cluster

The ADIC comprises the following components:

Analog display instruments
• Engine speed
• Coolant temperature
• Fuel tank level

Digital display instruments

• Driving speed
• PTO shaft speed front / rear (switchable)
• Lifting height of 3-point hitch front / rear (switchable)
• Wheel slip
• Time

DMD display for graphic symbols

(DOT MATRIX DISPLAY)

Adjustment buttons
• ADIC lighting (dimmer)
• Time (hours, minutes)

Warning and indicator lamps

Acoustic warning facility

Keypad with 16 function keys

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GENERAL NOTES
Handling plug-in connections
• High-pressure cleaning should be avoided in the vicinity of electrical plug-in connections.
• Plug-in connections that connect signal lines from sensors must not be treated with contact or cleaning spray
(e.g. MOS2) as this can cause malfunctions.
NOTE: Plug-in connections must be kept clean and dry.

Regulations for using jumper cables for starting

• Only connect in parallel to another 12 Volt supply (battery or vehicle).
• Do not reverse connect the poles.
• Take care when using starting aid devices – voltage peaks must not exceed 16 V.
• Never remove jumper cables during the starting procedure and ensure that the cable clamps cannot
inadvertently fall off. This will result in voltage peaks.

Regulations for carrying out electro-welding work on the tractor or on an

implement
• Switch the engine off. Ignition switch S1 must be in position ”0”.
• The ADIC must be disconnected. (CN1-CN3)
• Do not disconnect the battery.
• Disconnect the implement from the tractor (if possible) when performing welding work on implements.
• Connect the welding equipment ground to the part to be welded.
• The cables for the welding equipment must not run in the direct vicinity of electronic units, their supply lines,
sensors and their signal lines or cross such lines.
NOTE: Cables for welding equipment carry high currents during the welding process. These currents produce
powerful electromagnetic fields (alternating currents produce alternating fields). Memory modules / microprocessors
could get damaged.

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ANALOG AND DIGITAL DISPLAYS

10
2
1 3

5 4 6 9
7 8

SS04B181

1. ENGINE SPEED 6. PTO SHAFT SPEED / 3-POINT HITCH

POSITION / SLIP DISPLAY
2. COOLANT TEMPERATURE 7. TIME DISPLAY
3. FUEL LEVEL 8. ADJUSTMENT BUTTON – HOURS
4. DRIVING SPEED 9. ADJUSTMENT BUTTON – MINUTES
5. DIMMER ADIC LIGHTING 10. DMD (DOT MATRIX DISPLAY)

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WARNING AND INDICATOR LAMPS

7 8 9 10 11 12 13
6 14
5 15

4 16

3 20
17
21
2 18
22

1 19

28 27 26
25 23
24

SS04B181

1. FUEL CHECK / RESERVE 15. FUEL PRE-HEATING

2. FAST STEER 16. ENGINE OIL PRESSURE
3. DIFFERENTIAL LOCK 17. FRONT PTO SHAFT
4. 4-WHEEL DRIVE 18. REAR PTO SHAFT MANAGEMENT
5. TRAILER TRAFFICATOR, 2ND TRAILER 19. REAR PTO SHAFT
6. TRAILER TRAFFICATOR, 1ST TRAILER 20. FORWARD DRIVING DIRECTION
7. SIDELIGHT 21. N = NEUTRAL POSITION, TRANSMISSION
8. HIGH BEAM 22. REVERSE DRIVING DIRECTION
9. STOP WARNING LAMP 23. TRAFFICATOR INDICATOR, RIGHT
10. ENGINE MANAGEMENT 24. ENGINE SPEED REDUCTION
11. WARNING LAMP, DOT MATRIX DISPLAY 25. TRAFFICATOR INDICATOR, LEFT
12. SPRUNG FRONT AXLE 26. ENGINE BACK PRESSURE BRAKE
13. PARKING BRAKE 27. PRE-GLOWING INDICATOR
14. WARNING LAMP, TRAILER BRAKE 28. CHARGING INDICATOR LAMP

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ANALOG DISPLAY INSTRUMENTS

3 2

1
5

4
SS04B181

Engine speed display

The engine speed (1) is displayed in revs per minute x 100. The red area starts at 2500 rpm.

Coolant temperature display

The coolant temperature display (4) is divided into three areas.
Blue field → Temperature too low
Neutral area → Desired operating temperature
Red field → Temperature too high
If the temperature exceeds 110 °C, the temperature symbol appears on the DMD, the red warning lamp (3) starts
flashing and an acoustic warning signal sounds. (Critical warning!)
NOTE: The engine switches off automatically when the temperature exceeds 110 °C for more than 30 seconds.

Fuel level indicator

The fuel level indicator is divided into the areas EMPTY, RESERVE (red area), HALF FULL and FULL.
If the pointer reaches the red area, the indicator lamp (6) for fuel check (reserve) lights up.
The tank is then approx. 1/6 full.

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DIGITAL DISPLAY INSTRUMENTS

7
8

4 1 2 3 5 6

SS04B182

Display 1
The driving speed is indicated in kilometres per hour in display 1. The display can be switched over to miles per hour
in Setup menu 2.

Display 2
The following values can be called up in display 2 by pressing function keys 7 - 9.
• Lifting height of rear 3-point hitches – Display from approx. 10 - 96 % (press key 7 briefly)
• Lifting height of front 3-point hitches – Display from 0 - 100 % (press key 7 longer)
(front display only possible with front hitch management)
• Rear PTO shaft speed – Display in revs per minute (press key 8 briefly)
• Front PTO shaft speed – Display in revs per minute (press key 8 longer)
• Slip – Display in % (display only possible with radar sensor)

Display 3
The time is displayed in hours and minutes in display 3. The display can be switched over from 12 to 24 hr indication
in Setup menu 1.

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ADJUSTMENT BUTTONS
Dimmer adjustment button for ADIC lighting
The brightness of the display instruments and the function keys can be adjusted with the lighting switched on. The
brightness gradually changes on pressing the button (4) for a brief moment.
When the button is kept depressed, the dimmer runs through the whole setting range from bright to dark.
Hours / minutes adjustment button
Turn the ignition switch to ON and keep the Hours button (5) depressed for approx. 5 seconds. The time is adjusted
by one hour / minute by pressing button 5/6 for a short moment. When button 5/6 is kept depressed, you run through
the hours / minutes display.
After making the setting, wait approx. 5 sec. until the values stop flashing. (The new time setting is stored.)
Operating hours setting
The operating hours setting can be adjusted upwards, if necessary (e.g. a new ADIC is fitted).
• Turn the ignition switch to ON and keep the Hours button (5) and Minutes button (6) depressed for 15 seconds.
The value can be increased by pressing the Hours button.
• To store the value which has been set, keep both buttons (5 and 6) depressed for 15 seconds.
NOTE: The operating hours cannot be corrected downwards.

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DMD (DOT MATRIX DISPLAY)

The display symbols are split into four main groups:
• Warning
• Information
• Service
• System error

Warnings
These symbols refer to a critical fault during operation of the tractor.
Stop the tractor as soon as possible, determine the cause and rectify the
fault. SS02K039
Warnings are also supported acoustically and are split into
”NON-CRITICAL ALARMS” and ”CRITICAL ALARMS”.

NON-CRITICAL ALARM: In conjunction with the yellow warning lamp – Alarm sounds 2 x 1 second

CRITICAL ALARM: In conjunction with the red ”STOP” warning lamp – Alarm sounds periodically

Graphic symbols
1. COOLANT TEMPERATURE TOO HIGH – Red warning lamp
flashes and alarm sounds periodically.

2. RESERVOIR PRESSURE IN TRAILER BRAKE SYSTEM TOO

LOW – Red warning lamp flashes and ”Trailer brake” warning lamp
(item 14, page 9) lights up.
3. ENGINE OIL PRESSURE TOO LOW – Red warning lamp flashes,
alarm sounds periodically and ”Engine oil pressure” warning lamp
(item 16, page 9) lights up.

Information
The information symbols do not actually indicate a fault during operation of the tractor but they should not be ignored.
Take appropriate measures, as required.
1. LC display (LCD)/dot matrix display (DMD) brightness setting.

2. Speed display and PTO shaft operation

dot matrix symbol

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Service
These symbols inform the driver that basic tractor functions are impaired, for example: Air filter dirty, Service display,
etc.
1. Engine air filter blocked.
Yellow warning lamp flashes twice (no acoustic alarm)

2. Brake fluid level too low – in conjunction with red warning lamp

3. Engine coolant level too low – in conjunction with yellow warning

lamp

4. Fuel contamination caused by water – in conjunction with yellow

warning lamp (no acoustic alarm)

5. Hydraulic oil filter blocked – in conjunction with yellow warning lamp

6. Fuel filter blocked – in conjunction with yellow warning lamp

7. Small (”light”) service.

Yellow warning lamp flashes twice (no acoustic alarm)

8. Big (”heavy”) service.

Yellow warning lamp flashes twice (no acoustic alarm)

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KEYPADS

1 9

2 10

3 11
4
12
5
13

6
14

7 16 15
8
SS04B183

1. SERVICE INTERVAL 9. CHANGEOVER KEY FOR DISPLAYING

3-POINT HITCH POSITION FRONT / REAR
2. ODOMETER 10. CHANGEOVER KEY FOR DISPLAYING
PTO SHAFT SPEED FRONT / REAR
3. HECTARE COUNTER 11. WHEEL SLIP
4. HECTARE PERFORMANCE / HOUR 12. BATTERY VOLTAGE
5. MENU UP SCROLL KEY 13. ENGINE OPERATING HOURS DISPLAY
6. ENTER / SAVE KEY 14. KEY FOR TRACTOR RESET
7. MENU DOWN SCROLL KEY 15. TRAILER COMPRESSED AIR BRAKE SYSTEM
8. ESCAPE KEY WITHOUT SAVING 16. CHANGEOVER KEY FOR DRIVING STRATEGY
AND SPEED RANGE DISPLAY

Service interval key

The Service interval key (1) is used to call up the remaining driving hours until the next service (LIGHT / HEAVY) is
due.

Odometer key
The odometer key is used to display the distance travelled in km on the
DMD and to save it.
Two displays (”Memory A” and ”Memory B”) are available.
The display ”Memory A” can be used to measure partial distances and
the display ”Memory B” to measure the total distance, for example.
Press the Odometer key (2) once to display Memory A (partial distance)
and once again to display Memory B (total distance).

Display ranges:
0 - 19.999 km → Display: 0.001 km
20 - 199.99 km → Display: 0.01 km
200 - 1,999.9 km → Display: 0.1 km SS02K050

2000 - 19,999 km → Display: 1 km

To delete the stored value, keep the key (2) in the respective display (A or B) depressed for 3 seconds.

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Hectare counter key

The working width of the implement used must be stored before
activating the hectare counter.
(see Setup menu 1, page 19)
The key (3) is used to activate the hectare counter / memory. The area
symbol appears on the DMD and the total area that has been covered
is displayed in ha.

Display ranges:
0 - 199.99 ha → Display: 0.01 ha
200 - 1,999.9 ha → Display: 0.1 ha
2000 - 19,999 ha → Display: 1 ha
SS03A018

The following operating modes can be selected by pressing the key (3) several times:
• OFF
The hectare counter is switched off.
• ON
The hectare counter is switched on. The counting function is active as long as the tractor is driven, independent
of the position of the implement.
• A (AUTOMATIC)
The hectare counter is switched on. The counting function is only active as long as the tractor is driven and the
implement is lowered. Raising the implement interrupts the counting function.
To delete the stored values, keep the key (3) depressed in the OFF operating mode for 3 seconds.

Hectare performance / hour key

The working width of the implement used must also be stored before
activating the hectare performance display.
Press key (4) to access the Hectare performance menu.
The symbols for area and time and the probable hectare performance
(ha/h), dependent on the momentary driving speed, appear on the
DMD.
The hectare performance (ha/h) is displayed in steps of 0.01 ha. If the
hectare counter is in operating mode A (Automatic), then the display
reads 0 as long as the implement is raised. (The counting function is not
active.)

Menu up scroll key SS02K051

Menu up key or number entry. Press this key several times to scroll the menu upwards or to change a number.

Enter / Save key

For selecting the setting and programming modes (e.g. for working width adjustment, 12/24 clock adjustment, beeper
on/off).

Menu down scroll key

Menu down key or number entry. Press this key to scroll the menu downwards or to select a number on the dot matrix
display (DMD).

Escape key without saving

Press here to close or abort setting and programming modes without storing them.

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Key for displaying 3-point hitch position front / rear

Press briefly to get the lifting height of the rear linkage and longer to get
the lifting height of the front linkage (if fitted).
Here you can read off the position of the 3-point hitch on the display,
starting at approx. 10 % (lowest position) up to approx. 96 % (maximum
lifting height).
In the case of a front hitch with sensor, 0 - 100 is displayed.
NOTE: In the case of a front hitch without a sensor, the lifting height
cannot be displayed and a switchover is not possible.

SS02K037

Key for displaying PTO shaft speed front / rear

Press briefly to get the speed of the rear PTO shaft and longer to get the
speed of the front PTO shaft (if fitted).

Wheel slip key SS02K038

The rear wheel slip is displayed as a single or two-digit percentage

figure (%) (radar version only, otherwise key does not have a function).
The slip value is calculated on the basis of the information from the
transmission speed sensor (theoretical driving speed) and the radar
sensor (actual driving speed).

SS02K036

Battery voltage key

Press this key to display the battery symbol together with the digital display of the battery voltage.

Engine operating hours key

Press this key to display the total operating hours count of the tractor. The counted hours should be used as a guide
for the tractor service intervals.

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Key for tractor RESET

Key for tractor reset. If this key is pressed for approx. 10 seconds (until display A emits a short beep), the following
values are reset to the factory setting.
• Oil quantities for lowering for all 5 AUXs to 50 %
• Stored sequences in the headland management menu are deleted.
• The engine speed for engine speed reduction is reset to 1100 rpm.
• The 3-point hitch position (rear) at which the engine speed is raised or lowered and the PTO shaft is switched
on / off in PTO shaft management is reset to 50 %.
• The timers are inhibited and reset to 0.
• The momentary position of the front hitch (with sensor) is stored so that the front hitch does not move if the front
hitch pushbutton on the armrest is accidently pressed.
• In addition, this key is used, after being pressed for 5 seconds, to reset an active fault displayed on the ADIC so
that the driver has the normal ADIC display and can thus finish his work (only the yellow/red warning lamp
remains active). This function is only valid when there is an active fault. This fault is then suppressed. If another
fault occurs, then this is immediately displayed.

Key for compressed air trailer braking system

Press here to display the symbol for the compressed air trailer brake
(if fitted). One bar on the display corresponds to a pressure of approx.
1 bar.

SS04B184

Changeover key for driving strategy and speed range display

Driving strategy, driving range, speed and PTO shaft operation (D). C1,
C2, C3, M1, M2, M3 + km/h and PTO shaft symbol, if the vehicle is in
PTO shaft mode.

SS04B185

Sva 6-91700 EN Edition 03-2004

 4003-19

MENU SETTINGS
Setup menu 1
(for the customer)
The following settings can be made in Setup menu 1:
• Switching the beep on/off
• Time display 12 / 24 hour mode changeover
• Setting the working width 6
5
Access:
Turn the ignition switch to the ON position and then keep the Enter
key (6) depressed for 3 seconds.
”SET UP MENU” appears on the DMD.
After 2 seconds, the display automatically switches over to working
7 8
width setting. SS02K033

NOTE: If a fault has occurred (e.g. coolant temperature too high, trailer brake reservoir pressure too low,....), then
the fault must be suppressed by pressing the Tractor reset key (item 14, page 15) for 5 seconds. Otherwise Setup
menu 1 cannot be accessed.

Setting the working width

Example: Working width 4.5 m
• Access Setup menu 1 (see above)
• After 2 seconds, the display automatically switches over to working
width setting

SS03A019

• Press the Enter key (6). A flashing cursor appears at the first place
for entering the working width on the DMD.
• Use the UP scroll key (5) to select the blank space
• Use the DOWN scroll key (7) to shift the cursor to the right to the
next place
• Use the UP scroll key to enter the number 4
• Use the DOWN scroll key to shift the cursor another place to the
right
• Use the UP scroll key to enter the number 5
(if a number is also to be entered at the last place, then proceed in
the same way) SS03A020

• Store the setting by pressing the Enter key (6)

Sva 6-91700 EN Edition 03-2004

4003-20

Setting the beep

A beep sounds on pressing one of the function keys. This beep can be
switched on or off as required.
• Access Setup menu 1 (see page 19)
• Use the scroll bars (5 / 7) to call up the ”BEEP ON/OFF” submenu
• Press the Enter key (6) and set the arrow (X) in the display to ON /
OFF by means of the scroll keys (5 / 7)
• Store the setting by pressing the Enter key (6) once again
X

SS03N025
Switching over the time display
• Access Setup menu 1 (see page 19)
• Use the scroll bars (5 / 7) to call up the ”CLOCK SETTING”
submenu
• Press the Enter key (6) and set the arrow in the display to 12 / 24 by
means of the scroll keys (5 / 7)
• Store the setting by pressing the Enter key (6) once again

SS03H004

Sva 6-91700 EN Edition 03-2004

 4003-21

Setup menu 2
(for the workshops)
The following settings can be made in Setup menu 2:
• Changing the speed display (mph – km/h)
• Programming compressed air sensor available / not available
• Programming the service indicator 6
• Programming the driving speed display 5
(theoretical or via the radar sensor)
Access:
Turn the ignition switch to the ON position and, within 5 seconds, keep
the Enter key (6) and the Escape key (8) depressed (simultaneously) for
3 seconds. 7 8
SS02K033

Programming the compressed air sensor

• Access Setup menu 2 (see above)
• On entering the menu, the display automatically switches over to
the ”AIRBRAKE SENSOR” menu
• Turn the ignition switch ”OFF” and then ”ON” again

SS04A034

• Press the Enter key (6) and set the arrow to ”YES” or ”NO” by
means of the scroll keys (5 / 7)
• Store the setting by pressing the Enter key (6)

SS04A035

Switching over the speed display

• Access Setup menu 2 (see above)
• Use the scroll keys (5 / 7) to scroll through the menu until the
”MPH / Km/h” menu appears
• Press the Enter key (6) and set the arrow to the required display by
means of the scroll keys (5 / 7)
• Store the setting by pressing the Enter key (6)

SS03N026

Sva 6-91700 EN Edition 03-2004

4003-22

Programming the service indicator

This function can be used to program two service interval displays.
Factory setting:
LIGHT = 250 operating hours
HEAVY = 250 operating hours
• Access Setup menu 2 (see page 21)
• Use the scroll keys (5 / 7) to scroll through the menu until the
”SERVICE INTERVAL” menu appears

SS04A036
• Press the Enter key (6) and select the ”LIGHT” or ”HEAVY” display
by means of the scroll keys (5 / 7)

SS04A037

• Press the Enter key (6) again. A flashing cursor appears at the first
place in the entry field
• Enter the required number by pressing the UP scroll key (5). Jump
to the next place in the entry field by means of the DOWN scroll
key (7).
Use the UP scroll key again to enter the required number. Enter the
third number in the same way.
• Store the setting by pressing the Enter key (6)

SS04B188

NOTE: Enter the hours after which the Service message is to appear (e.g. 250).
Do not enter the operating hours after which the next service is due (e.g. 1250).

Sva 6-91700 EN Edition 03-2004

 4003-23

Programming the driving speed display

With this function it is possible to select whether the following information is displayed according to the radar signal
or theoretically via the driving speed sensor.
1. Current driving speed
2. Distance measurement (odometers ”A” and ”B”)
3. Hectare counter
4. Hectare performance / hour

This function can only be activated if the radar sensor is installed correctly.
• Access Setup menu 2 (see page 21)
• Use the scroll keys (5 / 7) to scroll through the menu until the
”WHEEL / RADAR” menu appears

SS04B186

• Press the Enter key (6) and select the ”WHEEL” or ”RADAR”
display by means of the scroll keys (5 / 7)
• Store the setting by pressing the Enter key (6).
The radar symbol appears on the top left-hand side of the DMD.
NOTE: If the ADIC is set to ”Radar” and the radar fails (radar
defective, faulty fuse,...), then the signal from the driving speed sensor
is automatically used for the display and the calculations. The radar
signal is automatically used again as soon as the radar sensor is
operating again.

SS04B187

Plugs on the ADIC

SV03B032

Sva 6-91700 EN Edition 03-2004

4003-24

TROUBLESHOOTING USING THE DIAGNOSTIC SYSTEM

NOTE: Correct measurement results are only ensured when the test conditions are met.

Test conditions
Symbol Meaning of symbol

Ignition switch in position ”0”

Ignition switch in position ”1”

Engine is turning over

X.. Plug

Pin Pin

Plug connected

Plug disconnected

Use a 21 W bulb as a load

NOTE: When measuring the voltage drop of a ground supply cable, the selected test lamp (for loading the cable to
be tested) must be connected from the cable’s terminal to a + supply. The measuring instrument (voltmeter) is
connected parallel to the ground cable.

Special tools required

Tool No. Designation Use

380000058 Diagnostic box, 100-pole General

380001492 26 pole ’Y’ adapter ADIC, plugs CN1 – CN3

1TSW 528-11
(available from 2 measuring cables, 1.5 m General
your dealer)

1TSW 528-2
(available from Test lamp, 21 W For loading supply lines
your dealer)

1TSW 516-1
Multimeter
(available from General
(Fluke 79 or similar)
your dealer)

Sva 6-91700 EN Edition 03-2004

 PLUG CN1
Measure- Measure from Measured
Designation Pin Cable Requirements CN1 CN1
ment pin to pin value

Sva 6-91700 EN
Supply, permanent + (+30)
26 CN1/26 U 21W 26 23 13 - 14 VDC
from F41 (3 Amps)

Supply
23 CN1/23 U 21W 23 Batt. 0.1 - 0.3 VDC
Ground

Supply, switched + (+15)

24 CN1/24 U 21W 24 23 13 - 14 VDC
from F14 (15 Amps)

Supply
22 CN1/22 U 21W 22 23 approx. 0.1 VDC
internal ground connection

Ignition switch in position ”1”

1.5 - 1.7 VDC
Dynamo positive (D+) 25 CN1/25 U 25 23
Charging indicator lamp has
13.5 - 14 VDC
gone out

”OFF” approx. 0 VDC

Sidelight (58) 15 CN1/15 U 15 23
”ON” 12 - 14 VDC

Trafficator indicator lamp 12 - 14 VDC

6 CN1/6 U flashes 6 23 alternately at
”right” approx. 0 VDC

Trafficator indicator lamp 12 - 14 VDC

5 CN1/5 U flashes 5 23 alternately at
”left” approx. 0 VDC

Suspension switched off 12 - 14 VDC

Indicator, sprung front axle 13 CN1/13 U 13 23
Suspension switched on approx. 0 VDC

Switch S3 open 12 - 14 VDC

Indicator, air filter 11 CN1/11 U 11 23
Switch S3 closed approx. 0 VDC

Indicator, hydraulics Ignition switch in position ”1” approx. 0 VDC

pressure filter
12 CN1/12 U 12 23 12 - 14 VDC
Engine running

Edition 03-2004
4003-25
 PLUG CN1 4003-26

Measure- Measure from

Designation Pin Cable Requirements CN1 CN1 Value
ment pin to pin

Sva 6-91700 EN
Fuel ”OFF”
pre-heating
16 CN1/16 U ”ON”
16 23

Coolant level ok 12 - 14 VDC

Indicator, coolant level 17 CN1/17 U 17 23
Coolant level too low approx. 0 VDC

12 - 14 VDC
Brake fluid level ok
Indicator, brake fluid 7 CN1/7 U 7 23
Brake fluid level too low
approx. 0 VDC

Edition 03-2004
 Plug CN2
Measure- Measure from
Designation Pin Cable Requirements CN2 Ground Value
ment pin to pin

Sva 6-91700 EN
Position ”Transport”
12 - 14 VDC
rear 3-point hitch 17 CN2/17 U "Control" 17 approx. 0 VDC
standard signal

Speed standard signal PTO shaft rotating

rear PTO shaft ”540” 6 - 7 VDC
PTO shaft does not rotate 12 - 14 VDC
14 CN2/14 U 14
PTO shaft ”540” at
54 Hz
engine speed of 1900 rpm

Speed standard signal PTO shaft rotating

rear PTO shaft ”1000” PTO shaft does not rotate 6 - 7 VDC
12 - 14 VDC
14 CN2/14 U 14
PTO shaft ”1000” at
engine speed of 1900 rpm 100 Hz

Tractor stationary 12 - 14 VDC

Driving speed
Tractor moving 6 - 7 VDC
standard signal
130 impulses/m
16 CN2/16 U 16 or
505 Hz at
14 km/h

Tractor stationary 12 - 14 VDC

Tractor moving 6 - 7 VDC
Radar sensor 130 impulses/m
standard signal
15 CN2/15 U 15 or
505 Hz at
14 km/h

Edition 03-2004
4003-27
 Plug CN3 4003-28

Measure- Measure from

Designation Pin Cable Requirements CN3 Ground Value
ment pin to pin

Sva 6-91700 EN
Hydr. trailer brake
”Italy”
12 CN3/12 U 12

Trafficators 12 - 14 VDC
trailer I 16 CN3/16 U flashing 16 alternately at
approx. 0 VDC

Trafficators 12 - 14 VDC
trailer II 13 CN3/13 U flashing 13 alternately at
approx. 0 VDC

Analog display Sensor B2/1,

Test values:
Tank 14 CN3/14 R replace with 14 see page 29
level resistor

Analog display Sensor B3,

Test values:
Compressed air 15 CN3/15 R replace with 15 see page 29
reservoir pressure resistor

High beam OFF approx. 0 VDC

Indicator, high beam 18 CN3/18 U 18
High beam ON 12 - 14 VDC

Edition 03-2004
 4003-29

TEST VALUES FOR SPEED DISPLAYS

Rear PTO shaft speed (standard signal from ADIC to standard signal socket)

Speed in rpm Frequency in Hz

540 54

1000 100

TEST VALUES FOR ANALOG DISPLAYS AND WARNING

Fuel level indicator, analog (signal from sensor B2/1)

Level Resistance in Ω Display area Warning

empty 10
red Yellow lamp ”Refuel” lights up
< 1/6 < 30

1/6 30

1/4 38

> 1/4 > 38 neutral

1/2 76 Yellow lamp ”Refuel” does not light up

3/4 113

full 180

Compressed air indicator, analog (signal from sensor B3)

Pressure in bar Resistance in Ω Display area Warning

0 10

2 52 Red lamp ”Trailer brake” flashes

4 88
neutral
< 5.5

6 124

8 155

10 184

Sva 6-91700 EN Edition 03-2004

 &KDSWHU


)81&7,21$/6&+(0$7,&',$*5$06
(/(&75,&$/



CNH Österreich GmbH Sva 6-92771 EN © 2006 CNH Österreich GmbH

Technical Documentation June, 2006
A - 4300 St. Valentin, Steyrer Straße 32
 4008-3

&217(176

GENERAL DESCRIPTION ....................................................................................................................................5

Abbreviations ....................................................................................................................................................5
Supply voltages .................................................................................................................................................5
General advise: .................................................................................................................................................5
A27 CAN module and A28 Plug module ---> DBD094270 ...............................................................................6
A30 ARU print DBD094271 ---> ........................................................................................................................6

FUNCTIONAL SCHEMATIC DIAGRAM FOR ADIC ..............................................................................................7

FUNCTIONAL SCHEMATIC DIAGRAM FOR EEM2 .............................................................................................9

FUNCTIONAL SCHEMATIC DIAGRAM FOR FMGR - SGR ...............................................................................11

FUNCTIONAL SCHEMATIC DIAGRAM FOR FMGR REVERSING FACILITY ...................................................15

FUNCTIONAL SCHEMATIC DIAGRAM FOR ECCU2 ........................................................................................17

FUNCTIONAL SCHEMATIC DIAGRAM FOR EDC .............................................................................................21

FUNCTIONAL SCHEMATIC DIAGRAM FOR REMOTE CONTROL VALVES ...................................................25

FUNCTIONAL SCHEMATIC DIAGRAM FOR REMOTE CONTROL VALVES - ADDITIONAL FUNCTIONS .....27

FUNCTIONAL SCHEMATIC DIAGRAM FOR FRONT AXLE WITH INDEPENDENT SUSPENSION ................29

FUNCTIONAL SCHEMATIC DIAGRAM FOR CAN BUS ....................................................................................31

FUNCTIONAL SCHEMATIC DIAGRAM FOR ISO BUS ......................................................................................33

Sva 6-92771 EN Edition 06-2006

4008-4

BLANK PAGE

Sva 6-92771 EN Edition 06-2006

 4008-5

*(1(5$/'(6&5,37,21
The key electric circuits are shown in the functional schematic diagrams, sub-divided into the individual main com-
ponents, e. g. control units, controllers and display instruments. The complete diagram of the individual electric cir-
cuits and/or functions should help the mechanic gain better comprehension. Faster narrowing down of errors is
thereby possible in the future.
The diagrams are structured so that the supply for each component is shown first. As a rule, the inputs are on the left
and the outputs on the right.
When troubleshooting in the wiring, the circuit diagram and/or list of connectors must be used.

$EEUHYLDWLRQV
ADIC............................................................................................................................ Analogue / digital instrument
ARU.............................................................................................................................................................. Armrest
AUX.........................................................................................................................................Remote control valve
DMD ................................................................................................................................... DOT MATRIX DISPLAY
DZG................................................................................................... Crankshaft position signal (upper dead point)
ECCU2 ....................................................................................................................................... Central control unit
EDC.............................................................................................................. Electronic 3-point hitch control system
EEM2 ..........................................................................................................................................Engine control unit
FMGR........................................................................................................... Vehicle/engine/transmission controller
GSV .................................................................................................................................................... Cyclic supply
HTS ............................................................................................. Field end management (headland management)
ICU ..........................................................................................................................................Performance monitor
KEY PADS ........................................................................................ Function keys for analogue/digital instrument
NTC.......................................................................................................................Negative temperature coefficient
PCB.....................................................................................Printed circuit board (relay circuit, terminal resistance)
PCU.......................................................................................................................... Electronic pumps - control unit
PTC ........................................................................................................................ Positive temperature coefficient
SGR .................................................................................................................................... Transmission controller

6XSSO\YROWDJHV
On-board voltage ...................................................................................................................................... 12 V +2.0
GSV1 ........................................................................................................................................................... 3 V ±0.2
GSV2 ........................................................................................................................................................... 3 V ±0.2
GSV3 ........................................................................................................................................................... 3 V ±0.2
GSV4 ........................................................................................................................................................ 6.4 V ±0.4

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Sva 6-92771 EN Edition 06-2006

4008-6

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SS05F006

$$58SULQW'%'!

SS05F007

Sva 6-92771 EN Edition 06-2006

 4008-7

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$ $
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CN1 26 16 24 23
$$',&
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X70 CN3
CAN H 3LORWODPSVDQGGLVSOD\VFRQWUROOHG
18 26
CAN L YLD&$1%86
42 25
X6/11 X6/8 X29
3LORWODPSVDQGGLVSOD\V 5 5 6
CN1 Speed signal
Generator D+ CN2 6 6 7
25 Starter switch position ON = 0.7V transmission 14 km/h = 504 Hz
16 1 1 2
Engine ON = 12V (Light OFF) Radar screen 14 km/h = 504 Hz
$ $ CN3 15 2 2 1
X12/20 X4/45 PTO shaft speed 1000 rpm = 100 Hz
18 High beam ON = 12V 14 3 3 3
11 3 Button transport 12V, button control 0V
17 4 4 4
X24/1 CN1
5 Lighting ON = 12V
15
X4/52 X4/51 2 A1 ADIC
5 Turn signal left
3 4 A2 EEM2
6 A4 FMGR
4 3  6 Turn signal right A4/3 15-pin plug connection
S A12 Central print
A14 Engine print
CN3 A60 ECCU2
16 Turn signal trailer I A61 Electronics, suspended front axle
B2/1 Fuel tank level transmitter, left
6 2 (11) X23/1 13 Turn signal trailer II B3 Compressed air transmitter
1 M CN1 26-pin plug connection
X24/3 CN1 CN1a 26-pin plug connection
1 9 Suspended front axle OFF = 11.7 V, CN2 26-pin plug connection
13 CN3 26-pin plug connection
ACTIVE = 0V (Light ON)
6 2 CN3 S3 Test switch for air filter
S 3 p >10 bar = 0 V S13 Control switch for brake fluid
S22 Control switch for coolant level
- (16) S23 Test switch for charge pressure 1bar
CN1 S50 Pushbutton for trailer brake valve
6 + 7 Brake fluid level OK = 11 V X4/45 4-pin plug connection
S X23/1 12 DMD Feed pump pressure OK (>1 bar) = 12 V X4/51 4-pin plug connection
X4/52 4-pin plug connection
J 11 Air filter OK = 11 V X6/8 6-pin plug connection
1
K 17 Coolant level OK = 12 V X6/10 6-pin plug connection
6 2 X6/11 6-pin plug connection
X24/3 % X24/3 CN3 X12/20 12-pin plug connection
2 G 3 15 Compressed air 8.1 bar = 155 Ω X18/1 18-pin plug connection
X20/1 20-pin plug connection
(11) CN1 X23/1 23-pin plug connection
GND X24/1 24-pin plug connection
22 X24/3 24-pin plug connection
180 Ω X29 Standard signal socket,
X70 70-pin plug connection
95 Ω Fuel tank level (11) Ground point, engine device carrier
X6/10 % X6/10 CN3 (16) Ground point, starter
1 2 1 3 14 10 Ω

Sva 6-92771 EN Edition 06-2006

4008-8

BLANK PAGE

Sva 6-92771 EN Edition 06-2006

 4008-9

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 7 
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 X1/14
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8 10
X3 7 13
% 5V
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X70 21 48 70 46 69
9 9 CAN H (11)
$
CAN + 18 $((0 A2 _GND
X7 15 CAN L
0.4V to 4.7V CAN - 42
; 2 2 16 6XSSO\
CAN H
3 17
GND 4 CAN L
4 18
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*YA1 39 40 25 8 6 33 4 2 3 1 5 7
3 3 12V 4 (11)
4 50 12V 5 SSR1 .
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CN3 17
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26 16
0 (11)
25 (PHUJHQF\VLJQDO
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3 M 1
36 0.8 to 4.4 V
$3&8 2
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12V
5 X23/2 1 7
GND M13 _GND
4 U 23 6
CAN H
3&8DFWLYDWLRQ 20 2 2.5 V
CAN L
44 1 2.5 V
6 43 5 Emergency shut-down
130 Hz at 900 rpm
% X1/3 S 19 8 DZG
335 Hz at 2300 rpm
1 X70
S 34 GND A1 ADIC X1 14-pin plug connection
A2 EEM2 X1/3 1-pin plug connection
X3/20 55 GND A2/2 PCU X1/10 Plug connection
GND
Q 1 62 A12 Central print X1/12 Plug connection
% 2 39 510 Hz at 900 rpm
1300 Hz at 2300 rpm
A14 Engine print X1/14 Plug connection
I 12V A27 CAN module ---> DBD..... X1/21 Plug connection
3 45 A28 Plug module ---> DBD..... X2/22 2-pin plug connection
6ZLWFKHVDQG A30 Print ARU DBD..... ---> X3 4-pin plug connection
VHQVRUV A50/1 Power module X3/12 3-pin plug connection
W X2/22 B20 Engine speed sensor X3/13 3-pin plug connection
GND
% 1 33 B21 Test switch, fuel delivery pressure X3/20 3-pin plug connection
5 2 PTC 1kΩ to 4.6 kΩ B22 Engine temperature sensor X4/71 4-pin plug connection
9
B23 „Water in fuel“ sensor X5/1 Plug connection
X3/13 X3/12 B28 Manual throttle X7 4-pin plug connection
12V B29 Sensor for charger pressure, X9/7 9-pin plug connection
5 A 1 25
0.7 V at water in fuel charged air temperature X18/4 18-pin plug connection
% B 2 31 9 V no water in fuel CN3 26-pin plug connection X20/1 20-pin plug connection
8 C 3
GND
22 E10/1 Heating flange X23/2 23-pin plug connection
K8/2 Relay, heating flange X24/2 24-pin plug connection
X4/71 M13 Fuel delivery pump X70 70-pin plug connection
GND
SW 1 59 P8 ICU YA1 44-pin plug connection ---> DBD.....
NTC 32 kΩ to 102 Ω P8/1 4-pin plug connection
% 2 12 YB1 44-pin plug connection ---> DBD.....
P8/2 4-pin plug connection (11) Ground point, engine device carrier
85 3 5V
11 R8 Potentiometer, accelerator pedal (16) Ground point, starter
4 35 1 V to approx. 2 V S6 Switch, engine oil pressure

Sva 6-92771 EN Edition 06-2006

4008-10

BLANK PAGE

Sva 6-92771 EN Edition 06-2006

 4008-11

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11 11 3 17 3 18 2
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4 18 2

GND
11 V
6
10 12 6
X6/3 X24/3 A4/2 1 12 2 11 9 10 3
6 3 10 8 NEUTRAL

0 V or 5 V
9 4 X16/21 /,03+20(FLUFXLW
2 11 7 DEAD MAN GND
GSV2 10
6 4 12 6 12 V
6KXWWOHOHYHU 14 Select 0 V** for FORWARDS
12 5 1 2 2 12 V
8 Select 0 V** for REVERSE
5 1 1 7 11 FORWARDS
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2 19 A21/5 1
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)$
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5 3 X4/59/c
3 2 A24 Hydrostat X5/1 Plug connection
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X14/14 4 1 A27 CAN module ---> DBD..... X6/1 4-pin plug connection
X4/14 X24/3 A4/2 A28 Plug module ---> DBD..... X6/3 6-pin plug connection
P8/2 3 4 1 GSV2
6 A30 Print ARU DBD..... ---> X6/9 7-pin plug connection
$ X20/1 X23/1 X10/14 12
)$ (7) 6  Ω A31 Multi controller X7 4-pin plug connection
 8 Q 7 (8) 3 4 14 3 V B17 Angle of rotation sensor, clutch X10/11 10-pin plug connection
6 2 5 13 3 V CN3 26-pin plug connection X10/12 10-pin plug connection
P8 ICU X10/14 10-pin plug connection
P8 10-pin plug connection X11 16-pin plug connection
CN3 X24/3 A4/2 &OXWFK P8/1 4-pin plug connection X14/14 14-pin plug connection
$$',& CAN L GSV2 P8/2 4-pin plug connection X14/15 14-pin plug connection
25 1 12 6
CAN H  Ω R8 Potentiometer, accelerator pedal X16/21 16-pin plug connection
26 6 A4/1 S4/4 Shuttle lever X18/4 18-pin plug connection
2 24 15 3 V S5 Switch for brake light X20/1 20-pin plug connection
S25 Switch for steering brake X21 14-pin plug connection
A4/4 S46 Switch, clutch X23/1 23-pin plug connection
A1 ADIC GND
1 13 4 S60/1 F/R button X23/2 23-pin plug connection
A2 EEM2
CAN H
CAN L

% 5.6V S60/2 Cruise control button X24/2 24-pin plug connection
A4 FMGR 2 14 11
A4/1 18-pin plug connection 8 3 15 12 1.1 to 4 V
S60/3 Speed button +
S60/4 Speed button -
X24/3
X70
24-pin plug connection
70-pin plug connection
A4/2 18-pin plug connection S60/5 HTS button YA1 44-pin plug connection
A4/3 15-pin plug connection X1 14-pin plug connection ---> DBD.....
A4/4 18-pin plug connection X4/70 A4/4 $FFHOHUDWRUSHGDO X4/14 4-pin plug connection YB1 44-pin plug connection
A12 Central print GND ---> DBD.....
1 1 X4/59/a 3-pin plug connection
A13 Roof print
X70 18 42 3 X4/59/b 3-pin plug connection (7) Ground point, roof hood, left
A14 Engine print
$((0 5 6 4.4 to 0.8 V X4/59/c 3-pin plug connection (8) Ground point, roof hood, right
A21 SGR transmission controller 5.8V (16) Ground point, starter
2 10 X4/70 4-pin plug connection
A21/4 12-pin plug connection
A21/5 12-pin plug connection 4 3 0.8 to 4.4 V
A23 Electronics X70 X23/2
A23 12-pin plug connection 36 U

Sva 6-92771 EN Edition 06-2006

4008-12

BLANK PAGE

Sva 6-92771 EN Edition 06-2006

 4008-13

$)0*5
A4/2 A21/2 $6*5
GSV3 5V
1 S 1 4
% GND
6 2 7 A21/3 <
X4/61 X4/61 A4/2
8 3 6 0.2 to 3.1 V 6 4V
1
GND
2 1 17 6HDWFRQWDFW A21/2 7
5V
6 S 1 11 2
GND
X4/25 X4/25 A4/2 % 2 8
2 1 16 3DUNLQJEUDNHRSHQ 8 3 5 0.2 to 1.2 V A21/3 <
4V
5 1
6 A21/2 GND
W 8
A4/1 1 3
(QJLQHEDFNSUHVVXUH % PTC 1 kΩ to 4.4 kΩ 2
2 1 3 EUDNH 5 2 10
X5 A21/4 A21/3 <
GND 4V
1 2 9 4 1
$ X14/4 A4/1 GND
8 GSV1
18
6 2 1 3 GND 9
S Opens at a difference in pressure of 2
> 5 bar
1 2 X10/4 6
6SHHGUDQJHV 12 V
1 A21/3 <

X24/5 A4/1 3 4V
1
 23 16 increase "+" < GND
 10
7 5 17 decrease "-" 2
3 6HQVRUVDQG 2
1 A4/3 VROHQRLGYDOYHV
12 V
6 5 1 A21/3 <
%UDNHRLOFRROLQJ < 4V
8 2 1
GND
2))
21
2 11
X24/5 A4/1 2
A21/7
5 1 8 5 0DQXDOPRGH
1
6
(16) % Q 10 to 6000 Hz
A21/3
4V
<
I 2 1 1
GND
 12

X24/5 A4/1 A21/8

0DQDJHPHQW 2
5 3 1 Q 1
3 DQG % 10 to 6000 Hz
1 4 2 DOOZKHHO I 2

A21/9
X3/23 X24/5 A4/4 1
5.8 V Q
a 1 11 14 3RWHQWLRPHWHU % I 2
10 to 6000 Hz
<
5 b 3 12 15 0 to 5.8 V IRUOLPLWORDG
1
6 c 2 13
GND
5
A21/5
A21/10 10 V
4
Q 1 GND
2))
21 A4/1 % I 2
10 to 6000 Hz 8 2
X24/3 13 3.0 V X17
1 3 18 6ZLWFKIRUSDUNLQJ <
A4/2 A21/6 2
GSV2 LQWHUORFN
1
12 6
% Q 10 to 6000 Hz A21/5
I 2 10 V
A4 FMGR A21/9 2-pin plug connection S2/58/2 Switch, manual mode 5 1
A4/1 18-pin plug connection A21/10 2-pin plug connection S2/59 Switch, all-wheel X24/5 24-pin plug connection
A4/2 18-pin plug connection B24 Speed sensor, cartridge input S2/61 Switch for parking interlock X17 Y - distributor
A4/3 15-pin plug connection B25 Speed sensor, planetary carrier 3/4 S8 Seat switch Y11 Solenoid valve for brake oil cooling
A4/4 18-pin plug connection B26 Speed sensor, cartridge output S20 Switch, engine back pressure brake Y12 Solenoid valve for brake oil cooling
A16 EDC print B27 Speed sensor, cartridge output S21 Switch, parking brake Y41 Solenoid valve, clutch 1
A21 SGR transmission controller B32 Temperature sensor, transmission oil S49/1 Switch, pressure filter Y42 Solenoid valve, clutch 2
A21/2 12-pin plug connection B35 Speed sensor, planetary carrier 1/2 X3/23 3-pin plug connection Y43 Solenoid valve, clutch 3 <
A21/3 12-pin plug connection B47 Pressure sensor for transmission X4/25 4-pin plug connection Y44 Solenoid valve, clutch 4 1
system pressure Y45 Solenoid valve, clutch, forward A21/5
A21/4 12-pin plug connection X4/61 4-pin plug connection 4V
A21/5 12-pin plug connection B51 Pressure sensor for transmission X5 2-pin plug connection Y46 Solenoid valve, clutch, reverse 6
lubrication pressure Y57 Solenoid valve, parking interlock ON GND
A21/6 2-pin plug connection X10/4 10-pin plug connection Y58 Solenoid valve, parking interlock OFF 7 2
A21/7 2-pin plug connection R23 Potentiometer for limit load X14/4 14-pin plug connection Y59 Solenoid valve, all-wheel
A21/8 2-pin plug connection S2/58/1 Switch, speed ranges X24/3 24-pin plug connection (16) Ground point, starter

Sva 6-92771 EN Edition 06-2006

4008-14

BLANK PAGE

Sva 6-92771 EN Edition 06-2006

 4008-15

)81&7,21$/6&+(0$7,&',$*5$0)25)0*55(9(56,1*)$&,/,7<
$)0*5
A4/2 3
6
X6/3 X24/3 A4/2 3 3
6
3 10 8 5
2 11 7  1
GSV2 
4 12 6 
X6/15 5 6
8 A4/2
1 2 2 4
2 8 NEUTRAL $
5 1 1 7 11 X2/4/1
7 7 DEAD MAN
6 3 3 8 10 3 GSV2 
1 6 (16)

X4/59/b
6KXWWOHOHYHU

X4/59/a
11 FORWARDS $6*5
$ X24/3 10 REVERSE X16/21 /,03+20(FLUFXLW
X2/4/1 X6/15 2 GND
10
19
 6 12 V
1 21 14 Select 0 V** for FORWARDS
12 V
3 20 8 Select 0 V** for REVERSE
$ X4/59/c A4/2
GSV3
1 **) Only if the
6 6 X4/59/b (A) and X4/59/c (B)
X6/58 X6/27 X6/27 X6/58 16 3DUNLQJEUDNHRSHQ plug connection is linked.
X4/25 X4/25/1 X4/25/1 X4/25 A4/2
2 2 1 1
6 2 2 1 1 16
6 6 5 5 A4/2
4 4 3 3 1
6 S8 Seat switch
6 A4/1 A4/1 (QJLQHEDFNSUHVVXUH S8/1 Reversible seat switch
S8/2 Reversible seat switch
2 1 3 3 EUDNH S20 Switch for engine back
4 6LJQDO pressure brake
UHYHUVLQJIDFLOLW\ S21 Switch, parking brake
A4/2 S46 Switch, clutch
17 6HDWFRQWDFW S46/1 Switch, clutch,
reversing facility
A4/4 X2/4/1 Plug connection
GND
X24/3 A4/4 4 &OXWFK X4/25 4-pin plug connection
5.6V X4/25/1 4-pin plug connection
1 13 4 11
% X4/59/a 3-pin plug connection
2 14 11 12 1.1 to 4 V X4/59/b 3-pin plug connection
8 3 15 12 X24/3 A4/2 A4/2 X4/59/c 3-pin plug connection
. 1 12 6
GSV2
6 X4/70 4-pin plug connection
4  Ω X4/70/1 4-pin plug connection
1 3 6 24 X6/3 6-pin plug connection
% 5 X6/15 6-pin plug connection
2 2
8 3
2 1 A4/1 A4/1 X6/27 6-pin plug connection
X6/58 6-pin plug connection
1 15 15 3 V
 Ω X16/21 16-pin plug connection
6 X23/2 23-pin plug connection
A2 EEM2 2 X24/3 24-pin plug connection
A4 FMGR A4/4
(16) 5.8V $FFHOHUDWRUSHGDO X70 70-pin plug connection
A4/1 18-pin plug connection X4/70 A4/4 10 (16) Ground point, starter
A4/2 18-pin plug connection GND
1 1 1
A4/4 18-pin plug connection
A12 Central print 5 3 6 . 3 0.8 to 4.4 V
A21 SGR transmission controller 2 10 4 6 4.4 to 0.8 V
A70 Seat switch, reversing facility 3
4 3 5
B17 Angle of rotation sensor, clutch
B17/1 Angle of rotation sensor, clutch, reversing facility 2 1
K5/60 Relay for clutch, reversing facility X4/70/1
K5/61 Relay, accelerator pedal, reversing facility 1 .
K5/62 Relay, accelerator pedal, reversing facility 3
P6 Display, reversing facility 5 4
3
R8 Potentiometer, accelerator pedal 2 5
R8/1 Potentiometer, accelerator pedal, reversing facility 4 2 1
S4/4 Shuttle lever
S4/4/1 Forwards - reverse switch, reversing facility $((0 X70 X23/2
36 U
(16)

Sva 6-92771 EN Edition 06-2006

 4008-16

$)0*5
X4/14 X24/3 A4/2 A4/2
GSV2 %UDNH
1 12 6 6
6  Ω
3 4 14 14 3 V
6 2 5 13 13 3 V

4
6
3

$ X14/4 A4/1 A4/1

GSV1
8 18 18
A4 FMGR
1 2 X10/4 6 A4/1 18-pin plug connection
A4/2 18-pin plug connection
6SHHGUDQJHV
 A4/4 18-pin plug connection

X24/5 A4/1 A4/1 A16 EDC print

7 23 16 16 increase "+" R23 Potentiometer for limit load
3 S2/58/1 Switch, speed ranges
1 5 17 17 decrease "-" S2/58/2 Switch, manual mode
6 S2/59 Switch, all-wheel
S2/61 Switch for parking interlock
S2/61/1 Switch for parking interlock,
2)) reversing facility
21
S5 Switch for brake light
X24/5 A4/1 A4/1 S5/1 Switch for brake light, reversing facility
5 1 8 5 5 0DQXDOPRGH S25 Switch for steering brake
X3/23 3-pin plug connection
6 X4/14 4-pin plug connection

X10/4 10-pin plug connection

X24/5 A4/1 A4/1 X14/4 14-pin plug connection

0DQDJHPHQW X24/3 24-pin plug connection
5 3 1 1 X24/5 24-pin plug connection
3 DQG
1 4 2 2 DOOZKHHO

X3/23 X24/5 A4/4 A4/4

5.8 V 3RWHQWLRPHWHU
a 1 11 14 14
IRUOLPLWORDG
5 b 3 12 15 15 0 to 5.8 V
GND
c 2 13 5 5

6
2))
21 A4/1 A4/1
X24/3 13 13 3.0 V
1 3 18 A4/2 A4/2 6ZLWFKIRUSDUNLQJ
GSV2
12 6 6 LQWHUORFN
6
2))
21

3 1

Sva 6-92771 EN Edition 06-2006

 4008-17

)81&7,21$/6&+(0$7,&',$*5$0)25(&&8
A1 ADIC X24/2 $
)$
A12 Central print 8 
A13 Roof print
A14 Engine print 9
)$
A60 ECCU2
X4/85a 1 2 22  X10/12 $ X10/11 X14/15 $
A62 Reverse fan unit )$
CN1a 26-pin plug connection
'
X4/85b 1 2 6 7 12 
CN2/E 26-pin plug connection
CN3 26-pin plug connection
CN3a 26-pin plug connection
CN3b 34-pin plug connection X14/14 X10/14 X23/1 X20/1 $
K5/16 Relay, reverse fan 2 25 34 1 2 3 14 21 26 25 26 19 )$
(16) 4 7 Q 8 
P8 ICU CN3a CN3b CN1a CN2/E CN1a
P8 10-pin plug connection $(&&8
P8/1 4-pin plug connection
P8/2 4-pin plug connection
S2/15/6 Switch, HTS A60_GND (7)
6XSSO\ P8 7 5 3 (8)
S2/15/7 Switch, speed reduction
S2/56 Switch for differential lock P8/1 3,&8
S2/74 Reverse fan pushbutton CAN H
15 3 CN3 $$',&

CN1a
P8/2
CAN L CAN H
16 4 3 26
CAN L
4 25
X10/9 CN1a
GSV4
2 10

6 <
CN3b
'LIIHUHQWLDOORFN 12 V
 5 1


X24/5 CN3b
5 2 24 Management
3 2
1 1 23 Differential lock ON
6
(16)


X24/5 CN3a +76

7 22 18 RECORD
3
1 24 19 PLAY
6
2))
21 $
6SHHGUHGXFWLRQ
X24/5 CN3a
X4/66
2 1 7 24
3 M
$
6 )$
X1/17

$ 5HYHUVLEOHIDQ
2))

X24/1 X24/3 CN3a 1

.
21
)$
 4 1 3 22 3 12 V 4
3 5 2
CN3b X24/3 X23/1 X2/25
12 V 1 2
8 16 H 1 4
X1/17 Plug connection X23/1 23-pin plug connection
X2/25 2-pin plug connection X24/1 24-pin plug connection
X4/66 4-pin plug connection X24/2 24-pin plug connection X2/25 2
X4/85a 4-pin plug connection X24/3 24-pin plug connection
X4/85b 4-pin plug connection X24/5 24-pin plug connection
X10/9 10-pin plug connection Y8 Heating valve CN3b
X10/11 10-pin plug connection Y10 Solenoid valve, differential lock 12 V
X10/12 10-pin plug connection (7) Ground point, roof hood, left 16 1
(8) Ground point, roof hood, right (11)
X10/14 10-pin plug connection
+HDWLQJYDOYH <
X14/14 14-pin plug connection (11) Ground point, engine device carrier
X14/15 14-pin plug connection (16) Ground point, starter 2
X20/1 20-pin plug connection

(16)

Sva 6-92771 EN Edition 06-2006

4008-18

BLANK PAGE

Sva 6-92771 EN Edition 06-2006

 4008-19

$(&&8

X10/9 CN1a
GSV4
2 10

6 )URQW372

21

2))
X24/5 CN3b
1 17 31 6.4 V when ON
3
7 18 30 6.4 V when OFF
CN2/E <
12 V**
7 1
X3/21 CN3b
(11) GND
Q C 3 X23/2 CN3b 225 Hz at 900 rpm 6 2
% B 2 N 22 490 Hz at 1900 rpm
I A 1 570 Hz at 2300 rpm
$
)$
X24/2 **) Activation for approx. 6 sec. with 3 V, then 12 V
 7

Q 3 CN2/E 150 Hz at 900 rpm

% 2 20 330 Hz at 1900 rpm CN3b <
I 1 400 Hz at 2300 rpm 14 12 V**
1

GND
6 18 2
(16)
21

2))
X24/5 CN3b
1 A12 Central print
14 33 6.4 V when ON A60 ECCU2
3
7 15 32 6.4 V when OFF B7 Rear PTO speed sensor
B8 Front PTO speed sensor
6 CN1a 26-pin plug connection
5HDU372 CN2/E 26-pin plug connection
2))
CN3a 26-pin plug connection
21 CN3b 34-pin plug connection
S2/70/1 Switch for front PTO
X24/5 CN3a S2/70/2 Switch for rear PTO
5 1 16 20 6.4 V with management ON S2/71 Switch for rear PTO, management
S17/1 External pushbutton, PTO shaft, rear left
6 S17/2 External pushbutton, PTO shaft, rear right
X3/21 3-pin plug connection
2))
X10/9 10-pin plug connection
X23/2 23-pin plug connection
21
CN3a X24/2 24-pin plug connection
1 2 21 6.4 V with pushbutton pressed X24/5 24-pin plug connection
 Ω Y4 Solenoid valve, front PTO
6 Y5 Solenoid valve, rear PTO
(11) Ground point, engine device carrier
2))
(16) Ground point, starter
21
CN3a
1 2 22 6.4 V with pushbutton pressed
 Ω

Sva 6-92771 EN Edition 06-2006

4008-20

BLANK PAGE

Sva 6-92771 EN Edition 06-2006

 4008-21

VHH1RWHSDJH
)81&7,21$/6&+(0$7,&',$*5$0)25('&
6
$ X24/2 X20/1 $
$505(67 )$ 6
X24/2  10 13 

)$ )$
$3/8*02'8/( 17 3  

$35,17$58 )$ 21
3
6 X14 X1 X18/4 18  2))

)$ 6 1
2 7 13 2 
X18/1 54c
5V (16) 1 O P X23/2 8 2
1 9 9 *1' ' 16

GSV4
6 X2 8 10
ARU + X5/1
2 X7 15 X24/3 1 54c
5V ARU - X2/12
1 2 16 1 X10/9 2 X10/9 6 8
CAN H (16)
$ 3 17
6 X4 X11 CAN L CN3a 2 X55 13 24 29 47 28 46
12V 4 18 CAN H CN1a 10 CN3a 4 1
1 16 $(&&8 15 $('&
$(&&8

6.4 V with EDC and AUX ON

6.4 V with EDC ON
X1 CAN L
6XSSO\
16
X21 X11 13 4 CN1a
GND
2 9 6 5 15
5 2 16
X21 X11 4 3
4 7 12 1
38
5 14
41
3 15 
5V  *1' CONTROL
1 1
)$ $
$ X14/4 
*YA1 6 8 41 33 3 1 4 2 5 7
12
GND
20
X10/4
TRANSPORT N X14/15 12
*YB1 6 8 41 33 3 1 4 2 5 7 9
14
10 V
2
N N
$&$102'8/( X10/4 X24/5 X10/11 7
N
STOP $
6 3 6 5 3.5 V with pushbutton pressed X10/12
N
A1 ADIC X3/18 3-pin plug connection RAPID RETRACTION
3XVKEXWWRQ
A12 Central print X3/19 3-pin plug connection
5 P8/1 3 4 6
A13 Roof print X4 4-pin plug connection 3,&8 P8
N N
A14 Engine print X5/1 Plug connection 7
X24/5 6.75 V transport X14/14
A16 EDC print X5/6 5-pin plug connection
A27 CAN module ---> DBD..... X7 4-pin plug connection X5/6 8 9 21 5.17 V control 5 4
A28 Plug module ---> DBD..... X10/4 10-pin plug connection 2 3.50 V rapid retraction 3
A30 Print ARU DBD..... ---> X10/9 10-pin plug connection
A31 Multi controller X10/10 10-pin plug connection 5 1 X10/4 (7)
A55 EDC box X10/11 10-pin plug connection 3 13 22 0 to 10 V P8/2 3 4 (8)
A60 ECCU2 X10/12 10-pin plug connection
CN1a 26-pin plug connection X10/14 10-pin plug connection
X3/17 X10/14 7
CN3 26-pin plug connection X11 16-pin plug connection 2 3RWHQWLRPHWHU
Ω
CN3a 26-pin plug connection X14 2-pin plug connection 5 1
R6/1 Potentiometer, setpoint X14/4 14-pin plug connection
R6/2 Potentiometer, lift limitation X14/14 14-pin plug connection 3 6 3 0 to 9.5 V
$ X20/1 X23/1
R6/3 Potentiometer, mixing X14/15 14-pin plug connection X3/18 )$
R6/4 Potentiometer, lowering speed X18/4 18-pin plug connection  8 Q
2
R6/5 Potentiometer, slip control X18/1 18-pin plug connection
S2/7/3 Switch, hydraulic master X20/1 20-pin plug connection 5 1
S2/72 Rapid retraction pushbutton X21 14-pin plug connection 3 11 4 0 to 10 V
S28 Switch, stroke / pressure equipment X23/1 23-pin plug connection
S33 Stop pushbutton X23/2 23-pin plug connection X3/16
S60/7 EDC Transport/control button X24/2 24-pin plug connection 2
P8 ICU X24/3 24-pin plug connection
P8 10-pin plug connection X24/5 24-pin plug connection 5 1
P8/1 4-pin plug connection X55 55-pin plug connection 3 4 23 0 to 10 V CN3 $$',&
P8/2 4-pin plug connection YA1 44-pin plug connection ---> DBD..... .Ω CAN L
X3/19 25
X1 14-pin plug connection YB1 44-pin plug connection ---> DBD..... CAN H
X2 2-pin plug connection (7) Ground point, roof hood, left 5 2
.Ω
26
X2/12 2-pin plug connection (8) Ground point, roof hood, right 1
X3/16 3-pin plug connection (16) Ground point, starter
X3/17 3-pin plug connection 3 1 25 2.5 to 7.4 V

Sva 6-92771 EN Edition 06-2006

4008-22

BLANK PAGE

Sva 6-92771 EN Edition 06-2006

 4008-23

$('&
A4 FMGR X55
A4/2 18-pin plug connection 10 V
3 39
A12 Central print
A16 EDC print % 2 6 2.5 to 7.5 V X55 <
A55 EDC box 8 1 35
GND
1
A60 ECCU2
B9/1 Angle of rotation sensor 6HQVRUVDQG
B10/1 Power sensor, left VROHQRLGYDOYHV 0 to 5 V
B10/2 Power sensor, right ) 3 55 2
B16 Radar sensor % 2 7 approx. 5 V not loaded
CN2/E 26-pin plug connection 8
CN3b 34-pin plug connection 1
H2/1 Diagnosis LED
H2/2 Slip LED
H2/3 RAISE LED ) 3
H2/4 LOWER LED % 2 26 approx. 5 V not loaded <
S2/15/5 RAISE/LOWER pushbutton
S2/73 Switch, slip control 8 1
GND
38 53
GND
1
S14/1 External pushbutton, LOWER, left
S14/2 External pushbutton, LOWER, right 41
S15/1 External pushbutton, RAISE, left 0 to 5 V
19 2
S15/2 External pushbutton, RAISE, right
X3/1 3-pin plug connection 5V
X4/2 4-pin plug connection 9
X4/3 4-pin plug connection 6 6
X4/12 4-pin plug connection
X10/4 10-pin plug connection
X10/9 10-pin plug connection 2)) 2))
X14/4 14-pin plug connection 21 21 $
X24/2 24-pin plug connection X14/4 X4/3
X24/5 24-pin plug connection 1 2 1 2 N +
 Ω  Ω 5 1
X55 55-pin plug connection
Y6 Solenoid valve, EDC, RAISE 6 6 2
Y7 Solenoid valve, EDC, LOWER N
(16) Ground point, starter 37 3 4
2)) 2))
([WHUQDOSXVKEXWWRQV 3
21 21 +
DQG/('V
1 2 1 2
 Ω  Ω

X14/4 X4/2
6 12 2
N
4
+
 3

X24/5 31 7
N
2
X24/5 
1 20
LOWER
36 5 V with pushbutton pressed
19 3 RAISE 1
6 7 21 17 5 V with pushbutton pressed +




X10/9 X10/4 $ X14/4

GND
9 1 5 7 12 20


14 GND

X14/4 9 X10/4 4
6OLSFRQWURO
X4/12 X3/1 $ CN2/E $ $
)$
1 1  8 Potentiometer R6/5 is shown
Y X24/2 on the previous page
% GND
2 3 5 CN3b (16)
I 3 2 15 21 9 A4/2 X24/2 19
Theoretical speed $
11 505 Hz at 14 km/h )$
Real speed 
10 505 Hz at 14 km/h

$
6WDQGDUGVLJQDO CN3b
Ground during transport
15 11

Sva 6-92771 EN Edition 06-2006

4008-24

BLANK PAGE

Sva 6-92771 EN Edition 06-2006

 4008-25

VHH1RWHSDJH $505(67 )81&7,21$/6&+(0$7,&',$*5$0)255(027(

6
$
X21
$3/8*02'8/(
X11 $35,17$58
X24/2
)$
&21752/9$/9(6
17 $ X4/83 X4/90 $8;
8 6 )$ CAN H
18  3 3
7 13 X1 X18/4 )$ CAN L
9 2 
X24/2 4 2
1 1 7 13 )$ CAN +
 24 1 1
6 10 9 9 CAN -
*1' 2 4
X19 2 1 8 10 (16)
CAN +
X7 15 X5/1
6 CAN - X4/91 $8;
2 16 CAN H
CAN H 3
3 17 CAN L
$ X5 CAN L 2
*1' *1' 4 18 CAN +
3 1
; 9
6 CAN -
% 1 4

2 
*1' 
7 3 X4/92 $8;
% ; 9 CAN H
5 6 1 3
GSV4 CAN L
6 8 2 2
9 CAN +
4 1
6 CAN -
8 X10/9 2 X10/9 6 8 4
X4 CN1a 10
*1'
4 CAN - X4/93 $8;
; 9 9 17 $(&&8 CN3a CAN H
1 CAN + 3
6.4 V with EDC and AUX ON 4 CAN L
% 2 CAN L 2
16 6.4 V with EDC ON 1 CAN +
X16 CAN H 1
5 9 Ω
*1' 15 CAN -
6 4
Ω
9
4 X10/11 X14/15 $
$ )$
5 7 12  X4/94 $8;
5 9 Ω CAN H
3
3 P8/1 3 4 1 2 X10/12 6
9 Ω
3,&8 CAN L
1 P8 2
CAN +
2 7 X14/14 X10/14 1
CAN -
X15 5 4 7 4
5 9 Ω
3
6
9 Ω
(7)
A X3/10 B
4 $ X20/1 X23/1
(8) )$
5  8 Q
5 9 Ω 120 Ω
3
9 Ω A12 Central print R20/5 Potentiometer AUX5 X10/14 10-pin plug connection
1 A13 Roof print S2/7/3 Switch, hydraulic master X11 16-pin plug connection
2 A14 Engine print S34 Switch AUX5 X12 4-pin plug connection
X12 A27 CAN module ---> DBD..... S35 Joystick pushbutton X14/14 14-pin plug connection
5 9
4
Ω A28 Plug module ---> DBD..... S60/6 AUX blue pushbutton X14/15 14-pin plug connection
A30 Print ARU DBD..... ---> S60/8 Shift pushbutton X15 6-pin plug connection
9 (float position)
1 A29 Joystick X16 6-pin plug connection
A31 Multi controller X1 14-pin plug connection X18/4 18-pin plug connection
2 A60 ECCU2 X3/10 3-pin plug connection X19 2-pin plug connection
X6 Ω B30 Joystick X4 4-pin plug connection X20/1 20-pin plug connection
longitudinal direction AUX1 X4/83 4-pin plug connection X21 14-pin plug connection
8
9
N B31 Joystick X4/90 4-pin plug connection X23/1 23-pin plug connection
2 transverse direction AUX2 X4/91 4-pin plug connection X24/2 24-pin plug connection
6 N
B52 Selector lever AUX4 X4/92 4-pin plug connection YA1 44-pin plug connection
3
N CN1a 26-pin plug connection X4/93 4-pin plug connection ---> DBD.....
 7 CN3a 26-pin plug connection X4/94 4-pin plug connection YB1 44-pin plug connection


 4 Ω 9 *1'

 *1' P8 ICU X5 2-pin plug connection ---> DBD.....
2 P8 10-pin plug connection X5/1 Plug connection (7) Ground point, roof hood, left
4 P8/1 4-pin plug connection X6 8-pin plug connection (8) Ground point, roof hood,
8 *YA1 35 41 32 30 28 26 24 27 31 29 37 9 19 23 34 6 8 39 40 33 3 1 4 2 5 7 R20/1 Potentiometer AUX1 X7 4-pin plug connection right
1 R20/2 Potentiometer AUX2 X10/9 10-pin plug connection (16) Ground, starter
5 *YB1 35 41 32 30 28 26 24 27 31 29 37 9 19 23 34 6 8 39 40 33 3 1 4 2 5 7
7 R20/3 Potentiometer AUX3 X10/11 10-pin plug connection
$&$102'8/( R20/4 Potentiometer AUX4 X10/12 10-pin plug connection

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$(&&8 CN1a X4/83 X4/90 $8;

CN1a CAN H
3
CAN H
3
GSV4 15
10 CAN L CAN L
16 4 2
6 CAN +
1
CAN +
1
CAN - CAN -
 17 2 4


3 X10/9 CN3a
X4/91 $8;
X10/9 6 1 8 1 6.4 V with EDC ON CAN H
3
2 8 2 6 4 6.4 V with EDC and AUX ON CAN L
2
$ CAN +
X24/2 1
$505(67 )$ CAN -
 24 4

X5/1
6 
X18/4 CN3a 
X4/92 $8;
X18/4 
RAISE CAN H
1 6 17 6.4 V with pushbutton pressed 3
12 3 LOWER X14/15 CAN L
7 7 16 6.4 V with pushbutton pressed )$ 2
 12 CAN +
1
6 CAN -
4

CAN H

CAN +
CAN L

CAN -
2))
21 CN3a X4/93 $8;
1 2 $ X10/11 CAN H
3
12 6.4 V with pushbutton pressed
 Ω 7 CAN L
6 2
CAN +
X10/12 6 1
CAN -
P8/1 3 4 1 2 4
2))
21
3,&8 P8
1 2 13 6.4 V with pushbutton pressed
 Ω 7 X14/14 X10/14 X4/94 $8;
6 5 4 7
CAN H
3
CAN L
2))
3 2
(7) CAN +
X23/2 X4/72 21
X4/72 X23/2 1
(8) CAN -
K 3 1 2 2 F 10 6.4 V with pushbutton pressed 4
 Ω
6 $
)$
X20/1 X23/1
A X3/10 B
 8 Q
2))

X4/72 21
X4/72 X23/2 120 Ω

4 1 2 1 G 11 6.4 V with pushbutton pressed A12 Central print X4/72 4-pin plug connection
A X23/2  Ω
A13 Roof print X4/83 4-pin plug connection
6 X4/90 4-pin plug connection
A14 Engine print
A60 ECCU2 X4/91 4-pin plug connection
2 X4/69 X4/92 4-pin plug connection
2)) B19 Angle of rotation sensor for front power lift
21
X4/69 CN1a 26-pin plug connection X4/93 4-pin plug connection
X23/2 X4/94 4-pin plug connection
CN3a 26-pin plug connection
1 2 2 D 23 6.4 V with pushbutton pressed
CN3b 34-pin plug connection X5/1 Plug connection
 Ω
6 P8 ICU X10/9 10-pin plug connection
P8 10-pin plug connection X10/11 10-pin plug connection
P8/1 4-pin plug connection X10/12 10-pin plug connection
2)) S2/7/3 Switch, hydraulic master X10/14 10-pin plug connection
21
X4/69 X23/2 S14/3 External pushbutton, front power lift LOWER X14/14 14-pin plug connection
S15/3 External pushbutton, front power lift RAISE X14/15 14-pin plug connection
1 2 1 C 26 6.4 V with pushbutton pressed S18/1 External push button, AUX BLUE pressure in - X18/4 18-pin plug connection
 Ω
S18/2 External push button, AUX BLUE pressure in + X20/1 20-pin plug connection
CN3b S19/1 External push button, AUX BROWN X23/1 23-pin plug connection
X3/22 X23/2 12 (up to DBD... YELOW) pressure in - X23/2 23-pin plug connection
8V S19/2 External push button, AUX BROWN X24/2 24-pin plug connection
3 3 S CN3a (7) Ground point, roof hood, left
(up to DBD... YELOW) pressure in +
% 2 2 T 8 2.5 to 4.7 V S28/1 Switch, front power lift management (8) Ground point, roof hood, right
8 1 1 R
GND
CN1a
X3/10 3-pin plug connection
X3/22 3-pin plug connection
23 X4/69 4-pin plug connection

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$
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)$
1 
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16 X24/1

2 X2/46

X12/20 8 6 9 10

$
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6



X12/20
7 2 12V when LOWERING
3
1 3 12V when RAISING $$',&
X12/20 X4/45 $ X24/1 CN1
0 V LED ON
11 3 5 13 12 V LED OFF
6



X12/20
7 4 12V with axle locked (OFF)
3
1 5 12V with pushbutton pressed
(calibration)
0V with management

<
GND
1
GND
1 C
% 12V 12 V when RAISING
2 A 2
, 3 B
20.25S: 6.0 to 18.5 mA
20.29S: 7.3 to 16.5 mA

A1 ADIC
A12 Central print <
GND GND
A60 ECCU2 1 C 1
A61 Electronics, suspended front axle % 12V
B33/1 Angle of rotation sensor, LEFT 2 A
B33/2 Angle of rotation sensor, RIGHT , 3 B
20.25S: 6.0 to 18.5 mA 12 V when RAISING and LOWERING 2
CN1 26-pin plug connection 20.29S: 7.3 to 16.5 mA
CN1a 26-pin plug connection
S2/15/1 Switch, front axle with independent
suspension UP/ DOWN
S2/15/2 Switch, front axle with independent <
suspension ON/ OFF $(&&8 CN1a GND
X2/45 X12/20 1
X2/45 2-pin plug connection
X2/46 2-pin plug connection 6 1 12 12V at v > 14 km/h
X4/45 4-pin plug connection 12 V when RAISING and LOWERING 2
X12/20 12-pin plug connection
X24/1 24-pin plug connection
Y14 Solenoid valve, UP / DOWN (black)
Y15 Solenoid valve, LEFT (blue)
Y16 Solenoid valve, RIGHT (green)

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VHH1RWHSDJH
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Sva 6-92771 EN Edition 06-2006

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SS06F008

Sva 6-92771 EN Edition 06-2006

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$

CNH Österreich GmbH Sva 6-93221 EN © 2006 CNH Österreich GmbH

Technical documentation June 2006
A - 4300 St. Valentin, Steyrer Strasse 32
 4008A-3

&217(176

GENERAL DESCRIPTION ....................................................................................................................................5

Abbreviations ....................................................................................................................................................5
Supply voltages .................................................................................................................................................5

FUNCTIONAL SCHEMATIC DIAGRAM FOR ADIC ..............................................................................................7

FUNCTIONAL SCHEMATIC DIAGRAM FOR EEM3 .............................................................................................9

FUNCTIONAL SCHEMATIC DIAGRAM FOR FMGR - SGR ...............................................................................13

FUNCTIONAL SCHEMATIC DIAGRAM FOR FMGR REVERSING FACILITY ...................................................17

FUNCTIONAL SCHEMATIC DIAGRAM FOR ECCU2 ........................................................................................19

FUNCTIONAL SCHEMATIC DIAGRAM FOR EDC .............................................................................................23

FUNCTIONAL SCHEMATIC DIAGRAM FOR REMOTE CONTROL VALVES ...................................................27

FUNCTIONAL SCHEMATIC DIAGRAM FOR REMOTE CONTROL VALVES - ADDITIONAL FUNCTIONS .....29

FUNCTIONAL SCHEMATIC DIAGRAM FOR FRONT AXLE WITH INDEPENDENT SUSPENSION ................31

FUNCTIONAL SCHEMATIC DIAGRAM FOR CAN BUS ....................................................................................33

FUNCTIONAL SCHEMATIC DIAGRAM FOR ISO BUS ......................................................................................35

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*(1(5$/'(6&5,37,21
The functional schematic diagrams show the key electric circuits, divided into individual components e. g. control
units, controllers and display instruments. The fact that individual electrical circuits / functions are illustrated in full
should help the mechanic gain better comprehension. Faster narrowing down of errors is thereby possible in the
future.
The diagrams are structured so that the supply for each component is shown first. As a rule, the inputs are on the left
and the outputs on the right.
When troubleshooting in the wiring, the circuit diagram and/or. list of connectors must be used.

$EEUHYLDWLRQV
ADIC ........................................................................................................................... Analogue / digital instrument
ARU ............................................................................................................................................................. Armrest
AUX ........................................................................................................................................Remote control valve
DMD ................................................................................................................................... DOT MATRIX DISPLAY
ECCU2 ...................................................................................................................................... Central control unit
EDC .................................................................................................................. Electronic power lift control system
EEM3 .........................................................................................................................................Engine control unit
FMGR .......................................................................................................... Vehicle/engine/transmission controller
GSV ................................................................................................................................................... Cyclic supply
HTS ............................................................................................ Field end management (headland management)
ICU .........................................................................................................................................Performance monitor
KEY PADS ....................................................................................... Function keys for analogue/digital instrument
NTC ......................................................................................................................Negative temperature coefficient
PCB ....................................................................................Printed circuit board (relay circuit, terminal resistance)
PTC ....................................................................................................................... Positive temperature coefficient
SGR ................................................................................................................................... Transmission controller

6XSSO\YROWDJHV
On-board voltage ...................................................................................................................................... 12 V +2.0
GSV1 .......................................................................................................................................................... 3 V ±0.2
GSV2 .......................................................................................................................................................... 3 V ±0.2
GSV3 .......................................................................................................................................................... 3 V ±0.2
GSV4 ....................................................................................................................................................... 6.4 V ±0.4

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 4008A-7

)81&7,21$/6&+(0$7,&',$*5$0)25$',&
$ $
)$ )$ )$
  
$((0 

X10/3 6 X18/1 11 X24/1 16 X24/1 4

$)0*5 $(&&8

CN1 26 16 24 23
$$',&
6XSSO\
A4/3 17 18 CN1a 15 16
X89/1 CN3
CAN H 3LORWODPSVDQGGLVSOD\VFRQWUROOHG
35 26
CAN L YLD&$1%86
34 25
X6/11 X6/8 X29
3LORWODPSVDQGGLVSOD\V 5 5 6
CN1 Speed signal
Generator D+ CN2 6 6 7
25 Starter switch position ON = 0.7V transmission 14 km/h = 504 Hz
16 1 1 2
Engine ON = 12V (Light OFF) Radar screen 14 km/h = 504 Hz
$ $ CN3 15 2 2 1
X12/20 X4/45 PTO shaft speed 1000 min-1 = 100 Hz
18 High beam ON = 12V 14 3 3 3
11 3 Button transport 12V, button control 0V
17 4 4 4
X24/1 CN1
5 Lighting ON = 12V
15
X4/52 X4/51 2 A1 ADIC
5 Turn signal left
3 4  16 A3 EEM3
6 A4 FMGR
4 3  6 Turn signal right A4/3 15-pin plug connection
S A12 Central print
A14 Engine print
CN3 A60 ECCU2
16 Turn signal trailer I A61 Electronics, suspended front axle
B2/1 Fuel tank level transmitter, left
6 2 13 Turn signal trailer II B3 Compressed air transmitter
1 CN1 26-pin plug connection
X24/3 CN1 CN1a 26-pin plug connection
1 9 Suspended front axle OFF = 11.7 V, CN2 26-pin plug connection
13 CN3 26-pin plug connection
ACTIVE = 0V (Light ON)
6 2 CN3 S3 Test switch for air filter
S 3 p >10 bar = 0 V S13 Control switch for brake fluid
S22 Control switch for coolant level
- (11) S23 Test switch for charge pressure 1bar
CN1 S50 Pushbutton for trailer brake valve
6 + 7 Brake fluid level OK = 11 V X4/45 4-pin plug connection
S X10/18 12 DMD Feed pump pressure OK. (>1 bar) = 12 V X4/51 4-pin plug connection
X4/52 4-pin plug connection
6 11 Air filter OK = 11 V X6/8 6-pin plug connection
1
7 17 Coolant level OK = 12 V X6/10 6-pin plug connection
6 2 X6/11 6-pin plug connection
X24/3 % X24/3 CN3 X10/3 10-pin plug connection
2 G 3 15 Compressed air 8.1 bar = 155 Ω X10/18 10-pin plug connection
X12/20 12-pin plug connection
CN1 X18/1 18-pin plug connection
GND X24/1 24-pin plug connection
22 X24/3 24-pin plug connection
180 Ω X29 Standard signal socket
X89/1 89-pin plug connection
95 Ω Fuel tank level (11) Ground point, engine component carrier, rear
X6/10 % X6/10 CN3
1 2 1 3 14 10 Ω

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 4008A-9

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$
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2 

X1/30/EEM )$
$ 
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$505(67 X89/1 40 9 8 3 2 11 10 5 6
17 18 X24/2 $((0
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$35,17$58 35
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34 
8 10 (11)
X30/3 7 13
% 9
0
1 9 X12/1
5V 12V
X30/7 3UHJORZLQJDQG ./3 9 3 M 1
0.4V to 4.7V IXHOGHOLYHU\SXPS 4
; 2 2 16 3 5
3
CAN H X89/1
17 1 2
CAN L 55 4 *1'
GND 4 4 18 X12/1
(11)

X1/30/1 (

P8/1 4 3
3,&8 + -
P8/2
3 .
4 3 5
(12)

1 2
X36/1 X2/19 X2/19
4
$$',& CN3 5
26
25
A1 ADIC X4/4 4-pin plug connection
A3 EEM3 X4/70 4-pin plug connection
A7 ID module X10/18 10-pin plug connection
A12 Central print X12/1 12-pin plug connection
(PHUJHQF\VLJQDO A14 Engine print X18/4 18-pin plug connection
5 X4/70 X24/3 X10/18 X89/1 A30 Print ARU X24/2 24-pin plug connection
4 16 10 79 0.8 to 4.4 V B28 Manual throttle X24/3 24-pin plug connection
CN3 26-pin plug connection X30/1 14-pin plug connection
E10/1 Heating flange X30/3 4-pin plug connection
K5/LP Relay, fuel delivery pump X30/7 4-pin plug connection
K8/2 Relay, heating flange X36/1 36-pin plug connection
M13 Fuel delivery pump X89/1 89-pin plug connection
P8 ICU (2) Ground point, EEM3 control unit
$,'PRGXOH (QJLQHLGHQWLILFDWLRQ P8/1 4-pin plug connection (11) Ground point, engine cable carrier,
X4/4 X89/1
12V P8/2 4-pin plug connection rear
4 21 R8 Potentiometer, accelerator pedal (12) Ground point, engine cable carrier,
GND front
120 Ω 1 29 120 Ω
X1/30/1 Screw connection
CAN L X1/30/EEM Screw connection
2 52
CAN H X2/19 2-pin plug connection
3 53

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4008A-10

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 4008A-11

$((0
% X3/12 X89/1 X16/1 X2/21
12V HP1
5 A 50 9 1
B 47
Fuel OK = 12 V <
GND Water in fuel = 0 V
8 C 65 10
HP2
2

C SH1
X4/29 X36/1 4
GND <
1 25
SW 2.5 kOhm with 20° C C SL1
2 29 13
% 3
5V
33
85 4 34 1.07 V with 1 bar 11
C SH2
atmospheric pressure <
C SL2
X2/22 X36/1 6
W 1 15
% GND 2.5 kOhm with 20° C C SH3
5 2 26 5
<
C SL3
X2/36 X36/1 12
W 1 35
% GND 2.5 kOhm with 20° C C SH4
5 2 8 3
<
C SL4
X3/37 X36/1 14
GND
S 1 24
C SH5
% 2 27 0.5 to 4.5 V 1
85 3 5V
32 <
C SL5
16
X3/38 X36/1
GND C SH6
S 1 12 2
% 2 14 0.5 to 4.5 V <
85 3 5V
13 15
C SL6

X3/39 X36/1
GND
S 1 17
A3 EEM3 X3/37 3-pin plug connection
% 2 21 0.5 to 4.5 V
B20 Engine speed sensor X3/38 3-pin plug connection
85 3 5V
31 B22 Coolant temperature sensor X3/39 3-pin plug connection
B23 'Water in fuel' sensor X3/40 3-pin plug connection
B29 Sensor for charger pressure, X4/29 4-pin plug connection
X2/28 X36/1 charge-air temperature X16/1 16-pin plug connection
Q GND B36 Fuel temperature sensor
1 19 X36/1 36-pin plug connection
% approx. 855 Hz at 900 rpm B37 Oil pressure sensor X89/1 89-pin plug connection
I 2 23 B38 Rail pressure sensor Y20 Solenoid valve, high-pressure pump
B39 Fuel delivery pressure sensor Y21 Injector 1
B40 Camshaft position sensor Y22 Injector 2
X3/40 X36/1 X2/21 2-pin plug connection Y23 Injector 3
Q 1 9 X2/22 2-pin plug connection Y24 Injector 4
GND approx. 52 Hz at 900 rpm
% 2 10 X2/28 2-pin plug connection Y25 Injector 5
I X2/36 2-pin plug connection Y26 Injector 6
3 X3/12 3-pin plug connection

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 4008A-13

)81&7,21$/6&+(0$7,&',$*5$0)25)0*56*5
$505(67
$ $+<'5267$7
)$ )$ )$

X30/11
$35,17$58   5
(11) )$ )$ )$
X21 X30/1 X18/4   
M
$ 2 9 8 10 X24/2 17 18 X24/2 1 6 X24/2 21 23
1 1 7 13 5
6 9 9
13 3 (11) (11)
X30/7 A4/3 10 14 13 A4/4 X16/21 13 12 3 X6/9 E F L M H K B
CAN H
6 2 16 $)0*5 17 1 $6*5
CAN H CAN L

GND
11 V
11 11 3 17 3 18 2 6XSSO\
CAN L 6XSSO\
4 18 2
6 A23 1 12 2 11 9 10 3
10 12 6

0 V or 5 V
X6/3 X24/3 A4/2 /,03+20(FLUFXLW
6 3 10 8 NEUTRAL
9 4 X16/21
2 11 7 DEAD MAN GND
GSV2 10
6 4 12 6 12 V
6KXWWOHOHYHU 14 Select 0 V** with FORWARDS
12 5 1 2 2 12 V
8 Select 0 V** with REVERSE $(/(&7521,&6
5 1 1 7 11 FORWARDS
**) Only if the A23 8 5 7 6
6 3 3 8 10 REVERSE
X4/59/b (A) and X4/59/c (B)

X4/59/b
plug connection is linked.

X4/59/a
A21/4 X6/1
11 4

CAN H
CAN L
X24/3 12 1
2 19 A21/5
1 21 3 3
$ X14/15 X10/11 $ X10/12 P8 3,&8 P8/1 3 20 9 2
)$
 12 7 6 7 4 X4/59/c
5 3 A1 ADIC S60/3 Speed button +
X4/14 X24/3 A4/2 %UDNH A3 EEM3 S60/4 Speed button -
3 GSV2
1 12 6 A4 FMGR S60/5 HTS button
6  Ω
3 14 3 V A4/1 18-pin plug connection X4/14 4-pin plug connection
$ 4
X10/3 X10/14 X14/14 P8/2 3 4 A4/2 18-pin plug connection X4/59/a 3-pin plug connection
)$ 6 2 5 13 3 V A4/3 15-pin plug connection X4/59/b 3-pin plug connection
 6 7 4 (7)
A4/4 18-pin plug connection X4/59/c 3-pin plug connection
(8) A12 Central print X4/70 4-pin plug connection
X24/3 A4/2 &OXWFK A13 Roof print X6/1 4-pin plug connection
GSV2 A14 Engine print X6/3 6-pin plug connection
1 12 6
 Ω A21 SGR transmission controller X6/9 7-pin plug connection
6 A4/1 A21/4 12-pin plug connection X10/3 10-pin plug connection
2 24 15 3 V A21/5 12-pin plug connection X10/11 10-pin plug connection
A23 Electronics X10/12 10-pin plug connection
CAN H
CAN L

A4/4 A23 12-pin plug connection X10/14 10-pin plug connection

GND A24 Hydrostat X10/18 10-pin plug connection
1 13 4
5.6V A30 Print ARU X14/14 14-pin plug connection
% 2 14 11 A31 Multi controller X14/15 14-pin plug connection
8 3 15 12 1.1 to 4 V B17 Angle of rotation sensor, clutch X16/21 16-pin plug connection
CN3 26-pin plug connection X18/4 18-pin plug connection
$$',& CN3 P8 ICU X21 14-pin plug connection
CAN L P8 10-pin plug connection X24/2 24-pin plug connection
25 X4/70 A4/4 $FFHOHUDWRUSHGDO
CAN H GND P8/1 4-pin plug connection X24/3 24-pin plug connection
26 1 1 P8/2 4-pin plug connection X30/1 14-pin plug connection
3 R8 Potentiometer, accelerator pedal X30/7 4-pin plug connection
X89/1 35 34 5 6 4.4 to 0.8 V
S4/4 Shuttle lever X30/11 16-pin plug connection
5.8V
2 10 S5 Switch for brake light X89/1 89-pin plug connection
$((0
4 3 0.8 to 4.4 V S25 Switch for steering brake (7) Ground point, roof hood, left
S46 Switch, clutch (8) Ground point, roof hood, right
S60/1 F/R button (11) Ground point, engine cable
X89/1 X10/18 X24/3 S60/2 Cruise control button carrier, rear
79 10 16

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4008A-14

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 4008A-15

$)0*5 $6*5
A4/2 A21/2
GSV3 5V
1 S 1 4
% GND
6 2 7 A21/3 <
X4/61 X4/61 A4/2
8 3 6 0.2 to 3.1 V 6 4V
1
GND
2 1 17 6HDWFRQWDFW A21/2 7
5V
6 S 1 11 2
GND
X4/25 X4/25 A4/2 % 2 8
2 1 16 3DUNLQJEUDNHRSHQ 8 3 5 0.2 to 1.2 V A21/3 <
4V
5 1
6 A21/2 GND
W 8
A4/1 1 3
% PTC 1 kΩ to 4.4 kΩ 2
2 1 3 (QJLQHEDFNSUHVVXUH 2 10
5
EUDNH
X5 A21/4 A21/3 <
$ GND 4V
X14/4 A4/1 1 2 9 4 1
GSV1 GND
8 18 6 2 1 3 GND 9
S Opens at a difference in pressure of 2
1 2 X10/4 6 > 5 bar
6SHHGUDQJHV

X24/5 A4/1 12 V
1 A21/3 <
4V
 23 16 increase "+" 3 1
 < GND
7 5 17 decrease "-" 10
3 2
1 6HQVRUVDQG 2
A4/3 VROHQRLGYDOYHV
6 %UDNHRLOFRROLQJ 5
12 V
1 A21/3 <
8 < 2 4V
1
2))
GND
21 2 11
X24/5 A4/1 2
5 1 8 5 0DQXDOPRGH A21/7
1
6 (11) % Q 10 to 6000 Hz
A21/3
4V
<
I 2 1 1

GND

X24/5 A4/1 12

0DQDJHPHQW A21/8
5 3 1 2
3 DQG Q 1
1 4 2 DOOZKHHO % I 2
10 to 6000 Hz

X3/23 X24/5 A4/4 A21/9

5.8 V
a 1 11 14 3RWHQWLRPHWHU Q 1
% I
10 to 6000 Hz
5 b 3 12 15 0 to 5.8 V IRUOLPLWORDG 2 <
6 c 2 13
GND
5 1
A21/5
A21/10 10 V
4
2))
X24/5 A4/1 Q 1 GND
21
% I 2
10 to 6000 Hz 8 2
18 13 3.0 V
6ZLWFKIRUSDUNLQJ X17
1 3 X24/3 A4/2 <
GSV2 LQWHUORFN A21/6
12 6 2
1
% Q 10 to 6000 Hz A21/5
A4 FMGR A21/10 2-pin plug connection S2/61 Switch for parking interlock I 2 10 V
5 1
A4/1 18-pin plug connection B24 Speed sensor, cartridge input S8 Seat switch
A4/2 18-pin plug connection B25 Speed sensor, planetary carrier 3/4 S20 Switch, engine back pressure brake
A4/3 15-pin plug connection B26 Speed sensor, cartridge output S21 Switch, parking brake Y12 Solenoid valve for brake oil cooling
A4/4 18-pin plug connection B27 Speed sensor, cartridge output S49/1 Switch, pressure filter Y41 Solenoid valve, clutch 1
A16 EDC print B32 Temperature sensor, transmission oil X3/23 3-pin plug connection Y42 Solenoid valve, clutch 2
A21 SGR transmission controller B35 Speed sensor, planetary carrier 1/2 X4/25 4-pin plug connection Y43 Solenoid valve, clutch 3 <
A21/2 12-pin plug connection B47 Pressure sensor for transmission X4/61 4-pin plug connection Y44 Solenoid valve, clutch 4 A21/5 1
A21/3 12-pin plug connection system pressure X5 2-pin plug connection Y45 Solenoid valve, clutch, forward 4V
A21/4 12-pin plug connection B51 Pressure sensor for transmission X10/4 10-pin plug connection Y46 Solenoid valve, clutch, reverse 6
A21/5 12-pin plug connection lubricating pressure X14/4 14-pin plug connection Y57 Solenoid valve, parking interlock ON GND
7 2
A21/6 2-pin plug connection R23 Potentiometer for limit load X17 Y - distributor Y58 Solenoid valve, parking interlock OFF
A21/7 2-pin plug connection S2/58/1 Switch, speed ranges X24/3 24-pin plug connection Y59 Solenoid valve, all-wheel
A21/8 2-pin plug connection S2/58/2 Switch, manual mode X24/5 24-pin plug connection (11) Ground point, engine cable carrier, rear
A21/9 2-pin plug connection S2/59 Switch, all-wheel Y11 Solenoid valve for brake oil cooling

Sva 6-93221 EN Edition 06-2006

4008A-16

BLANK PAGE

Sva 6-93221 EN Edition 06-2006

 4008A-17

)81&7,21$/6&+(0$7,&',$*5$0)25)0*55(9(56,1*)$&,/,7<
$)0*5
A4/2 3
6
X6/3 X24/3 A4/2 3 3
6
3 10 8 5
2 11 7  1
GSV2 
4 12 6 
X6/15 5 6
8 A4/2
1 2 2 4
2 8 NEUTRAL $
5 1 1 7 11 X2/4/1
7 7 DEAD MAN
6 3 3 8 10 3 GSV2 
1 6 (11)

X4/59/b
6KXWWOHOHYHU

X4/59/a
11 FORWARDS $6*5
$ X24/3 10 REVERSE X16/21 /,03+20(FLUFXLW
X2/4/1 X6/15 2 GND
10
19
 6 12 V
1 21 14 Select 0 V** with FORWARDS
12 V
3 20 8 Select 0 V** with REVERSE
$ X4/59/c A4/2
GSV3
1 **) Only if the
6 6 X4/59/b (A) and X4/59/c (B)
X6/58 X6/27 X6/27 X6/58 16 3DUNLQJEUDNHRSHQ plug connection is linked.
X4/25 X4/25/1 X4/25/1 X4/25 A4/2
2 2 1 1
6 2 2 1 1 16
6 6 5 5 A4/2
3 3 6 S8 Seat switch
4 4
6 1 S8/1 Reversible seat switch
A4/1 A4/1 (QJLQHEDFNSUHVVXUH
S8/2 Reversible seat switch
2 1 3 3 EUDNH S20 Switch, engine back
4 6LJQDO pressure brake
UHYHUVLQJIDFLOLW\ S21 Switch, parking brake
A4/2 S46 Switch, clutch
17 6HDWFRQWDFW S46/1 Switch, clutch,
reversing facility
A4/4 X2/4/1 Plug connection
GND
X24/3 A4/4 4 &OXWFK X4/25 4-pin plug connection
5.6V X4/25/1 4-pin plug connection
1 13 4 11
% X4/59/a 3-pin plug connection
2 14 11 12 1.1 to 4 V X4/59/b 3-pin plug connection
8 3 15 12 X24/3 A4/2 A4/2 X4/59/c 3-pin plug connection
. 1 12 6
GSV2
6 X4/70 4-pin plug connection
4  Ω X4/70/1 4-pin plug connection
1 3 6 24 X6/3 6-pin plug connection
% 5 X6/15 6-pin plug connection
2 2
8 3
2 1 A4/1 A4/1 X6/27 6-pin plug connection
X6/58 6-pin plug connection
1 15 15 3 V
 Ω X10/18 10-pin plug connection
6 X16/21 16-pin plug connection
A3 EEM3 2 X24/3 24-pin plug connection
A4 FMGR A4/4
(11) 5.8V $FFHOHUDWRUSHGDO X89/1 89-pin plug connection
A4/1 18-pin plug connection X4/70 A4/4 10 (11) Ground point, engine
A4/2 18-pin plug connection GND cable carrier, rear
1 1 1
A4/4 18-pin plug connection
A12 Central print 5 3 6 . 3 0.8 to 4.4 V
A21 SGR transmission controller 2 10 4 6 4.4 to 0.8 V
A70 Seat switch, reversing facility 3
4 3 5
B17 Angle of rotation sensor, clutch
B17/1 Angle of rotation sensor, clutch, reversing facility 2 1
K5/60 Relay for clutch, reversing facility X4/70/1
K5/61 Relay, accelerator pedal, reversing facility 1 .
K5/62 Relay, accelerator pedal , reversing facility 3
P6 Display, reversing facility 5 4
3
R8 Potentiometer, accelerator pedal 2 5
R8/1 Potentiometer, accelerator pedal, reversing facility 4 2 1
S4/4 Shuttle lever
S4/4/1 Forwards - reverse switch, reversing facility $((0 X89/1 X10/18 X24/3
79 10 16
(11)

Sva 6-93221 EN Edition 06-2006

 4008A-18

$)0*5
X4/14 X24/3 A4/2 A4/2
GSV2 %UDNH
1 12 6 6
6  Ω
3 4 14 14 3 V
6 2 5 13 13 3 V

4
6
3

$ X14/4 A4/1 A4/1

GSV1
8 18 18
A4 FMGR
1 2 X10/4 6 A4/1 18-pin plug connection
A4/2 18-pin plug connection
 6SHHGUDQJHV A4/4 18-pin plug connection

X24/5 A4/1 A4/1 A16 EDC print

7 23 16 16 increase "+" R23 Potentiometer for limit load
3 S2/58/1 Switch, speed ranges
1 5 17 17 decrease "-" S2/58/2 Switch, manual mode
6 S2/59 Switch, all-wheel
S2/61 Switch for parking interlock
S2/61/1 Switch for parking interlock,
2)) reversing facility
21
S5 Switch for brake light
X24/5 A4/1 A4/1 S5/1 Switch for brake light, reversing facility
5 1 8 5 5 0DQXDOPRGH S25 Switch for steering brake
X3/23 3-pin plug connection
6 X4/14 4-pin plug connection

X10/4 10-pin plug connection

X24/5 A4/1 A4/1 X14/4 14-pin plug connection

0DQDJHPHQW X24/3 24-pin plug connection
5 3 1 1 X24/5 24-pin plug connection
3 DQG
1 4 2 2 DOOZKHHO

X3/23 X24/5 A4/4 A4/4

5.8 V 3RWHQWLRPHWHU
a 1 11 14 14
IRUOLPLWORDG
5 b 3 12 15 15 0 to 5.8 V
GND
c 2 13 5 5

6
2))
21 A4/1 A4/1
X24/3 13 13 3.0 V
1 3 18 A4/2 A4/2 6ZLWFKIRUSDUNLQJ
GSV2
12 6 6 LQWHUORFN
6
2))
21

3 1

Sva 6-93221 EN Edition 06-2006

 4008A-19

)81&7,21$/6&+(0$7,&',$*5$0)25(&&8
A1 ADIC X24/2 $ )$
A12 Central print 8  X14/15
A13 Roof print )$
A14 Engine print 9  12
)$
A60 ECCU2 X4/85/a 1 2 22 
A62 Reverse fan unit
CN1a 26-pin plug connection X4/85/b 1 2
'
CN2/E 26-pin plug connection
CN3 26-pin plug connection
CN3a 26-pin plug connection
CN3b 34-pin plug connection 2 25 34 1 2 3 14 21 26 25 26 19
K5/FAN Relay, reverse fan (11) X10/12 $ X10/11
P8 ICU
CN3a CN3b CN1a CN2/E CN1a
$(&&8 6 7
P8 10-pin plug connection
P8/1 4-pin plug connection
P8/2 4-pin plug connection A60_GND
S2/15/6 Switch, HTS 6XSSO\
S2/15/7 Switch, speed reduction
S2/56 Switch for differential lock CAN H
15

CN1a
S2/74 Reverse fan pushbutton CAN L (7)
X1/31/1 Screw connection 16 P8 7 5 3 (8)
X4/64 4-pin plug connection 3,&8 $$',&
X10/9 CN1a P8/1 P8/2 CN3
GSV4 CAN H
2 10 3 3 26
CAN L
4 4 25
6
 'LIIHUHQWLDOORFN

X24/5 CN3b

24 Management CN3b < X14/14 4
5 2 12 V
3 5 1
1 1 23 Differential lock ON
6 2 X10/14 7


X24/5 CN3a +76

(11)
7 22 18 RECORD
3
1 24 19 PLAY
6 X10/3 6
$
)$
2))  $
21
6SHHGUHGXFWLRQ .)$1 X4/64 X4/66
X24/5 CN3a 4
5 1 7 24 )$ 3 5 4 3 M

1 2 3
6 CN3b 1
X6/2
12 V 2
5HYHUVHIDQ 8 3 1
$
2))

)$
X24/1 21
X24/3 CN3a X1/31/1
 4 1 3 22 3 12 V 2
*1'
4

(11)
X4/66 4-pin plug connection X14/15 14-pin plug connection
X4/85/a 4-pin plug connection X24/1 24-pin plug connection
X4/85/b 4-pin plug connection X24/2 24-pin plug connection
X6/2 6-pin plug connection X24/3 24-pin plug connection
X10/3 10-pin plug connection X24/5 24-pin plug connection
X10/9 10-pin plug connection Y8 Heating valve CN3b
X10/11 10-pin plug connection Y10 Solenoid valve, differential lock 12 V
16 1
X10/12 10-pin plug connection (7) Ground point, roof hood, left
X10/14 10-pin plug connection (8) Ground point, roof hood, right
Y8
+HDWLQJYDOYH
X14/14 14-pin plug connection (11) Ground point, engine cable carrier, rear 2

(11)

Sva 6-93221 EN Edition 06-2006

4008A-20

BLANK PAGE

Sva 6-93221 EN Edition 06-2006

 4008A-21

$(&&8

X10/9 CN1a
GSV4
2 10

6 )URQW372

21

2))
X24/5 CN3b
1 17 31 6.4 V when ON
3
7 18 30 6.4 V when OFF
CN2/E <
12 V**
7 1
X3/21 CN3b
(11) GND
Q C 3 CN3b 225 Hz at 900 rmp 6 2
% B 2 22 490 Hz at 1900 rmp
I A 1 570 Hz at 2300 rmp
$
)$
X24/2 **) Activation approx. 6 sec. with 3 V, then 12 V
 7

Q 3 CN2/E 150 Hz at 900 rmp

% 2 20 330 Hz at 1900 rmp CN3b <
I 1 400 Hz at 2300 rmp 14 12 V**
1

GND
6 18 2
(11)
21

2))
X24/5 CN3b
1 14 33 6.4 V when ON
3
7 15 32 6.4 V when OFF A12 Central print
6 A60 ECCU2
5HDU372 B7 Rear PTO speed sensor
B8 Front PTO speed sensor
2))
21
CN1a 26-pin plug connection
CN2/E 26-pin plug connection
X24/5 CN3a CN3a 26-pin plug connection
5 1 16 20 6.4 V with management ON CN3b 34-pin plug connection
6 S2/70/1 Switch for front PTO
S2/70/2 Switch for rear PTO
S2/71 Switch for rear PTO, management
2)) S17/1 External pushbutton for PTO, rear left
21
CN3a S17/2 External pushbutton for PTO, rear right
1 2 21 6.4 V with pushbutton pressed X3/21 3-pin plug connection
 Ω X10/9 10-pin plug connection
6 X24/2 24-pin plug connection
X24/5 24-pin plug connection
2)) Y4 Solenoid valve, front PTO
21
CN3a Y5 Solenoid valve, rear PTO
(11) Ground point, engine cable carrier, rear
1 2 22 6.4 V with pushbutton pressed
 Ω

Sva 6-93221 EN Edition 06-2006

4008A-22

BLANK PAGE

Sva 6-93221 EN Edition 06-2006

 4008A-23

)81&7,21$/6&+(0$7,&',$*5$0)25('&
6

$ X24/2 $


)$ 6 

X24/2  10 X6/2 

$505(67 )$ 3
17 1
$35,17$58
)$ 21
)$ 6 1
18 
X18/1
2))
4 
6 X30/14 8 2
X30/1 X18/4 ' 16 54c

GSV4
2 1
5V 7 13
1 X24/3 1
9 9
6 X30/2 (11) 1 54c
8 10 $(&&8 CN3a
2 X2/12 X10/9 2 6 8
5V X30/7 2
1 X55 13 24 29 47 28 46 (11)
2 16 CAN H
CAN H 50 $('&
$ 3 17 CAN L
X4 X30/11 52 6XSSO\ 10 4 1 CN3a
6 4 18
CAN L CN1a
1 16 $

6.4 V with EDC and

AUX ON
6.4 V with EDC ON
12V X30/1 15 (&&8
X21 X30/11 13 4 16
2 GND 9 6 5
5 2
38
X21 X30/11 4 3
41
4 7 12 1
CONTROL
5 14
$ )$
3 15  $ X14/4 
5V X10/9 4 5 7 GND
1 1  *1' X10/4 12 20
N
TRANSPORT
9 10 V X14/15 12
N N 14 2
X10/4 X24/5
STOP N X10/11 7
6 3 6 5 3.5 V with pushbutton pressed
$
N
RAPID RETRACTION
5 3XVKEXWWRQ
N N X10/12 6
X24/5 6.75 V transport P8/1 3 4
A1 ADIC X3/18 3-pin plug connection 8 9 3,&8
A12 Central print X3/19 3-pin plug connection X5/6 21 5.17 V control P8
2 3.50 V rapid retraction
A13 Roof print X4 4-pin plug connection 7
A14 Engine print X5/6 5-pin plug connection c a
1 5
A16 EDC print X6/2 6-pin plug connection 5 X14/4
b
A30 Print ARU X10/3 10-pin plug connection 3 13 22 0 to 10 V 3
A31 Multi controller X10/4 10-pin plug connection
A55 EDC box X10/9 10-pin plug connection X3/17 (7)
A60 ECCU2 X10/11 10-pin plug connection 2 P8/2 3 4 (8)
Ω 3RWHQWLRPHWHU X14/14 4
CN1a 26-pin plug connection X10/12 10-pin plug connection c a
1
CN3 26-pin plug connection X10/14 10-pin plug connection 5
b
CN3a 26-pin plug connection X14/4 14-pin plug connection 3 6 3 0 to 9.5 V
R6/1 Potentiometer, setpoint X14/14 14-pin plug connection
R6/2 Potentiometer, lift limitation X14/15 14-pin plug connection X3/18
X10/14 7
R6/3 Potentiometer, mixing X18/1 18-pin plug connection 2
R6/4 Potentiometer, lowering speed X18/4 18-pin plug connection c a
1 $
R6/5 Potentiometer, slip control X21 14-pin plug connection 5 )$
X10/3
b
S2/7/3 Switch, hydraulic master X24/2 24-pin plug connection 3 11 4 0 to 10 V  6
S2/72 Rapid retraction pushbutton X24/3 24-pin plug connection
S28 Switch, stroke / pressure equipment X24/5 24-pin plug connection X3/16
S33 Stop pushbutton X30/1 14-pin plug connection 2
S60/7 EDC Transport/control button X30/2 2-pin plug connection c a
1
P8 ICU X30/7 4-pin plug connection 5 $$',&
b
P8 10-pin plug connection X30/11 16-pin plug connection 3 4 23 0 to 10 V CN3
P8/1 4-pin plug connection X30/14 2-pin plug connection .Ω CAN L
X3/19 25
P8/2 4-pin plug connection X55 55-pin plug connection CAN H
X2/12 2-pin plug connection (7) Ground point, roof hood, left 5 2
.Ω
26
X3/16 3-pin plug connection (8) Ground point, roof hood, right c a
1
X3/17 3-pin plug connection (11) Ground point, engine cable carrier, rear b
3 1 25 2.5 to 7.4 V

Sva 6-93221 EN Edition 06-2006

4008A-24

BLANK PAGE

Sva 6-93221 EN Edition 06-2006

 4008A-25

$('&
A4 FMGR X55
A4/2 18-pin plug connection 10 V
3 39
A12 Central print
A16 EDC print % 2 6 2.5 to 7.5 V X55 <
A55 EDC box 8 1 35
GND
1
A60 ECCU2 6HQVRUVDQG
B9/1 Angle of rotation sensor
B10/1 Power sensor, left VROHQRLGYDOYHV 0 to 5 V
) 3 55 2
B10/2 Power sensor, right
B16 Radar sensor
% 2 7 approx. 5 V not loaded
CN2/E 26-pin plug connection 8 1
CN3b 34-pin plug connection
H2/1 Diagnosis LED
H2/2 Slip LED
) 3 <
H2/3 RAISE LED % GND
H2/4 LOWER LED 2 26 approx. 5 V not loaded 53 1
S2/15/5 RAISE/LOWER pushbutton 8 1
GND
38
S2/73 Switch, slip control 0 to 5 V
S14/1 External pushbutton, LOWER, left 41 19 2
S14/2 External pushbutton, LOWER, right
S15/1 External pushbutton, RAISE, left
S15/2 External pushbutton, RAISE, right 5V
9
X3/1 3-pin plug connection
X3/2 3-pin plug connection 6 6
X4/2 4-pin plug connection
X4/3 4-pin plug connection
2)) 2))
X10/4 10-pin plug connection 21 21 $
X10/9 10-pin plug connection
X14/4 X4/3
X14/4 14-pin plug connection 1 2 1 2 N +
X24/2 24-pin plug connection  Ω  Ω 5 1
X24/5 24-pin plug connection 6 2
X55 55-pin plug connection
6 N
Y6 Solenoid valve, EDC RAISE 37 3 4
Y7 Solenoid valve, EDC LOWER 2)) 2))
3
(11) Ground point, engine cable carrier, rear 21 21 ([WHUQDOSXVKEXWWRQV +
DQG/('V
1 2 1 2
 Ω  Ω

X14/4 X4/2
6 12 2
N
4
+
 3

X24/5 N
X24/5 
DOWN 31 7 2
1 20 36 5 V with pushbutton pressed
19 3 RAISE 1
7 21 17 5 V with pushbutton pressed +
6




X10/9 X10/4 $ X14/4 

GND
9 1 5 7 12 20

14 GND
X14/4 9 X10/4 4

6OLSFRQWURO
X3/2 X3/1 $ CN2/E $ $
)$
Y 1 1  X24/2 8 Potentiometer R6/5 is shown (11)
B16 GND
2 3 5 CN3b on the previous page X24/2 19
I 3 2 15 21 9 A4/2 $
)$
Theoretical speed 
11 505 Hz at 14 km/h
Real speed
10 505 Hz at 14 km/h
$
6WDQGDUGVLJQDO CN3b
Ground during transport
15 11

Sva 6-93221 EN Edition 06-2006

4008A-26

BLANK PAGE

Sva 6-93221 EN Edition 06-2006

 4008A-27

$
$505(67 )81&7,21$/6&+(0$7,&',$*5$0)255(027(
6 X21 X30/11 $35,17$58 X30/1 X18/4 X24/2
)$ $
&21752/9$/9(6
8 6 7 13 17 X4/83 X4/90 $8;
)$ CAN H
7 13 9 9 18  3 3
9 )$ CAN L
1 1 8 10 24  4 2
CAN +
6 10 1 1
CAN -
X30/19 2 1 X30/7 (11)
2 4
2 16
6 CAN H
3 17 X4/91 $8;
CAN L CAN H
4 18 (11) 3
$ X30/5 CAN L
*1' *1'
6 2
3 CAN +
; 9 1
% 1 
CAN -
 4
2 

*1' 3
7
% ; 9 6 1 X4/92 $8;
5 GSV4 CAN H
8 2 3
6 CAN L
9 2
6 4 2 X10/9 X10/9 6 8 CAN +
1
8 CAN -
4
X30/4 CN1a $(&&8 CN3a
*1'
4 10 6.4 V with EDC and AUX ON 4
; 9 9 CAN L X4/93 $8;
1 16 6.4 V with EDC ON 1 CAN H
CAN H 3
% 2 15 CAN L
2
X30/16 $ CAN +
5 9 Ω *1' $ X10/11 X14/15 1
6 )$ CAN -
9 Ω 7 12  4
4
5 X10/12 6 $
5 9
3
Ω X10/14 X10/3 X4/94 $8;
)$ CAN H
9 Ω 7 6  3
1 CAN L
2
2 X14/14 CAN +
1
X30/15 4 CAN -
5 9 Ω 4
6
9 Ω (7)
4 P8 7 5 3 (8)
A X3/10 B
5 P8/1 3,&8
5 9
3
Ω CAN L
4 120 Ω
9 Ω CAN H
1 3
2
X30/12 A12 Central print R20/4 Potentiometer AUX4 X14/14 14-pin plug connection
5 9
4
Ω
A13 Roof print R20/5 Potentiometer AUX5 X14/15 14-pin plug connection
9 Ω A14 Engine print S2/7/3 Switch, hydraulic master X18/4 18-pin plug connection
1 A30 Print ARU S34 Switch AUX5 X21 14-pin plug connection
2 A29 Joystick S35 Joystick pushbutton X24/2 24-pin plug connection
Ω A31 Multi controller S60/6 AUX blue pushbutton X30/1 14-pin plug connection
X30/6 A60 ECCU2 S60/8 Shift pushbutton X30/4 4-pin plug connection
8 B30 Joystick (float position) X30/5 2-pin plug connection
9
N longitudinal direction AUX1 X3/10 3-pin plug connection X30/6 8-pin plug connection
2 B31 Joystick X4/83 4-pin plug connection X30/7 4-pin plug connection
6 N
transverse direction AUX2 X4/90 4-pin plug connection X30/11 16-pin plug connection
3
N B52 Selector lever AUX4 X4/91 4-pin plug connection X30/12 4-pin plug connection
 7 CN1a 26-pin plug connection X4/92 4-pin plug connection X30/15 6-pin plug connection

 4 Ω CN3a 26-pin plug connection X4/93 4-pin plug connection X30/16 6-pin plug connection
2 P8 ICU X4/94 4-pin plug connection X30/19 2-pin plug connection
4 P8 10-pin plug connection X10/3 10-pin plug connection (7) Ground point, roof hood, left
8 P8/1 4-pin plug connection X10/9 10-pin plug connection (8) Ground point, roof hood, right
1 R20/1 Potentiometer AUX1 X10/11 10-pin plug connection (11) Ground point,
5 R20/2 Potentiometer AUX2 X10/12 10-pin plug connection engine cable carrier, rear
7
R20/3 Potentiometer AUX3 X10/14 10-pin plug connection

Sva 6-93221 EN Edition 06-2006

4008A-28

BLANK PAGE

Sva 6-93221 EN Edition 06-2006

 4008A-29

)81&7,21$/6&+(0$7,&',$*5$0)255(027(&21752/9$/9(6$'',7,21$/)81&7,216

$(&&8 CN1a X4/83 X4/90 $8;

CN1a CAN H
3
CAN H
3
GSV4 15
10 CAN L CAN L
16 4 2
6 CAN +
1
CAN +
1
CAN - CAN -


2 4

3 X10/9 CN3a
X4/91 $8;
X10/9 6 1 8 1 6.4 V with EDC ON
$ CAN H
X24/2 3
2 8 2 6 4 6.4 V with EDC and AUX ON )$ CAN L
 24 (11) 2
CAN +
1
$505(67 X14/15 CAN -
)$ 4
 12


6 
X18/4 CN3a X4/92 $8;
X18/4 
RAISE CAN H
1 6 17 6.4 V with pushbutton pressed 3
12 3 LOWER CAN L
7 7 16 6.4 V with pushbutton pressed 2
$ X10/11 CAN +
1
6 7 CAN -
4
X10/12 6 $
2))
CN3a X10/14 X10/3
21
)$ X4/93 $8;
7 6 
CAN H
1 2 12 6.4 V with pushbutton pressed 3
 Ω CAN L
6 2
CAN +
4 X14/14 1
CAN -
2))
21
4

1 2 13 6.4 V with pushbutton pressed (7)

 Ω P8 7 5 3 (8) X4/94 $8;
6 3,&8 CAN H
3
P8/1
CAN L CAN L
2))
4 2
CAN H CAN +
X4/72 21
X4/72 3 1
CAN -
3 1 2 2 10 6.4 V with pushbutton pressed 4
 Ω
6 A X3/10 B
2))

X4/72 21
X4/72 120 Ω
4 1 2 1 11 6.4 V with pushbutton pressed
 Ω
A12 Central print X4/69 4-pin plug connection
6 A13 Roof print X4/72 4-pin plug connection
A14 Engine print X4/83 4-pin plug connection
2 X4/69 2)) A60 ECCU2 X4/90 4-pin plug connection
21
X4/69 B19 Angle of rotation sensor for front power lift X4/91 4-pin plug connection
CN1a 26-pin plug connection X4/92 4-pin plug connection
1 2 3 23 6.4 V with pushbutton pressed CN3a 26-pin plug connection X4/93 4-pin plug connection
 Ω
6 CN3b 34-pin plug connection X4/94 4-pin plug connection
P8 ICU X10/3 10-pin plug connection
P8 10-pin plug connection X10/9 10-pin plug connection
2)) P8/1 4-pin plug connection X10/11 10-pin plug connection
21
X4/69 S2/7/3 Switch, hydraulic master X10/12 10-pin plug connection
1 2 1 26 6.4 V with pushbutton pressed S14/3 External pushbutton, front power lift LOWER X10/14 10-pin plug connection
 Ω S15/3 External pushbutton, front power lift, RAISE X14/14 14-pin plug connection
CN3b S18/1 External pushbutton, AUX BLUE pressure in - X14/15 14-pin plug connection
12 S18/2 External pushbutton, AUX BLUE pressure in + X18/4 18-pin plug connection
X3/22 S19/1 External pushbutton, AUX BROWN pressure in - X24/2 24-pin plug connection
8V
3 3 CN3a S19/2 External pushbutton, AUX BROWN pressure in + (7) Ground point, roof hood, left
% 2 2 8 2.5 to 4.7 V S28/1 Switch for front power lift management (8) Ground point, roof hood, right
X3/10 3-pin plug connection (11) Ground point, engine cable carrier, rear
8 1 1
GND
CN1a X3/22 3-pin plug connection
23

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4008A-30

BLANK PAGE

Sva 6-93221 EN Edition 06-2006

 4008A-31

)81&7,21$/6&+(0$7,&',$*5$0)25)5217$;/(:,7+,1'(3(1'(176863(16,21
$
X4/45
)$
1 
)$
2 

*1'

16 X24/1

2 X2/46

X12/20 8 6 9 10

$
6XSSO\
6



X12/20
7 2 12V when LOWERING
3
1 3 12V when RAISING $$',&
X12/20 X4/45 $ X24/1 CN1
0 V LED ON
11 3 5 13 12 V LED OFF
6



X12/20
7 4 12V with axle locked (OFF)
3
1 5 12V with pushbutton pressed
(calibration)
0V with management

<
GND
1
GND
1 C
% 12V 12 V when RAISING
2 A 2
A1 ADIC , 3 B 7.3 to 16.5 mA
A12 Central print
A60 ECCU2
A61 Electronics, front axle with independent
suspension <
GND GND
B33/1 Angle of rotation sensor, LEFT 1 C 1
B33/2 Angle of rotation sensor, RIGHT % 12V
2 A
CN1 26-pin plug connection , 12 V when RAISING and LOWERING
CN1a 26-pin plug connection 3 B 7.3 to 16.5 mA 2
S2/15/1 Switch, front axle with independent
suspension UP/ DOWN
S2/15/2 Switch, front axle with independent
suspension ON/ OFF <
X2/45 2-pin plug connection $(&&8 CN1a GND
X2/45 X12/20 1
X2/46 2-pin plug connection
X4/45 4-pin plug connection 6 1 12 12V when v > 14 km/h
X12/20 12-pin plug connection 12 V when RAISING and LOWERING 2
X24/1 24-pin plug connection
Y14 Solenoid valve, UP / DOWN (black)
Y15 Solenoid valve, LEFT (blue)
Y16 Solenoid valve, RIGHT (green)

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4008A-32

BLANK PAGE

Sva 6-93221 EN Edition 06-2006

 4008A-33

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SS06E002

Sva 6-93221 EN Edition 06-2006

4008A-34

BLANK PAGE

Sva 6-93221 EN Edition 06-2006

 4008A-35

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SS06E003

Sva 6-93221 EN Edition 06-2006

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CNH Österreich GmbH Sva 6-92970 EN © 2005 CNH Österreich GmbH

Technical Documentation July 2005
A - 4300 St. Valentin, Steyrer Strasse 32
 4009-3

7$%/(2)&217(176
WIRING HARNESS CODING ................................................................................................................................7

MAIN CONNECTOR ..............................................................................................................................................8

CONTROLLER AND PRINTS ..............................................................................................................................11

FLYING FUSES AND RELAYS ...........................................................................................................................13

IDENTIFICATION AND COLOUR CODING OF CABLES ...................................................................................14

Abbreviations ..............................................................................................................................................15

ENGINE BONNET WIRING HARNESS ..............................................................................................................16

ENGINE WIRING HARNESS ..............................................................................................................................20

1. Additional line 2. alternator, Magneton 95 A ...........................................................................................33
2. Additional line for 7-pin trailer socket and power socket, front................................................................33
3. Additional line for angle of rotation sensor, front.....................................................................................33
4. Additional line for speed sensor, PTO front ............................................................................................33
5. Additional line for fuel-water separator sensor........................................................................................33
6. Additional line for reversible fan ..............................................................................................................33
7. Additional line for battery ground ............................................................................................................34
8. Additional line for battery starter + ..........................................................................................................34
9. Additional line for electrical battery main switch + ..................................................................................34
10. Additional line for electrical starter main switch + .................................................................................34
11. Additional line for Magneton alternator .................................................................................................35
12. Additional line for Denso alternator .......................................................................................................35
13. Additional line for main switch battery +................................................................................................35
14. Additional line for main switch starter + ................................................................................................35

INSTRUMENTS WIRING HARNESS ..................................................................................................................42

1. Additional line 2. alternator .....................................................................................................................53
2. Additional line for electrical battery main switch .....................................................................................53
3. Additional line for single wheel, sprung front axle ...................................................................................53
4. Additional line for Webasto heater ..........................................................................................................53

CAB WIRING HARNESS ON RIGHT ..................................................................................................................60

1. Additional line for bridge, Molex 2-pin.....................................................................................................76
2. Additional line for mobile phone precaution ............................................................................................76
3. Additional line for lifting/pressure ............................................................................................................76
4. Additional line for hydraulic trailer brake .................................................................................................77
5. Additional line for hydraulic trailer brake solenoid valve .........................................................................77
6. Additional line for standard signal socket T1 ..........................................................................................77
7. Additional line for standard signal socket T2 ..........................................................................................77
8. Additional line for radar sensor ...............................................................................................................77
9. Additional line for power socket, additional monitor, cab ........................................................................77
10. Additional line for additional side marker lights, wide tyres...................................................................77

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4009-4

CONTROL PANEL WIRING HARNESS, RIGHT ................................................................................................ 84

1. Additional line for potentiometer for nominal value and EDC lighting .................................................... 91
2. Additional line for potentiometer for lifting limitation ............................................................................... 91
3. Additional line for potentiometer for mixing ............................................................................................ 91
4. Additional line for potentiometer for lowering speed .............................................................................. 91
5. Additional line for potentiometer for slip control ..................................................................................... 91
6. Additional line for potentiometer for limit load ........................................................................................ 91
7. Additional line for potentiometer for panel lighting ................................................................................. 91

CARTRIDGE WIRING HARNESS ...................................................................................................................... 94

1. Additional line for Linde electronics - hydrostat...................................................................................... 99

CAB WIRING HARNESS ON LEFT .................................................................................................................. 101

1. Additional line 2. power socket, rear .................................................................................................... 105
2. Additional line for trailer socket, 7-pin, front ......................................................................................... 105

ROOF SUPPLY WIRING HARNESS ................................................................................................................ 107

ROOF WIRING HARNESS ............................................................................................................................... 110

1. Additional line for turn signal side marker lights and worklights, front left and right ............................. 120
2. Additional line for side marker lights, front left and right (wide tyres) ................................................... 121
3. Additional line for side marker lights and additional light, front left and right........................................ 121
4. Additional line for auxiliary headlights and worklights .......................................................................... 121
5. Additional line for number plate lighting ............................................................................................... 121
6. Additional line for all-round light bar ..................................................................................................... 121
7. Additional line for 6 worklights.............................................................................................................. 123
8. Additional line for electrical mirror adjustment and heating.................................................................. 123
9. Additional line for air conditioning system ............................................................................................ 123
10. Additional line for solenoid, all-round light, standard socket .............................................................. 123
11. Additional line for all-round light ......................................................................................................... 123
12. Additional line for wiper, hinged windscreen, front ............................................................................. 123
13. Additional line for blower ventilation ................................................................................................... 125
14. Additional line for front heated windscreen ........................................................................................ 125
15. Additional line for rear heated windscreen ......................................................................................... 125
16. Additional line for mirror heating......................................................................................................... 125
17. Additional Xenon worklight ................................................................................................................. 125

ELECTRICAL REMOTE CONTROL VALVES WIRING HARNESS ................................................................. 144

1. Additional line for external button, powerlift, front ................................................................................ 147
2. Additional line for external button for front remote control valves ........................................................ 147

REVERSE TRAVEL EQUIPMENT WIRING HARNESS ................................................................................... 150

1. Additional line for wash tank extension ............................................................................................... 157
2. Additional line for rear wiper extension ............................................................................................... 157

ISO BUS WIRING HARNESS ........................................................................................................................... 160

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 4009-5

COMPONENTS .................................................................................................................................................167
Armrest .....................................................................................................................................................167
Central print A12 (Würth) ..........................................................................................................................168
Central print A12 (Berifors) .......................................................................................................................170
Roof print A13 (Würth) ..............................................................................................................................172
Roof print A13 (Berifors) ...........................................................................................................................173
Engine print A14 (Würth) ..........................................................................................................................174
Engine print A14 (Berifors)........................................................................................................................175
EDC print A16 (Würth) ..............................................................................................................................176
EDC print A16 (Berifors) ...........................................................................................................................177
Can module A27 and plug module A28 to DBD094270............................................................................178
Print ARU A30 as of DBD094271 .............................................................................................................179
Relays .......................................................................................................................................................180
Components - engine and fuel system .....................................................................................................182
Components - transmission ......................................................................................................................186
Components - differential lock ..................................................................................................................189
Components - front PTO...........................................................................................................................190
Components - rear PTO...........................................................................................................................190
Components - individual wheel, sprung front axle ....................................................................................191
Components - brake .................................................................................................................................192
Components - reverse travel equipment...................................................................................................194
Components - hydraulics ..........................................................................................................................196
Components - EDC...................................................................................................................................198
Components - front powerlift.....................................................................................................................199
Components - air conditioning system......................................................................................................200
Components - cab.....................................................................................................................................203

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 4009-7

:,5,1*+$51(66&2',1*

+/ Engine bonnet wiring harness &/ Cab wiring harness, left

(0 Engine wiring harness 56 Roof supply wiring harness
&, Instruments wiring harness 50 Roof wiring harness
&5 Cab wiring harness, right $9 Electrical remote control valves wiring harness
&' Control panel wiring harness, right 5' Reverse travel equipment wiring harness
&$ Cartridge wiring harness ,% ISO BUS wiring harness

Sva 6-92970 EN Edition 07-2005

4009-8

0$,1&211(&725

; Plug connection for worklight, ; Plug connection for cab wiring harness on right -
engine bonnet and horn engine wiring harness
; Plug connection for engine wiring harness
; Plug connection for headlight
(Berifors)
; Plug connection for engine wiring harness
; Plug connection for EEM2 engine control unit
(Würth)
; Plug connection for instruments wiring harness -
engine wiring harness

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 4009-9

$ FMGR plug connection (white) &1 Plug connection for ISO-BUS
$ FMGR plug connection (dark grey) ; Plug connection for cab wiring harness on right -
$ FMGR plug connection (blue) control panel

; Plug connection for cab wiring harness on right-

$ FMGR plug connection (grey)
control panel
&1D Plug connection for ECCU2 ; SGR plug connection
&1E Plug connection for ECCU2 ; Plug connection for EDC box

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4009-10

; Plug connection for instruments wiring harness -

: Plug connection for radio start
central print
; Screw-plug connection for ; Plug connection for central print -
potential, 15/2 central print cab wiring harness on left
; Plug connection for sprung front axle ; Plug connection for roof print supply
; Plug connection for trailer brake „Italy“ -
; Plug connection for roof supply
central print
; Plug connection for central print -
;D Plug connection for LIMP HOME [A]
roof supply
; Plug connection for instruments wiring harness -
;E Plug connection for LIMP HOME [A]
central print
; Plug connection for instruments wiring harness -
;F Plug connection for LIMP HOME [B]
central print
; Screw-plug connection for ; Plug connection for cab wiring harness on right-
potential 31, central print central print

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 4009-11

&21752//(5$1'35,176

$ ADIC $ CAN module (up to DBD094270)

$ EEM2 control unit $ Plug module (up to DBD094270)
$ PCU electronic pumps - control unit $ Print ARU (as of DBD094271)
$ Engine print (Würth or Berifors) $ Electronics, sprung front axle
$ SGR - transmission controller $ KEY PADS
$ Linde electronics

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4009-12

$ FMGR $ Blower control

$ Central print (Würth or Berifors) $ EDC control unit
$ Roof print $ ECCU2
$ EDC print $ Worklight panel
$ Electronics, Xenon worklight, right 3 Display (for reverse travel equipment)
$ Electronics, Xenon worklight, left 3 ICU
$ Air conditioning control

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 4009-13

)/<,1*)86(6$1'5(/$<6

)XVHV
F80 Potential 30 ISO-BUS ............................ 20 A F87 Electrical battery main switch,
F81 Potential 30 ISO-BUS ............................ 25 A potential 30.............................................10 A
F82 Potential 30 ISO-BUS ............................ 40 A F104 Engine preheating, potential 30..............20 A
F200 Main fuse .............................................200 A

5HOD\V
K4/2/2 Time relay for interior light (reverse travel equipment)
K5/16 Relay for reversible fan K5/80 Relay for potential 15 ISO-BUS
K5/37 Relay for trailer brake, Italy K5/81 Relay for ECU power, ISO-BUS
K5/42 Relay D+ 2nd alternator K5/82 Relay for power socket, ISO-BUS
K5/54 Relay for electrical battery main switch [54] K6/7 Relay, heated rear window
K5/60 Relay for coupling (reverse travel equipment) K6/8 Relay, heated windscreen
K5/61 Relay for front accelerator K8/2 Relay for heating flange 300A
(reverse travel equipment) Q2 Relay for electrical battery main switch
K5/62 Relay for rear accelerator V8/1 ISO-BUS diode group

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4009-14

,'(17,),&$7,21$1'&2/285&2',1*2)&$%/(6
All the cables of a plug on a wiring harness are colour coded.
Below you will find the list of the colours used and their code letters.

&DEOHFRORXURUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH &RGHOHWWHU &RORXU 7\SHRIXVH
A Red Potential 30 (continuous H Orange VDC, stabilised by the E-box
current)
B Beige -- control line (ground end) K Bright blue D+
C White + control line (positive end) L Brown Ground via a box
D Yellow + 15 Si (Potential 15 safety) M Ground strap
E Grey Potential 58 lighting N Pink
F Green Signal line P Colourless Reserve
G Violet + potential 15 (15.1 or 15.2) Black Ground, directly
power activated following to a grounding point
the start switch

127( 7KHÄ&$1+³DQGÄ&$1/³FDEOHVGRQRWFRUUHVSRQGWRWKHDIRUHPHQWLRQHGVWDQGDUG
Ä&$1+³LV\HOORZDQGÄ&$1/³LVJUHHQ

&DEOHFRGHV
The individual wiring harnesses, the assignment of
plugs on the wiring harness and their precise locations
are described in detail on the following pages. The pre-
cise pin assignment and cable codes of the individual
cables are specified for all plugs.

7KHFDEOHFRGHVDUHVWUXFWXUHGDVIROORZV
1. Number of plug bush (pin)
2. Abbreviation - wiring harness
3. Code letter - cable colour
4. Cable number

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 4009-15

$EEUHYLDWLRQV
ADIC............................................................................................................................. Analogue/ digital instrument
ARU.............................................................................................................................................................. Armrest
AUX.........................................................................................................................................Remote control valve
BB light.......................................................................................................................Turn signal side marker lights
DZG.............................................................................................. Signal of crankshaft position (upper dead point)
DMM..............................................................................................................................................Digital multimeter
ECCU2 ....................................................................................................................................... Central control unit
EDC................................................................................................................................Electronic powerlift control
Engine control unit ........................................................................................................................................ (EEM)
FMGR.......................................................................................................Vehicle - engine - transmission controller
GSV .................................................................................................................................................... Cyclic supply
HTS ............................................................................................. Field end management (headland management)
ICU .................................................................................................................................................... Power monitor
KEY PADS ...................................................................................... Function keys for analogue / digital instrument
NTC.......................................................................................................................Negative temperature coefficient
PCB....................................................................................Printed circuit board (relay circuit, terminal resistance)
PCU......................................................................................................................... Electronic pumps - control unit
PTC ....................................................................................................................... Positive temperature coefficient
SBB light .......................................................................................................... Final turn signal side marker lights
SGR .................................................................................................................................... Transmission controller

127( 7KHGHWDLOVLQVTXDUHEUDFNHWV>[[@DUHZULWWHQRQWKHSOXJ

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4009-16

(1*,1(%211(7:,5,1*+$51(66

 Ground point, engine component carrier Fig. 1 ( Worklight, right Fig. 3
( Headlight, left Fig. 2 + Signal horn Fig. 2
; Plug connection for worklight,
( Headlight, right Fig. 3
engine bonnet and horn Fig. 4
( Headlight, left Fig. 2 ; Plug connection for headlight Fig. 4

Sva 6-92970 EN Edition 07-2005

 4009-17

3OXJSRVLWLRQVDQGSLQDVVLJQPHQWV

Fig. 1

Fig. 2

Sva 6-92970 EN Edition 07-2005

4009-18

Fig. 3

Fig. 4

Sva 6-92970 EN Edition 07-2005

 4009-19

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4009-20

(1*,1(:,5,1*+$51(66

Sva 6-92970 EN Edition 07-2005

 4009-21

; Screw-plug connection for engine print,

 Ground point, engine component carrier Fig.1
Denso alternator, potential 15 Fig.3
$B*1' Screw connection for ground point, ; Plug connection for temperature sensor
engine control unit Fig.18 EEM2 [22] Fig.13
' 2. alternator G2/2/2 [D+] Fig.2 ; Plug connection for reversible fan [LU] Fig.3
; Plug connection for
( Heating flange Fig.4
„Water in fuel “ [WIF] sensor Fig.3
; Plug connection for
)LOWHUKJ Filter heating Fig.2
engine speed sensor Fig.16
)/ Button for front loader solenoid ; Plug connection for speed sensor,
valve [Fl+] Fig.5 PTO, front Fig.5
. Plug connection for relay, ; Plug connection for angle of rotation sensor,
300A heating flange Fig.6 power lift, front [LAGE] Fig.5
0B*1'Screw connection for ground point, ; Plug connection for worklight,
Fuel delivery pump Fig.7 engine bonnet and horn Fig.17
; Plug connection for external button,
0 Fuel delivery pump Fig.7
power lift, front [FHW] Fig.5
; Plug connection for sensor for charge air
6 Test switch for air filter Fig.10
pressure, charge-air temperature Fig.4
; Plug-in connection for external pushbutton,
6 Test switch for brake fluid Fig.8
frontAUX brown [EHS] Fig.5
; Plug connection for fuel injection
6 Test switch for coolant level Fig.9
pump [7] Fig.19
; Plug connection for engine wiring harness
6 Pushbutton for air conditioning system Fig.11
(Würth) Fig.14
; Plug connection for instruments wiring
; Plug connection for terminal 50, starterFig.2
harness - engine wiring harness Fig.15
; Plug connection for fuel filter ; Plug connection for cab wiring harness on
pressure sensor Fig.7 right - engine wiring harness Fig.15
; Screw connection for engine print, ; Plug connection for engine wiring harness
potential 30, EEM 2 Fig.12 (Berifors) Fig.14
; Screw connection for engine print, ; Plug connection for EEM2 engine control
potential 30 Fig.2 unit Fig.18
; Screw connection for engine print,
< Plug connection for magnetic coupling,
potential 30, EEM2,
air conditioning compressor Fig.11
fuel delivery pump Fig.12
; Screw-plug connection for
engine print, potential 31 Fig.3

Sva 6-92970 EN Edition 07-2005

4009-22

0 Screw connection for starter,

) Screw connection for main fuse Fig.20
potential 30 Fig.23
*% Screw connection for alternator,
6 Pushbutton for engine oil Fig.23
120A Magneton Fig.21
*% Screw connection for alternator, ; Plug connection for potential 30,
140A Denso Fig.22 clock / radio Fig.24
0 Plug connection for starter,
; Plug connection for alternator Fig.25
terminal 50 Fig.23

Sva 6-92970 EN Edition 07-2005

 4009-23

3OXJSRVLWLRQVDQGSLQDVVLJQPHQWV

Fig. 1

Fig. 2

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4009-24

Fig. 3

Fig. 4

Sva 6-92970 EN Edition 07-2005

 4009-25

Fig. 5

Fig. 6

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4009-26

Fig. 7

Fig. 8

Fig. 9

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 4009-27

Fig. 10

Fig. 11

Fig. 12

Fig. 13

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4009-28

Fig. 14

Fig. 15

Fig. 16

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 4009-29

Fig. 17

Fig. 18

Fig. 19

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Fig. 20

Fig. 21

Fig. 22

Fig. 23

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 4009-31

Fig. 24

Fig. 25

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4009-32

Sva 6-92970 EN Edition 07-2005

 4009-33

$GGLWLRQDOOLQHDOWHUQDWRU0DJQHWRQ$
' Plug connection 2. alternator, *% Screw connection for alternator,
G2/2/2 Magneton 95A [D+] Fig. 101 Magneton 95A Fig. 101
; Screw connection for engine print,
' Plug connection 2. alternator Fig. 102
potential 30 Fig. 102

$GGLWLRQDOOLQHIRUSLQWUDLOHUVRFNHWDQGSRZHUVRFNHWIURQW
 Ground point, engine component
; Trailer socket, 7-pin, front Fig. 106
carrier Fig. 103
; Plug connection for 7-pin trailer
; Power socket, front Fig. 106
socket, front [7pol.vo] Fig. 104
; Screw connection for engine print,
power socket,
front, potential 30 Fig. 105

$GGLWLRQDOOLQHIRUDQJOHRIURWDWLRQVHQVRUIURQW
% Angle of rotation sensor ; Plug connection for angle of rotation sensor
[LAGESENSOR VO] Fig. 107 [LAGE] Fig. 108

$GGLWLRQDOOLQHIRUVSHHGVHQVRU372IURQW
; Plug connection for speed sensor,
% Plug connection for speed sensor Fig. 109
PTO front [PTO] Fig. 110

$GGLWLRQDOOLQHIRUIXHOZDWHUVHSDUDWRUVHQVRU
; Plug connection for ; Plug connection for
water in fuel [WIF] Fig. 111 sensor B23 [WIF] Fig. 112

$GGLWLRQDOOLQHIRUUHYHUVLEOHIDQ
; Plug connection for
. Relay for reversible fan Fig. 113
reversible fan [LU] Fig. 115
; Plug connection for
; Screw connection for reversible fan Fig. 114
reversible fan [LU] Fig. 116

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4009-34

$GGLWLRQDOOLQHIRUEDWWHU\JURXQG
 Screw connection for battery ground -
* Battery terminal Fig. 117
starter Fig. 117

$GGLWLRQDOOLQHIRUEDWWHU\VWDUWHU
; Plug connection for potential 30,
* Battery terminal Fig. 118
clock / radio Fig. 118
0 Starter Fig. 119

$GGLWLRQDOOLQHIRUHOHFWULFDOEDWWHU\PDLQVZLWFK
; Plug connection for potential 30,
* Battery terminal Fig. 118
clock / radio Fig. 118
4 Electrical main switch Fig. 120

$GGLWLRQDOOLQHIRUHOHFWULFDOVWDUWHUPDLQVZLWFK
0 Starter Fig. 119 4$ Electrical main switch Fig. 120

Sva 6-92970 EN Edition 07-2005

 4009-35

$GGLWLRQDOOLQHIRU0DJQHWRQDOWHUQDWRU
* Plug connection for alternator,
; Plug connection for alternator Fig. 121
Magneton 120A, terminal D+, W Fig. 121

$GGLWLRQDOOLQHIRU'HQVRDOWHUQDWRU
* Plug connection for alternator,
; Plug connection for alternator Fig. 122
Denso 140A G2/3 Fig. 122

$GGLWLRQDOOLQHIRUPDLQVZLWFKEDWWHU\
; Plug connection for potential 30,
* Battery terminal Fig. 118
clock / radio Fig. 118
4 Main switch Fig. 123

$GGLWLRQDOOLQHIRUPDLQVZLWFKVWDUWHU
0 Starter Fig. 124 4 Main switch Fig. 124

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3OXJSRVLWLRQVDQGSLQDVVLJQPHQWV

Fig. 101

Fig. 102

Fig. 103

Fig. 104

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 4009-37

Fig. 105

Fig. 106

Fig. 107

Fig. 108

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4009-38

Fig. 109

Fig. 110

Fig. 111

Fig. 112

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 4009-39

Fig. 113

Fig. 114

Fig. 115

Fig. 116

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Fig. 117

Fig. 118

Fig. 119

Fig. 120

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Fig. 121

Fig. 122

Fig. 123

Fig. 124

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4009-42

,167580(176:,5,1*+$51(66

Sva 6-92970 EN Edition 07-2005

 4009-43

; Plug connection for

 Ground point, engine component carrier Fig.1
Optistop brake light Fig.12
 Ground point for cab Fig.2 ; Plug connection for headlight Fig.13
; Plug connection for engine
 Ground point for starter Fig.3
preheating precaution [WEBASTO] Fig.11
% Angle of rotation sensor for clutch Fig.4 ; Plug connection for heating Fig.14
&1 Plug connection for ADIC Fig.5 ;D Plug connection for LIMP HOME [A] Fig.15
&1 Plug connection for ADIC Fig.5 ;E Plug connection for LIMP HOME [A] Fig.15
;F Plug connection for LIMP HOME,
&1 Plug connection for ADIC Fig.5
black [B] Fig.15
' 2. alternator G2/2/2 [D+] Fig.6 ; Plug connection for ADIC diagnosis Fig.15
6 Start switch Fig.7 ; Plug connection for keypads Fig.5
; Screw-plug connection for
6 Light switch [LICHT] Fig.7
potential 31, central print Fig.15
; Plug connection for
6 Hazard warning light switch [WARN] Fig.7
front parallel wipers Fig.16
6 Switch for parking interlock ; Plug connection for instruments
[PARKBREMSE] Fig.7 wiring harness - steering column [3] Fig.17
; Plug connection for instruments
6 Pushbutton for reversible fan Fig.7
wiring harness - central print [6] Fig.15
; Plug connection for cab wiring harness on
6 Clutch switch 80% Fig.4
left - instruments wiring harness [10] Fig.16
6 Blower switch 1-2-3 Fig.7 ; Plug connection for standard signal Fig.16
; Screw connection for central print ; Plug connection for roof supply wiring
supply, potential 30, start switch Fig.8 harness Fig.16
; Screw connection for central print, ; Plug connection for instruments
potential 30 Fig.8 wiring harness - steering column [8] Fig.17
; Screw connection for engine print, ; Plug connection for instruments
potential 30 Fig.9 wiring harness - central print [1] Fig.19
; Plug connection for potential 15/2, ; Plug connection for instruments wiring
15 A, blower, heating Fig.8 harness - engine wiring harness Fig.20
; Plug connection for potential 58/31, ; Plug connection for instruments
sprung front axle [GE.VA] Fig.10 wiring harness - central print [1] Fig.19
; Plug connection for cab wiring harness on ; Plug connection for instruments wiring
right - harness-
instruments wiring harness ISOBUS Fig.11 - cab wiring harness on right [3] Fig.21

Sva 6-92970 EN Edition 07-2005

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Fig. 1

Fig. 2

Fig. 3

Fig. 4

Sva 6-92970 EN Edition 07-2005

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Fig. 5

Fig. 6

Sva 6-92970 EN Edition 07-2005

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Fig. 7

Sva 6-92970 EN Edition 07-2005

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Fig. 8

Fig. 9

Fig. 10

Sva 6-92970 EN Edition 07-2005

4009-48

Fig. 11

Fig. 12

Fig. 13

Fig. 14

Sva 6-92970 EN Edition 07-2005

 4009-49

Fig. 15

Sva 6-92970 EN Edition 07-2005

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Fig. 16

Fig. 17

Sva 6-92970 EN Edition 07-2005

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Fig. 19

Fig. 20

Fig. 21

Sva 6-92970 EN Edition 07-2005

4009-52

Sva 6-92970 EN Edition 07-2005

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. Relay D+ 2nd alternator Fig. 101 6 Start switch Fig. 102
; Plug connection for central print,
/ Indicator lamp 2. alternator Fig. 102
potential 15/2 Fig. 103
; Screw-plug connection for
/ Indicator lamp 2. alternator Fig. 102
potential 31, central print Fig. 103

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) Fuse for electrical ; Plug connection for central print,
battery main switch, potential 30 Fig. 104 potential 15/2 Fig. 108
. Relay for electrical ; Plug connection for indicator - electrical
battery main switch [54] Fig. 105 battery main switch [10] Fig. 104
;D Plug connection for potential 58/31,
4 Screw connection 30
electrical
for electrical battery main switch Fig. 106
battery main switch [46a] Fig. 109
;E Plug connection for potential 58/31,
4 Screw connection for electrical
electrical
battery main switch, control circuit Fig. 106
battery main switch [X2/46b] Fig. 109
4 Screw connection for electrical ; Screw-plug connection for
battery main switch, control circuit Fig. 106 potential 31, central print Fig. 108
6 Switch for electrical
battery main switch [BATT.-HS] Fig. 107

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6 Switch for sprung front axle ; Plug connection for potential 58/31,
UP/DOWN [VA auf/ab] Fig. 110 sprung front axle [VA] Fig. 112
6 Switch for sprung ; Plug connection for
front axle ON/OFF [VA ein] Fig. 110 sprung front axle [45] Fig. 113
; Plug connection for cab wiring harness on
; Plug connection for control block,
right - additional line for sprung
sprung front axle [VA] Fig. 114
front axle [45] Fig. 111

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) Fuse for engine preheating, ; Plug connection for fuel delivery pump,
potential 30 Fig. 115 engine preheating Fig. 117
* Screw connection for battery terminal, ; Plug connection for supply,
potential 30 Fig. 115 engine preheating, potential 30 Fig. 118
; Plug connection for diagnosis, ; Plug connection for engine preheating
engine preheating [DIAG] Fig. 116 precaution [WEBASTO] Fig. 119
; Plug connection for clock timer - ; Plug connection for engine preheating,
control unit for engine preheating [16]Fig. 116 clock Fig. 120
; Screw-plug connection for ; Plug connection for engine preheating,
engine print, potential 31 Fig. 116 ECU Fig. 118

Sva 6-92970 EN Edition 07-2005

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Fig. 102

Fig. 103

Sva 6-92970 EN Edition 07-2005

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Fig. 104

Fig. 105

Fig. 106

Fig. 107

Sva 6-92970 EN Edition 07-2005

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Fig. 108

Fig. 109

Fig. 110

Sva 6-92970 EN Edition 07-2005

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Fig. 111

Fig. 112

Fig. 113

Fig. 114

Sva 6-92970 EN Edition 07-2005

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Fig. 115

Fig. 116

Fig. 117

Fig. 118

Sva 6-92970 EN Edition 07-2005

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Fig. 119

Fig. 120

Sva 6-92970 EN Edition 07-2005

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 Ground point for starter Fig.1 % Rear PTO shaft speed sensor Fig.4
% EDC angle of rotation sensor
$ FMGR plug connection - white [1] Fig.2
[LAGESENSOR] Fig.5
$ FMGR plug connection -
% Power sensor, left Fig.6
dark grey [2] Fig.2
$ FMGR plug connection - blue [3] Fig.2 % Power sensor, right Fig.7
$ FMGR plug connection - grey [4] Fig.2 &1D Plug connection for ECCU2 Fig.8
$B*1'Screw connection for ground point
&1( Plug connection for ECCU2 Fig.8
ECCU2 Fig.8
% Compressed air sensor Fig.3 &1D Plug connection for ECCU2 Fig.9

Sva 6-92970 EN Edition 07-2005

 4009-61

; Plug connection for

&1E Plug connection for ECCU2 Fig.9
remote control valves [83] Fig.25
;D Plug connection for cab wiring harness on
( Worklight, fender, right Fig.10
right - ISO BUS preparations Fig.25
;E Plug connection for cab wiring harness on
3 Plug connection for ICU CAN [DISP] Fig.12
right -ISO BUS preparations Fig.25
6 External button for LOWER, left ; Screw-plug connection for
[SENKEN] Fig.13 potential 31, central print Fig.26
6 External button for LOWER, right ; Plug connection for
[SENKEN] Fig.10 mobile phone socket, left Fig.22
6 External button for RAISE, left ; Socket for diagnosis service tool
[HEBEN] Fig.13 [DIAGNOSE] Fig.17
6 External button for RAISE, right ; Plug connection for cab wiring harness on
[HEBEN] Fig.10 right - control panel Fig.27
; Plug connection for EDC print -
6 External button for PTO, rear left Fig.13
control panel Fig.28
6 External button for PTO, rear right Fig.11 ; Plug connection for SGR [A21] Fig.29
6 External button for AUX BLUE, pressure in - ; Plug connection for cab wiring harness on
[ATS] Fig.14 right - armrest Fig.30
6 External button for AUX BLUE pressure in + ; Plug connection for cab wiring harness on
[ATH] Fig.14 right - engine wiring harness Fig.31
; Plug connection for cab wiring harness on
6 Switch for engine back pressure brake Fig.15
right - central print [2] Fig.18
; Plug connection for instruments wiring
6 Control switch for feed pressure 1 bar Fig.16 harness -
cab wiring harness on right [3] Fig.32
6 Changeover switch for ; Plug connection for cab wiring harness on
CAN SGR/FMGR Fig.17 right - control panel Fig.27
; Plug connection for central print,
; Plug connection for EDC box Fig.33
potential 15/2 Fig.18
< Solenoid valve for PTO front
; Plug connection for OP.CHG Fig.19
[PTO VO] Fig.32
; Plug connection for lift/pressure Fig.19 < Solenoid valve for PTO rear [PTO] Fig.35
; Plug connection for cab wiring harness on < Solenoid valve for EDC RAISE grey
right - sprung front axle [45] Fig.20 [HEBEN] Fig.36
; Plug connection for cab wiring harness on
< Solenoid valve for EDC, LOWER, black
right - instruments wiring harness
[SENKEN] Fig.37
ISO BUS Fig.21
; Plug connection for < Solenoid valve for AUX heating valve
handbrake switch [25] Fig.22 [HEIZ] Fig.38
;5 Plug connection for < Solenoid valve for differential lock
SBB light, right Fig.11 [DIFF] Fig.35
; Plug connection for Grammer seat Fig.23 < Solenoid valve for brake oil cooling 1 Fig.39
; Plug connection for accelerator [70] Fig.24 < Solenoid valve for brake oil cooling 2 Fig.40

Sva 6-92970 EN Edition 07-2005

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Fig. 1

Fig. 2

Sva 6-92970 EN Edition 07-2005

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Fig. 3

Fig. 4

Fig. 5

Fig. 6

Sva 6-92970 EN Edition 07-2005

4009-64

Fig. 7

Fig. 8

Sva 6-92970 EN Edition 07-2005

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Fig. 9

Fig. 10

Sva 6-92970 EN Edition 07-2005

4009-66

Fig. 11

Fig. 12

Fig. 13

Sva 6-92970 EN Edition 07-2005

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Fig. 14

Fig. 15

Fig. 16

Sva 6-92970 EN Edition 07-2005

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Fig. 17

Fig. 18

Sva 6-92970 EN Edition 07-2005

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Fig. 19

Fig. 20

Fig. 21

Fig. 22

Sva 6-92970 EN Edition 07-2005

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Fig. 23

Fig. 24

Fig. 25

Sva 6-92970 EN Edition 07-2005

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Fig. 26

Fig. 27

Fig. 28

Sva 6-92970 EN Edition 07-2005

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Fig. 29

Fig. 30

Fig. 31

Fig. 32

Sva 6-92970 EN Edition 07-2005

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Fig. 33

Fig. 34

Fig. 35

Sva 6-92970 EN Edition 07-2005

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Fig. 36

Fig. 37

Fig. 38

Fig. 39

Sva 6-92970 EN Edition 07-2005

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Fig. 40

Sva 6-92970 EN Edition 07-2005

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; Plug connection for air conditioning
system Fig. 101

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; Plug connection for
( Mobile phone socket, left Fig. 102
mobile phone socket, left [13] Fig. 103

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6 Changeover switch for lifting / ; Plug connection for lifting /
pressure Fig. 104 pressure Fig. 105

Sva 6-92970 EN Edition 07-2005

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. Relay for trailer brake,
Italy [ITALY] Fig. 106 ; Plug connection for additional line for
trailer brake, Italy,
; Plug connection for trailer brake, trailer brake valve [MGV] Fig. 108
„Italy“, central print [ITALB] Fig. 107

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6 Pushbutton for trailer brake valve Fig. 109 < Solenoid valve, trailer brake Fig. 109
; Plug connection for additional line for
trailer brake, Italy,
trailer brake [MGV] Fig. 110

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; Plug connection for
; Standard signal socket Fig. 112
standard signal socket [NORMS] Fig. 111

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; Plug connection for standard signal
; Plug connection for
socket, instruments wiring harness
standard signal socket [NORMS] Fig. 113
[NORMS] Fig. 114

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; Plug connection for radar sensor,
; Plug connection for radar sensor Fig. 116
central print Fig. 115

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; Screw connection for ; Screw-plug connection for
power socket, cab, 30 A Fig. 117 potential 31, central print Fig. 118
; Plug connection for central print,
; Power socket for cab 30 A Fig. 119
potential 15/2 Fig. 118

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;/ Plug connection for
;/ Plug connection for additional lights Fig. 120
SBB light, left Fig. 122
;5 Plug connection for
;5 Plug connection for additional lights Fig. 121
SBB light, right Fig. 123

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Fig. 102

Fig. 103

Sva 6-92970 EN Edition 07-2005

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Fig. 105

Fig. 106

Fig. 107

Sva 6-92970 EN Edition 07-2005

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Fig. 108

Fig. 109

Fig. 110

Fig. 111

Sva 6-92970 EN Edition 07-2005

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Fig. 112

Fig. 113

Fig. 114

Fig. 115

Sva 6-92970 EN Edition 07-2005

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Fig. 116

Fig. 117

Fig. 118

Fig. 119

Sva 6-92970 EN Edition 07-2005

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Fig. 120

Fig. 121

Fig. 122

Fig. 123

Sva 6-92970 EN Edition 07-2005

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Sva 6-92970 EN Edition 07-2005

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( Cigarette lighter, right [E11] Fig.1 6 Switch for front PTO [PTO VO] Fig.8
+ LED diagnosis Fig.2 6 Switch for rear PTO [PTO HI] Fig.8
6 Switch for rear PTO
+ Slip LED Fig.3
management [PTO M] Fig.8
+ Raise LED Fig.2 6 Switch for traction control [ASR] Fig.3
+ Lower LED Fig.2 ; 2-pin socket 30/31 [2/1] Fig.1
; Plug connection for full-load
6 Switch for hydraulic master [MASTER] Fig.4
potentiometer Fig.10
; Plug connection for
6 Raise / Lower button [INNEN] Fig.4
diagnosis / slip LED [2] Fig.9
; Plug connection for
6 Switch for HTS [HTS] Fig.5
Raise / Lower LED [3] Fig.9
; Plug connection for EDC print -
6 Switch for reducing speed
cigarette lighter,
[DREHZAHLABSENKUNG] Fig.5
2-pin socket [13] Fig.11
6 Switch for differential lock management ; Plug connection for EDC print -
[DIFF HI] Fig.6 armrest (GSV) [4] Fig.9
6 Switch for speed ranges ; Plug connection for cab wiring harness
[RANGE] Fig.7 on right, control panel [9] Fig.12
6 Switch for manual mode ; Plug connection for cab wiring harness
[MAN.MOD] Fig.7 on right, control panel [5] Fig.12
6 Switch for 4-wheel drive management
[4 WD] Fig.6

Sva 6-92970 EN Edition 07-2005

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Fig. 1

Fig. 2

Fig. 3

Sva 6-92970 EN Edition 07-2005

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Fig. 4

Fig. 5

Sva 6-92970 EN Edition 07-2005

4009-88

Fig. 6

Fig. 7

Sva 6-92970 EN Edition 07-2005

 4009-89

Fig. 8

Fig. 9

Sva 6-92970 EN Edition 07-2005

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Fig. 10

Fig. 11

Fig. 12

Sva 6-92970 EN Edition 07-2005

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; Plug connection for potentiometer for nominal value and lighting Fig. 101

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; Plug connection for potentiometer for lifting limitation Fig. 102

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; Plug connection for potentiometer for mixing Fig. 103

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; Plug connection for potentiometer for lowering speed Fig. 104

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; Plug connection for potentiometer for slip control Fig. 105

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; Plug connection for potentiometer for limit load Fig. 106

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; Plug connection for EDC print - potentiometer for control panel lighting, right Fig. 107

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Fig. 102

Fig. 103

Fig. 104

Sva 6-92970 EN Edition 07-2005

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Fig. 106

Fig. 107

Sva 6-92970 EN Edition 07-2005

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$ SGR plug connection, grey Fig.1 6 Switch for 5bar pressure filter Fig.4
$ SGR plug connection, black Fig.1 ; Plug connection for pressure filter Fig.5
$ SGR plug connection, green Fig.1 ; Plug connection for Linde electronics Fig.6
$ SGR plug connection, brown Fig.1 < Solenoid valve for clutch 1 Fig.3
$ Plug connection for speed sensor,
< Solenoid valve for clutch 2 Fig.3
black, planet carrier 1 / 2, B35 Fig.8
$ Plug connection for speed sensor,
< Solenoid valve for clutch 3 Fig.3
grey, cartridge, input B24 Fig.8
$ Plug connection for speed sensor,
< Solenoid valve for clutch 4 Fig.3
brown, planet carrier 3 / 4, B25 Fig.8
$ Plug connection for speed sensor,
< Solenoid valve, clutch, forwards Fig.3
green, cartridge, output B27 Fig.8
$ Plug connection for speed sensor,
< Solenoid valve, clutch, reverse Fig.7
orange, cartridge, output B26 Fig.8
% Temperature sensor, transmission oil Fig.2 < Solenoid valve, parking interlock On Fig.7
% Pressure sensor for transmission system
< Solenoid valve, parking interlock Off Fig.7
pressure Fig.3
% Pressure sensor for transmission lubricating
< 4-wheel drive solenoid valve Fig.7
pressure Fig.3

Sva 6-92970 EN Edition 07-2005

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Fig. 1

Fig. 2

Sva 6-92970 EN Edition 07-2005

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Fig. 3

Sva 6-92970 EN Edition 07-2005

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Fig. 4

Fig. 5

Fig. 6

Sva 6-92970 EN Edition 07-2005

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Fig. 7

Fig. 8

Sva 6-92970 EN Edition 07-2005

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; Plug connection for Linde electronics
$ Plug connection for Linde electronicsFig. 101
- hydrostat A24 Fig. 103
; Plug connection for Linde electronicsFig. 102

Sva 6-92970 EN Edition 07-2005

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Fig. 102

Fig. 103

Sva 6-92970 EN Edition 07-2005

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;/ Plug connection for SBB light,

 Ground point, engine component carrier Fig.1
rear left Fig.3
; Plug connection for cab wiring harness on
% Fuel tank level transmitter, left Fig.2
left - instruments wiring harness [10] Fig.7
; Plug connection for cab wiring harness on
( Worklight, fender, left Fig.3 left - 7-pin trailer socket,
front [7 Pol.Vo] Fig.6
0 Plug connection for motor,
; Trailer socket, 7-pin, rear Fig.8
windscreen washer system, rear [H] Fig.4
0 Plug connection for motor, ; Plug connection for cab wiring harness on
screen washer system, front [F] Fig.4 left - central print [8] Fig.6
; Screw connection
; 1. Power socket 40 A, rear Fig.8
1. Power socket 40 A Fig.5
; Screw connection for central print,
potential 15/2 Fig.6

Sva 6-92970 EN Edition 07-2005

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Fig. 1

Fig. 2

Fig. 3

Fig. 4

Sva 6-92970 EN Edition 07-2005

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Fig. 5

Fig. 6

Fig. 7

Sva 6-92970 EN Edition 07-2005

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Fig. 8

Sva 6-92970 EN Edition 07-2005

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; Screw connection ; Screw-plug connection for
2. power socket 40 A Fig. 101 potential 31, central print Fig. 101
; Plug connection for central print, ; 2. power socket
potential 15/2 Fig. 101 40 A, rear Fig. 102

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; Plug connection for central print, ; Plug connection for 7-pin trailer socket,
potential 15/2 Fig. 103 front [7pol.vo] Fig. 104
; Plug connection for cab wiring harness on
left - 7-pin trailer
socket, front [7pol.vo] Fig. 103

Sva 6-92970 EN Edition 07-2005

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Fig. 102

Fig. 103

Fig. 104

Sva 6-92970 EN Edition 07-2005

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; Plug connection for roof supply

 Ground point, engine component carrier Fig.1
[14] Fig.3
; Screw connection for engine print, ; Plug connection for central print -
potential 30 Fig.2 wiring harness for roof supply [15] Fig.5
; Plug connection for roof ; Screw connection for potential 30,
print supply [11] Fig.3 roof print supply Fig.3
; Plug connection for instruments wiring
; Screw connection for
harness
ground point, roof print Fig.3
roof supply wiring harness [14] Fig.4

Sva 6-92970 EN Edition 07-2005

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Fig. 1

Fig. 2

Fig. 3

Sva 6-92970 EN Edition 07-2005

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Fig. 4

Fig. 5

Sva 6-92970 EN Edition 07-2005

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Sva 6-92970 EN Edition 07-2005

 4009-111

; Plug connection for worklight,

 Roof ground point, front left Fig.1
external rear left Fig.6
; Plug connection for worklight,
 Roof ground point, front right Fig.2
internal rear left Fig.18
; Socket for all-round light, left,
$$ Plug connection for radio Fig.5
magnetic Fig.3
; Socket for all-round light, right,
$% Plug connection for loudspeaker Fig.5
magnetic Fig.4
; [X4/ASW] Plug connection for roof print,
% Loudspeaker on left Fig.6
front worklight Fig.16
; [X4/ESW] Plug connection for roof print,
% Loudspeaker, right Fig.7
auxiliary lamp Fig.16
; Plug connection for roof print,
( Interior light Fig.8
wiper motor, rear [65] Fig.16
;/ Plug connection for
( Spot Fig.9
number plate lighting, roof, left Fig.6
;5 Plug connection for
. Time relay for interior light Fig.10 number plate lighting,
roof, right Fig.7
; Socket for front left auxiliary and
0 Plug connection for rear wiper motor Fig.10
worklight Fig.1
; Socket for auxiliary and
3 ICU plug connection Fig.11
worklight, front right Fig.2
;/ Plug connection for
3 ICU CAN plug connection Fig.11 flashing marker light, front left
[BB-L] Fig.19
;5 Plug connection for
6 Switch for auxiliary lamp Fig.12 flashing marker light, front right
[BB-R] Fig.20
6 Switch for washer/wiper system, rear ; Plug connection for roof print,
[Wi.hi] Fig.12 wiper motor, rear [23] Fig.16
6 Switch for worklights ; Plug connection for roof wiring harness,
4+2, front Fig.12 roof print [12] Fig.16
; Plug connection for roof wiring harness,
6 Switch for left door contact Fig.13
roof print [13] Fig.16
; Plug connection for roof supply
6 Switch for right door contact Fig.14
[14] Fig.21
; Plug connection for wiper motor, ; Screw connection for
hinged windscreen, front [Wi-VO] Fig.15 ground point, roof print Fig.16
; Plug connection for roof print, ; Plug connection for all-round light,
wiper motor, front [17] Fig.16 left Fig.3
; Plug connection for worklights, ; Plug connection for all-round light,
external rear right Fig.7 right Fig.4
; Plug connection for worklights, ; Plug connection for worklight
internal rear right Fig.17 panel Fig.12

Sva 6-92970 EN Edition 07-2005

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Fig. 1

Fig. 2

Sva 6-92970 EN Edition 07-2005

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Fig. 3

Fig. 4

Fig. 5

Sva 6-92970 EN Edition 07-2005

4009-114

Fig. 6

Fig. 7

Sva 6-92970 EN Edition 07-2005

 4009-115

Fig. 8

Fig. 9

Fig. 10

Sva 6-92970 EN Edition 07-2005

4009-116

Fig. 11

Fig. 12

Sva 6-92970 EN Edition 07-2005

 4009-117

Fig. 13

Fig. 14

Fig. 15

Sva 6-92970 EN Edition 07-2005

4009-118

Fig. 16

Fig. 17

Sva 6-92970 EN Edition 07-2005

 4009-119

Fig. 18

Fig. 19

Fig. 20

Fig. 21

Sva 6-92970 EN Edition 07-2005

4009-120

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DQGULJKW
(Plug connection for turn signal, side marker ( Worklight front, right on
and doorway lights, front, left Fig. 101 turn signal - side marker lights Fig. 102
( Plug connection for turn signal ;/ Plug connection for turn signal
side marker lights, front, right Fig. 102 side marker lights, front, left Fig. 103
( Worklight front, left on ;5 Plug connection for turn signal
turn signal - side marker lights Fig. 101 side marker lights front, right Fig. 104

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 4009-121

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( Plug connection for turn signal ( Plug connection for turn signal
side marker lights, front, left Fig. 105 side marker lights, front, right Fig. 107
( Plug connection for turn signal ( Plug connection for turn signal
side marker lights, front, left Fig. 106 side marker lights front, right Fig. 108

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ULJKW
( Additional side marker light, ( Additional side marker light,
front, left Fig. 109 front, right Fig. 111
( Plug connection for turn signal ( Plug connection for turn signal
side marker lights, front, left Fig. 105 side marker lights, front, right Fig. 107
( Plug connection for turn signal ( Plug connection for side marker lights,
side marker lights, front, left Fig. 110 front, right Fig. 112

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 Roof ground point, front, left Fig. 113 ( Auxiliary headlights, right Fig. 116
( Roof worklight front,
 Roof ground point front, right Fig.114
centre, left [M] Fig. 115
; Socket for auxiliary and ( Roof worklight front,
worklight, front, left Fig. 113 centre, right [M] Fig. 116
; Socket for auxiliary and ( Roof worklight front,
worklight, front, right Fig. 114 exterior, left [A] Fig. 115
( Roof worklight front,
( Auxiliary lamp, left Fig. 115
exterior, right [A] Fig. 116

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( Number plate lighting, ;/ Plug connection for number plate lighting,
roof, left Fig. 117 roof, left Fig. 118
( Number plate lighting, ;5 Plug connection for number plate lighting,
roof, right Fig. 117 roof, right Fig. 119

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; (X4/ASW) Plug connection for ; (X4/ESW) Plug connection for
supply, lighting, all-round light bar Fig. 120 supply, lighting, all-round light bar Fig. 120
; Plug connection for
all-round light, left Fig. 121

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( Worklight, roof, front,
 Roof ground point, front left Fig. 122
exterior, right [A] Fig. 125
( Worklight, roof, front,
 Roof ground point, front right Fig. 123
interior, left [I] Fig. 124
( Worklight, roof, front, ( Worklight, roof, front,
centre, left[M] Fig. 124 interior, right [I] Fig. 125
( Worklight, roof, front, ; Socket for auxiliary and
centre, right [M] Fig. 125 worklight, front left Fig. 122
( Worklight, roof, front, ; Socket for auxiliary and
exterior, left [A] Fig. 124 worklight, roof, front, Fig. 123

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; Plug connection for electrical
6 Switch for heated mirror [HEIZSP] Fig. 126
mirror, right [SPIEGEL] Fig. 128
; Plug connection for mirror adjustment, ; Plug connection for electrical
roof print [X3/13] Fig. 127 mirror, left [SPIEGEL] Fig. 129
; Plug connection for heated mirror, ; Plug connection for mirror
roof print [15] Fig. 127 adjustment switch Fig. 126
; Plug connection for switch,
heated mirror, roof print [39] Fig. 127

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; Plug connection for roof print, ; Plug connection for temperature sensor Fig.
supply, blower Fig. 130 132
; Plug connection for blower motor, ; Plug connection for potentiometer,
air conditioning Fig. 131 blower Fig. 132
; Plug connection for supply, ; Plug connection for potentiometer,
air conditioning control Fig. 130 air conditioning control Fig. 132

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; Socket for all-round light, left Fig. 133 ; Socket for all-round light, right Fig. 134

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; Plug connection for all-round light,
$ All-round light, left Fig. 135
left Fig. 135
; Plug connection for all-round light,
$ All-round light, right Fig. 136
right Fig. 136

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; Plug connection for wiper motor,
0 Wiper motor, front Fig. 137
hinged windscreen, front Fig. 138

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; Plug connection for roof print,
0 Motor blower, roof Fig. 139
blower Fig. 141
6 Blower switch 1-2-3, roof Fig. 140

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; Plug connection for roof print,
( Front heated windscreen Fig. 142
fronted heated windscreen [90] Fig. 145
. Relay for heated windscreen, ; Plug connection for switch,
front [HZS VO] Fig. 143 windscreen, front, roof print [41] Fig. 145
6 Switch for heated windscreen, ; Screw connection for
front [HZS VO] Fig. 144 ground point, roof print Fig. 145
; Screw connection for potential 30,
roof print, heated windscreens Fig. 145

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; Plug connection for roof print,
( Rear heated windscreen Fig. 146
rear heated windscreen [91] Fig. 149
. Relay for heated rear windscreen ; Plug connection for switch,
[HZS HI] Fig. 147 windscreen, rear, roof print [42] Fig. 149
6 Switch for heated rear windscreen ; Screw connection for
[HZS HI] Fig. 148 ground point, roof print Fig. 149
; Screw connection for potential 30,
roof print, heated windscreens Fig. 149

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; Plug connection for heated mirror,
( Left heated mirror Fig. 150
roof print [15] Fig. 153
; Plug connection for switch,
( Heated mirror, right Fig. 151
heated mirror, roof print [39] Fig. 153
6 Switch for heated mirror [HEIZSP] Fig. 152

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; Plug connection for electronics, ; Plug connection for headlight,
Xenon, input, right Fig. 154 external right rear Fig. 154
; Plug connection for electronics, ; Plug connection for headlight,
Xenon, input, left Fig. 155 internal rear right Fig. 154
; Plug connection for electronics, ; Plug connection for worklight,
Xenon, output, right Fig. 154 external rear left Fig. 155
; Plug connection for electronics, ; Plug connection for worklight,
Xenon, output, left Fig. 155 internal rear left Fig. 155

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Fig. 101

Fig. 102

Fig. 103

Fig. 104

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Fig. 105

Fig. 106

Fig. 107

Fig. 108

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Fig. 109

Fig. 110

Fig. 111

Fig. 112

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Fig. 113

Fig. 114

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Fig. 115

Fig. 116

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Fig. 117

Fig. 118

Fig. 119

Fig. 120

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Fig. 121

Fig. 122

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Fig. 123

Fig. 124

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Fig. 125

Fig. 126

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Fig. 127

Fig. 128

Fig. 129

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Fig. 131

Fig. 132

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Fig. 133

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Fig. 135

Fig. 136

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Fig. 137

Fig. 138

Fig. 139

Fig. 140

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Fig. 141

Fig. 142

Fig. 143

Fig. 144

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Fig. 146

Fig. 147

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Fig. 148

Fig. 149

Fig. 150

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Fig. 151

Fig. 152

Fig. 153

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Fig. 154

Fig. 155

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; Plug connection for

; Plug connection for AUX 3 Fig.3
terminal resistor Fig.1
; Plug connection for remote control valves
; Plug connection for AUX 4 Fig.4
[EHS] Fig.2
; Plug connection for AUX 1 Fig.3 ; Plug connection for AUX 5 Fig.4
; Plug connection for AUX 2 Fig.3

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Fig. 1

Fig. 2

Fig. 3

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Fig. 4

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 4009-147

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6 External button for powerlift, front, ; Plug connection for external button,
LOWER [Senken] Fig. 101 powerlift, front [FHW] Fig. 102
6 External button for powerlift, front
RAISE [Heben] Fig. 101

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6 External button for AUX BROWN
; Plug connection for external button,
(up to DBD...YELLOW) pressure in -
front AUX brown [EHS] Fig.104
[Senken] Fig. 103
6 External button for AUX BRAUN
(up to DBD...YELLOW) pressure in +
[Heben] Fig. 103

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Fig. 101

Fig. 102

Fig. 103

Fig. 104

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$ FMGR plug connection - white [1] Fig. 1 6 Parking interlock switch [PARK] Fig. 7
$ FMGR plug connection -
6 Horn button [HORN] Fig. 7
dark grey [1] Fig. 2
$ FMGR plug connection -
6 Forwards - reverse switch [V/R] Fig. 7
dark grey [2] Fig. 1
$ FMGR plug connection -
6 Brake light switch [BREMSL] Fig. 8
dark grey [2] Fig. 2
$ FMGR plug connection - grey [4] Fig. 1 6 Clutch switch 80% [KUPPL] Fig. 8
$ FMGR plug connection - ; Plug connection for handbrake switch
dark grey [4] Fig. 2 [HANDBREMSE] Fig. 9
% Angle of rotation sensor for clutch ; Plug connection for handbrake switch
[DW-KUPPL Fig. 3 [HANDBREMSE] Fig. 10
; Plug connection for accelerator
+RUQ Plug connection for horn Fig. 4
[FAHRPEDAL] Fig. 10
; Plug connection for
. Relay for clutch [Kupplung] Fig. 5
mobile phone socket, left Fig. 9
. Relay for front accelerator ; Plug connection for
[FAHRPEDAL1] Fig. 5 mobile phone socket, left Fig. 10
. Relay for rear accelerator ; Plug connection for seat switch
[FAHRPEDAL1] Fig. 5 [SITZ RF] Fig. 11
3 Plug connection for reverse travel equipment
display [DISPLAY] Fig. 6

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Fig. 1

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Fig. 2

Fig. 3

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Fig. 4

Fig. 5

Fig. 6

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Fig. 7

Fig. 8

Fig. 9

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Fig. 10

Fig. 11

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0 Plug connection for motor, 0 Plug connection for motor,
windscreen washer system, rear Fig. 101 screen washer system, front Fig. 101
0 Plug connection for motor, 0 Plug connection for motor,
windscreen washer system, rear Fig. 102 screen washer system, front Fig. 102

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0 Plug connection for motor, 0 Plug connection for wiper motor,
rear angled wiper Fig. 103 hinged windscreen, front Fig. 104

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Fig. 101

Fig. 102

Fig. 103

Fig. 104

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 4009-161

 Screw connection for battery ground - ; Plug connection for potential 30,
starter Fig. 1 ISO-BUS Fig. 4
; Plug connection for LBS socket,
&1 Plug connection for ECCU2 ISO-BUS Fig. 2
ISO-BUS Fig. 8
; Plug connection for cab wiring harness on
) Fuse for potential 30, ISO-BUS Fig. 3 right -
instruments wiring harness ISOBUS Fig. 9
; Plug connection for terminal resistor,
) Fuse for potential 30, ISO-BUS Fig. 3
ISO-BUS Fig. 10
;D Plug connection for cab wiring harness
) Fuse for potential 30, ISO-BUS Fig. 4
on right - ISO-BUS preparations Fig. 11
;E Plug connection for cab wiring harness
) Screw connection for main fuse Fig. 5
on right - ISO-BUS preparations Fig. 11
; Plug connection for LBS socket,
. Relay for potential 15, ISO-BUS Fig. 6
ISO-BUS Fig. 8
. Relay for ECU power, ISO-BUS Fig. 6 ; Socket for diagnosis service tool Fig. 12
; Plug connection for virtual terminal,
. Relay for power socket, ISO-BUS Fig. 7
ISO-BUS Fig. 13
9 ISO-BUS diode group Fig. 7 ; Socket for LBS, ISO-BUS Fig. 14

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Fig. 1

Fig. 2

Fig. 3

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Fig. 4

Fig. 5

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Fig. 6

Fig. 7

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Fig. 8

Fig. 9

Fig. 10

Fig. 11

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Fig. 12

Fig. 13

Fig. 14

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A27 CAN module up to DBD094270 S34 Button for 5th AUX

A28 Plug module up to DBD094270 S35 Joystick button
A29 Joystick for 2 AUX S2/72 Rapid retraction button
A30 Print ARU as of DBD094271 S33 EDC stop button
A31 Multicontroller II S28/1 Button for front powerlift management
B28 Man. oper. accelerator slider X18/4 Plug connection for cab wiring harness on
B52 Operating lever for AUX (black) right -armrest
R20/1 Potentiometer 1. AUX X6/58 Plug connection for seat (reverse travel
R20/2 Potentiometer 2. AUX equipment)
R20/3 Potentiometer for 3rd AUX X6/27 Plug connection for seat switch, ARU console
R20/4 Potentiometer for 4th AUX (reverse travel equipment)
R20/5 Potentiometer for 5th AUX

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W1/4 Plug connection for radio start X3/5 Plug connection for reserve
X1/6/1 Screw connection X12/20 Plug connection for sprung front axle
2. Power socket 40A X4/51 Plug connection for trailer brake „Italy“
X1/6/2 Screw connection X5/1 Screw-plug connection for potential 31
1. Power socket 40A X6/5 Reserve
X1/8 Screw connection for start switch supply X6/6 Plug connection for instruments wiring
X1/11 Screw connection for potential 30 harness
X1/26 Plug connection for potential 15/2, X10/8 Plug connection for cab wiring harness on left
heating blower X10/14 Plug connection for roof supply
X1/60 Screw connection for power socket, X18/1 Plug connection for instruments wiring
cab 30 A, potential 30 harness
X2/4/1 Screw-plug connection for potential 15/2 X24/1 Plug connection for instruments wiring
X2/4/2 Screw-plug connection for potential 15/2 harness
X3/1 Plug connection for radar sensor X24/2 Plug connection for cab wiring harness on right

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)XVHV
F1 Supply for start switch ........................... 20 A F30 Supply for engine print, potential 15/2......5 A
F2 Power socket for cab, F31 Supply for radar sensor, potential 15/2.....5 A
potential 30 ............................................ 25 A F32 Supply for PTO sensors,
F3 1. Power socket, potential 30 ................ 40 A potential 15/2..........................................10 A
F4 2. Power socket, potential 30 ................ 40 A F33 Supply for hazard warning light system,
F5 Supply, indicator, potential 15/1 ............. 15 A potential 30.............................................10 A
F6 ADIC, keypads potential 15/1 .................. 5 A F34 Headlight, roof right 56b ........................7.5 A
F7 Relay for 56a potential 30...................... 15 A F35 Headlight, roof left 56b ..........................7.5 A
F8 Reserve potential 30................................ 5 A F36 Headlight, engine bonnet, right 56b ......7.5 A
F9 SGR potential 30 ................................... 10 A F37 Headlight, engine bonnet, left 56b.........7.5 A
F10 Supply for ECCU2, potential 30............... 5 A F38 Trailer socket, potential 58L
F11 Relay for worklight, fender, front and rear............................................5 A
potential 30 ............................................ 10 A F39 Trailer socket, potential 58R
F12 Light switch, potential 30 ....................... 10 A front and rear............................................5 A
F13 Cigarette lighter, 2-pin socket, F40 Supply for steering column switch,
diagnosis plug, EDC - print potential 15/1..........................................15 A
potential 30 ........................................... 7.5 A F41 Reserve supply,
F14 FMGR, potential 30 .............................. 7.5 A potential 15/1 X6/5 ...............................7.5 A
F15 Reserve potential 15/2........................... 10 A F42 Reserve supply,
F16 Supply for CAN, FMGR, ARU, AUX, potential 15/1 X6/5 ..................................5 A
changeover switch for diagnosis, ICU F43 Reserve supply,
potential 15/2 ........................................... 5 A potential 15/1 X6/5 ..................................5 A
F17 Blower for heating, potential 15/2 .......... 20 A F44 Reserve supply, potential 15/1 .................5 A
F18 SGR potential 15/1 .................................. 5 A F45 Supply for roof, ICU potential 15/1 ...........5 A
F19 Supply for ARU, EDC, potential 15/1....... 5 A F46 Relay for brake light, Optistop,
F20 Supply for ARU, EDC, potential 15/1....... 5 A potential 15/1..........................................10 A
F21 Supply for D+ relay, ECCU2, EDC .......... 5 A F47 Supply for AUX potential 15/1 ..................5 A
F22 Reserve for supply, terminal 30 X6/5...... 5 A F48 Supply for seat, trailer brake „Italy“
F23 Reserve for supply, terminal 30 X6/5...... 5 A potential 15/1..........................................20 A
F24 58 L Parking right, left, rear, ADIC, F49 Supply for potential 15/1 EDC box ...........5 A
switch lighting, instrument board, F50 Supply for potential 15/1 ECCU2 ...........25 A
trailer socket, front and rear, F51 Supply for potential 15/1 FMGR .............10 A
ISO BUS ............................................... 7.5 A F52 Trailer socket, indicator, right
F25 58 R Parking light, right, rear, ARU, front and rear.........................................7.5 A
switch lighting, control panel, F53 Trailer socket, indicator left
mobile phone socket............................. 7.5 A front and rear.........................................7.5 A
F26 Parallel wiper, horn, interval relay, F54 Reserve supply, potential 30 X6/5...........5 A
potential 15/2 ........................................ 7.5 A F55 Trailer socket, brake light
F27 Sprung front axle, potential 30............... 10 A front and rear..........................................10 A
F28 Sprung front axle, potential 15/2.............. 5 A
F29 Supply for power socket
front and rear, standard signal socket,
reversible fan, potential 15/2 ................. 10 A

5HOD\V

K2 Trafficator relay K5/10 Relay, light (potential 58)

K3 Interval relay K5/11 Relay potential D+ supply
K5/5 Switchover relay for high beam K5/12 Relay, brake light, Optistop
K5/6 Switchover relay for dipped beam K5/43 Relay, D+ cut-off
K5/7/1 Relay potential 15/1 supply K5/56a Relay for high beam
K5/7/2 Relay potential 15/2 supply K5/56b Relay for dipped beam
K5/9 Relay, worklight, fender

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W1/4 Plug connection for radio start X4/51 Plug connection for trailer brake „Italy“
X1/6/1 Screw connection 2. Power socket 40A X5/1 Screw-plug connection for potential 31
X1/6/2 Screw connection 1. Power socket 40A X6/5 Reserve
X1/8 Screw connection for start switch supply X6/6 Plug connection for instruments wiring
X1/11 [X1/61/1] Screw connection for potential 30 harness
X1/26 Plug connection for potential 15/2, X10/8 Plug connection for cab wiring harness on left
heating blower X10/14 Plug connection for roof supply
X1/60 Screw connection for power socket, X18/1 Plug connection for instruments wiring
cab 30 A, potential 30 harness
X2/4/1 Screw-plug connection for potential 15/2 X24/1 Plug connection for instruments wiring
X2/4/2 Screw-plug connection for potential 15/2 harness
X3/1 Plug connection for radar sensor X24/2 Plug connection for cab wiring harness on
X3/5 Plug connection for reserve right
X12/20 Plug connection for sprung front axle

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)XVHV
F1 Supply for start switch ........................... 20 A F30 Supply for engine print, potential 15/2......5 A
F2 Power socket for cab, F31 Supply for radar sensor, potential 15/2.....5 A
potential 30 ............................................ 25 A F32 Supply for PTO sensors,
F3 1. Power socket, potential 30 ................ 40 A potential 15/2..........................................10 A
F4 2. Power socket, potential 30 ................ 40 A F33 Supply for hazard warning light system,
F5 Supply, indicator, potential 15/1 ............. 15 A potential 30.............................................10 A
F6 ADIC, keypads potential 15/1 .................. 5 A F34 Headlight, roof right 56b ........................7.5 A
F7 Relay for 56a potential 30...................... 15 A F35 Headlight, roof left 56b ..........................7.5 A
F8 Reserve potential 30................................ 5 A F36 Headlight, engine bonnet, right 56b ......7.5 A
F9 SGR potential 30 ................................... 10 A F37 Headlight, engine bonnet, left 56b.........7.5 A
F10 Supply for ECCU2, potential 30............... 5 A F38 Trailer socket, potential 58L
F11 Relay for worklight, fender, front and rear............................................5 A
potential 30 ............................................ 10 A F39 Trailer socket, potential 58R
F12 Light switch, potential 30 ....................... 10 A front and rear............................................5 A
F13 Cigarette lighter, 2-pin socket, F40 Supply for steering column switch,
diagnosis connector, EDC - print potential 15/1..........................................15 A
potential 30 ........................................... 7.5 A F41 Reserve supply,
F14 FMGR, potential 30 .............................. 7.5 A potential 15/1 X6/5 ...............................7.5 A
F15 Reserve potential 15/2........................... 10 A F42 Reserve supply,
F16 Supply for CAN, FMGR, ARU, AUX, potential 15/1 X6/5 ..................................5 A
changeover switch for diagnosis, ICU F43 Reserve supply,
potential 15/2 ........................................... 5 A potential 15/1 X6/5 ..................................5 A
F17 Blower for heating, potential 15/2 .......... 20 A F44 Reserve supply, potential 15/1 .................5 A
F18 SGR potential 15/1 .................................. 5 A F45 Supply for roof, ICU potential 15/1 ...........5 A
F19 Supply for ARU, EDC, potential 15/1....... 5 A F46 Relay for brake light, Optistop,
F20 Supply for ARU, EDC, potential 15/1....... 5 A potential 15/1..........................................10 A
F21 Supply for D+ relay, ECCU2, EDC .......... 5 A F47 Supply for AUX potential 15/1 ..................5 A
F22 Reserve for supply, terminal 30 X6/5...... 5 A F48 Supply for seat, trailer brake „Italy“
F23 Reserve for supply, terminal 30 X6/5...... 5 A potential 15/1..........................................20 A
F24 58 L Parking right, left, rear, ADIC, F49 Supply for potential 15/1 EDC box ...........5 A
switch lighting, instrument board, F50 Supply for potential 15/1 ECCU2 ...........25 A
trailer socket, front and rear, F51 Supply for potential 15/1 FMGR .............10 A
ISO BUS ............................................... 7.5 A F52 Trailer socket, indicator, right
F25 58 R Parking light, right, rear, ARU, front and rear.........................................7.5 A
switch lighting, control panel, F53 Trailer socket, indicator left
mobile phone socket............................. 7.5 A front and rear.........................................7.5 A
F26 Parallel wiper, horn, interval relay, F54 Reserve supply, potential 30 X6/5...........5 A
potential 15/2 ........................................ 7.5 A F55 Trailer socket, brake light
F27 Sprung front axle, potential 30............... 10 A front and rear..........................................10 A
F28 Sprung front axle, potential 15/2.............. 5 A
F29 Supply for power socket
front and rear, standard signal socket,
reversible fan, potential 15/2 ................. 10 A

5HOD\V
K2 Trafficator relay K5/10 Relay, light (potential 58)
K3 Interval relay K5/11 Relay potential D+ supply
K5/5 Switchover relay for high beam K5/12 Relay, brake light, Optistop
K5/6 Switchover relay for dipped beam K5/43 Relay, D+ cut-off
K5/7/1 Relay potential 15/1 supply K5/56a Relay for high beam
K5/7/2 Relay potential 15/2 supply K5/56b Relay for dipped beam
K5/9 [K5/3] Relay for worklight, fender

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5RRISULQW$:UWK

/LVWRISOXJV
X1/24 Screw connection for potential 30, supply
heated windscreens X4/65 Plug connection for rear wiper motor
X2/9 Plug connection for blower supply X4/ASW [X4/38] Plug connection for
X2/14 Plug connection for air conditioning system worklight, front
X4/19 Plug connection for front heated windscreen X4/ASW [X4/38] Plug connection for lighting supply,
X4/20 Plug connection for rear heated windscreen all-round light bar
X3/80 Plug connection for mirror adjustment [X3/13] X4/ESW [X4/40] Plug connection for auxiliary lamp
X4/15 Plug connection for heated mirror X4/ESW [X4/40] Plug connection for lighting supply,
X4/16 Plug connection, reserve all-round light bar
X4/17 Plug connection for front wiper motor X4/65 Plug connection for rear wiper motor
X4/39 Plug connection for heated mirror switch X10/11 Plug connection for roof print supply
X4/41 Plug connection for front heated windscreen X10/12 Plug connection for roof wiring harness
switch X10/13 Plug connection for roof wiring harness
X4/42 Plug connection for rear heated windscreen X16/4 Screw connection for potential 30,
switch roof print supply
X4/44 Plug connection for air conditioning control X16/5 Screw connection for potential 31, roof print

)XVHV
F60 Side marker light, front left, F70 2 worklights, rear ....................................10 A
number plate lighting on roof .................. 3 A F71 Heated mirror .......................................7.5 A
F61 Side marker light, front right, ICU F72 Supply for radio, interior lights,
switch lighting, roof, spot, radio and ASW panel supply, potential 30................5 A
ASW panel lighting, activation F74 Reserve potential 30 ..............................25 A
of all worklights ........................................ 5 A F76 Heated rear windscreen .........................25 A
F63 Rear wiper ............................................ 7.5 A F77 Heated front windscreen .......................25 A
F64 Front wiper on hinged windscreen........ 7.5 A F100 Electrically adjustable mirror ....................5 A
F65 Control, air conditioning system............... 5 A F101 ASW panel supply for
F66 Blower / air conditioning system ........... 20 A 4 worklights, front,
F67 4 worklights, front (exterior) ................... 15 A worklight on BB light ..............................25 A
F68 4 worklights, rear, ASW panel F102 4+2 worklights, front ...............................15 A
supply, potential 30 ................................ 10 A F103 Air conditioning pushbutton .....................5 A
F69 All-round light, ASW panel
supply, potential 30 ................................ 15 A

5HOD\V
K5/29 Supply, potential, terminal 15 K5/32 Supply for D+ air conditioning system
K5/30 4 worklights, rear (exterior) K5/33 4+2 worklights, front
K5/31 4 worklights, front (exterior) K5/36 Reserve

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 4009-173

5RRISULQW$%HULIRUV

/LVWRISOXJV
X1/24 Screw connection for potential 30, supply
heated windscreens X4/65 Plug connection for rear wiper motor
X2/9 Plug connection for blower supply X4/ASW [X4/38] Plug connection for
X2/14 Plug connection for air conditioning system worklight, front
X4/19 Plug connection for front heated windscreen X4/ASW [X4/38] Plug connection for lighting supply,
X4/20 Plug connection for rear heated windscreen all-round light bar
X3/80 Plug connection for mirror adjustment [X3/13] X4/ESW [X4/40] Plug connection for auxiliary lamp
X4/15 Plug connection for heated mirror X4/ESW [X4/40] Plug connection for lighting supply,
X4/16 Plug connection, reserve all-round light bar
X4/17 Plug connection for front wiper motor X4/65 Plug connection for rear wiper motor
X4/39 Plug connection for heated mirror switch X10/11 Plug connection for roof print supply
X4/41 Plug connection for front heated windscreen X10/12 Plug connection for roof wiring harness
switch X10/13 Plug connection for roof wiring harness
X4/42 Plug connection for rear heated windscreen X16/4 Screw connection for potential 30,
switch roof print supply
X4/44 Plug connection for air conditioning control X16/5 Screw connection for potential 31, roof print

)XVHV
F60 Side marker light, front left, F70 2 worklights, rear ....................................10 A
number plate lighting on roof .................. 3 A F71 Heated mirror .......................................7.5 A
F61 Side marker light, front right, ICU F72 Supply for radio, interior lights,
switch lighting, roof, spot, radio and ASW panel supply, potential 30................5 A
ASW panel lighting, activation F74 Reserve potential 30 ..............................25 A
of all worklights ........................................ 5 A F76 Heated rear windscreen .........................25 A
F63 Rear wiper ............................................ 7.5 A F77 Heated front windscreen .......................25 A
F64 Front wiper on hinged windscreen........ 7.5 A F100 Electrically adjustable mirror ....................5 A
F65 Control, air conditioning system............... 5 A F101 ASW panel supply for
F66 Blower / air conditioning system ........... 20 A 4 worklights, front,
F67 4 worklights, front (exterior) ................... 15 A worklight on BB light ..............................25 A
F68 4 worklights, rear, ASW panel F102 4+2 worklights, front ...............................15 A
supply, potential 30 ................................ 10 A F103 Air conditioning pushbutton .....................5 A
F69 All-round light, ASW panel
supply, potential 30 ................................ 15 A

5HOD\V
K5/29 Supply, potential, terminal 15 K5/32 Supply for D+ air conditioning system
K5/30 4 worklights, rear (exterior) K5/33 4+2 worklights, front
K5/31 4 worklights, front (exterior) K5/36 Reserve

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(QJLQHSULQW$:UWK

/LVWRISOXJV
X1/2 Plug connection for engine wiring harness, X1/21 Screw-plug connection for engine print,
terminal 50 potential 31
X1/9 Screw connection for fuel filter heating X1/22 Screw-plug connection for engine print,
X1/10 Screw connection for supply, potential 31
potential 30 EEM2 X1/31 Screw connection for engine print, power
X1/11 Plug connection for potential D+ socket, front, potential 30
X1/12 Screw connection for potential 30 X2/5 Screw-plug connection for engine print,
X1/14 Screw connection for PCU potential 30 Denso alternator, potential 15
X1/16 Plug connection for clock, X20/1 Plug connection for engine wiring harness
Webasto engine preheating (Würth)
X1/17 Screw connection for reversible fan

)XVHV
F89 Potential 15, engine .............................. 15 A F94 Supply for EEM2, PCU,
F90 Air conditioning compressor, pushbutton 5 A potential 30 ............................................25 A
F91 Supply for EDC, potential 30 ................ 7.5 A F95 Reversible fan ........................................15 A
F92 Supply for EEM2, potential 30 ............... 10 A F96 Reserve .................................................7.5 A
F93 Supply for clock, ADIC, radio, F97 Supply for EEM2, potential 15................10 A
potential 30 .............................................. 5 A F98 Fuel filter heating, potential 30 ...............20 A
F99 Power socket, front................................ 30 A

5HOD\V
K5/3 Relay for engine print, potential 15 K8/1 Relay for starter

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(QJLQHSULQW$%HULIRUV

/LVWRISOXJV
X1/2 Plug connection for engine wiring harness, X1/17 Screw connection for reversible fan
terminal 50 X1/21 Screw-plug connection for engine print,
X1/9 Screw connection for fuel filter heating potential 31
X1/10 Screw connection for supply, X1/22 Screw-plug connection for engine print,
potential 30 EEM2 potential 31
X1/11 Plug connection for potential D+ X1/31 Screw connection for engine print, power
X1/12 Screw connection for potential 30 socket, front, potential 30
X1/14 Screw connection for PCU potential 30 X24/12 Plug connection for engine wiring harness
X1/16 Plug connection for clock, (Berifors)
Webasto engine preheating

)XVHV
F90 Air conditioning compressor, pushbutton 5 A F95 Reversible fan ........................................15 A
F91 Supply for EDC, potential 30 ................ 7.5 A F96 Reserve .................................................7.5 A
F92 Supply for EEM2, potential 30 ............... 10 A F97 Supply for EEM2, potential 15................10 A
F93 Supply for clock, ADIC, radio, F98 Fuel filter heating, potential 30 ...............10 A
potential 30 .............................................. 5 A F99 Power socket, front................................ 40 A
F94 Supply for EEM2, PCU,
potential 30 ........................................... 25 A

5HOD\V
K5/3 Relay for engine print, potential 15 K8/1 Relay for starter

Sva 6-92970 EN Edition 07-2005

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('&SULQW$:UWK

/LVWRISOXJV
X2/6 Plug connection for lighting, X4/2 Plug connection for diagnosis LED, slip LED
potentiometer EDC X4/3 Plug connection for raise LED, lower LED
X3/16 Plug connection for potentiometer, X5/6 Plug connection for nominal value
lowering speed potentiometer
X3/17 Plug connection for potentiometer, X6/13 Plug connection for cigarette lighter and
raising speed 2-pin socket
X3/18 Plug connection for potentiometer, X10/4 Plug connection for EDC print - arm rest
EDC mix (GSV)
X3/19 Plug connection for potentiometer, X14/4 Plug connection for EDC print - control panel
slip control

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('&SULQW$%HULIRUV

/LVWRISOXJV
X2/6 Plug connection for lighting, X4/2 Plug connection for diagnosis LED, slip LED
potentiometer EDC X4/3 Plug connection for raise LED, lower LED
X3/16 Plug connection for potentiometer, X5/6 Plug connection for nominal value
lowering speed potentiometer
X3/17 Plug connection for potentiometer, X6/13 Plug connection for cigarette lighter and
raising speed 2-pin socket
X3/18 Plug connection for potentiometer, X10/4 Plug connection for EDC print - arm rest
EDC mix (GSV)
X3/19 Plug connection for potentiometer, X14/4 Plug connection for EDC print - control panel
slip control

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&DQPRGXOH$DQGSOXJPRGXOH$WR'%'

/LVWRISOXJV
X28/1 Plug connection for ARU - X28/11 Plug connection for ARU - multicontroller II
cab wiring harness on right X28/12 Plug connection for ARU - potentiometer
X28/2 Plug connection for ARU - rapid retraction AUX 5
button X28/13 Plug connection for ARU lighting
X28/3 Plug connection for ARU - man. oper. X28/14 Plug connection for ARU button, EDC Stop
accelerator slider X28/15 Plug connection for ARU - potentiometer
X28/4 Plug connection for ARU - AUX control lever AUX 3 and AUX 4
X28/5 Plug connection for ARU - AUX joystick X28/16 Plug connection for ARU - potentiometer
X28/6 Plug connection for ARU - AUX button AUX 1 and AUX 2
X28/7 Plug connection for ARU CAN - BUS YA1 Plug connection for ARU plug module -
X28/8 Plug connection for ARU reserve CAN module
X28/9 Plug connection for ARU - lighting, switch, YB1 Plug connection for ARU CAN module -
management, front powerlift plug module

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3ULQW$58$DVRI'%'

/LVWRISOXJV
X30/1 Plug connection for ARU - X30/9 Plug connection for ARU - lighting, switch,
cab wiring harness on right management, front powerlift
X30/2 Plug connection for ARU - rapid retraction X30/11 Plug connection for ARU - multicontroller II
button X30/12 Plug connection for ARU - potentiometer
X30/3 Plug connection for ARU - man. oper. AUX 5
accelerator slider X30/13 Plug connection for ARU lighting
X30/4 Plug connection for ARU - AUX control lever X30/14 Plug connection for ARU button, EDC Stop
X30/5 Plug connection for ARU - AUX joystick X30/15 Plug connection for ARU - potentiometer
X30/6 Plug connection for ARU - AUX button AUX 3 and AUX 4
X30/7 Plug connection for ARU CAN - BUS X30/16 Plug connection for ARU - potentiometer
X30/8 Plug connection for ARU reserve AUX 1 and AUX 2

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4009-180

5HOD\V
0LQLDWXUHUHOD\
(K6/7, K6/8)

Contacts ................................................normally open

Duty cycle ............................................................ 100%
Nominal voltage ...............................................12 VDC
Loading ........................................................ max. 30 A
Resistance 85 - 86 ........................................ 65 Ω ± 10%

0LQLDWXUHUHOD\
(K5/3, K5/7/1, K5/7/2, K5/12, K5/80, K5/81)

Contacts ......................................................... changer

Duty cycle ............................................................ 100%
Nominal voltage ...............................................12 VDC
Loading ................................................... max. 20/30 A
Resistance 85 - 86 ........................................ 65 Ω ± 10%

0LFURUHOD\
(K5/5, K5/6, K5/9, K5/10, K5/11, K5/16, K5/29,K5/30,
K5/31, K5/33, K5/37, K5/42, K5/43, K5/54, K5/56a,
K5/56b, K5/60, K5/61, K5/62)

Contacts ......................................................... changer

Duty cycle .......................................................... 100 %
Nominal voltage ...............................................12 VDC
Loading ................................................... max. 15/25 A
Resistance 1 - 2.................................80 Ω±10% at 23°C
Interference suppression resistance ................. 680 Ω

3RZHUUHOD\
(K5/32, K5/82, K8/1)

Contact ...................................................normally open

Duty cycle .......................................................... 100 %
Nominal voltage ...............................................12 VDC
Loading ........................................................ max. 70 A
Resistance 1 - 2.................................................... 80 Ω
Interference suppression resistance .................. 560 Ω

7LPHUHOD\ZLWKGHOD\
(K4/2/2)

Contacts ......................................................... changer

Retention period .............................................. 40 sec.
Duty cycle .......................................................... 100 %
Nominal voltage ...............................................12 VDC
Loading .......................................................... max. 5 A

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,QGLFDWRUUHOD\
(K2)

Nominal voltage .............................................. 12 VDC

Frequency ........................... 90 indicator code/ min ± 30

,QWHUYDOUHOD\
(K3)

Nominal voltage .............................................. 12 VDC

Interval period .............................................6 sec. ± 1.5

3RZHUUHOD\
(K8/2)

Contacts ................................................ normally open

Nominal voltage .............................................. 12 VDC
Loading ......................................................max. 300 A
Resistance 1 - 2 (at 20°C) ........................... 37.5 Ω ± 6.5%
(including interference-suppression resistance)

(OHFWULFDOEDWWHU\PDLQVZLWFK
(Q2)

Nominal voltage .............................................. 12 VDC

Operating current .......................................max. 250 A
Nominal consumption during normal operations .. 0.4 A
Type of protection................................................. IP 65

'LRGHJURXS
(V8/1)

Nominal voltage .............................................. 12 VDC

Nominal current ................................................... 1.5 A
Locking voltage ................................................ 1000 V

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4009-182

&RPSRQHQWVHQJLQHDQGIXHOV\VWHP
3XVKEXWWRQIRUHQJLQHRLO6

Contact ................................................ normally closed

Switching point ........................................... p > 0.5 bar

6$LUILOWHUFRQWUROVZLWFK

Contact ...................................................normally open

Switching point ............................> 65±3 mbar vacuum

6SHHGVHQVRUIRUHQJLQH%

Design ....................................................... Hall sensor

Pin 3 (supply) ...................................................12 VDC
Pin 1 (supply) .................................................... ground
Current consumption ................................ max. 15 mA
Pin 2 (signal) ............................................square-wave
Number of teeth on sensor wheel ........................36 -1
Insulation resistance ........................................>100kΩ

0DQRSHUDFFHOHUDWRUVOLGHU%

Design ...................................................... Hall element

Pin 1 (supply) .................................................... 5 VDC
Pin 4 (supply) .................................................... ground
Current consumption ................................ max. 15 mA
Pin 2 (signal) ........................................................ VDC
Load resistance ................................... min. 4.5 k-Ohm
Insulation resistance ........................................>100kΩ

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6&RQWUROVZLWFKFRRODQWOHYHO

(Reed switch)

Contact .................................................. normally open

Nominal voltage .............................................. 12 VDC

(QJLQHWHPSHUDWXUHVHQVRU% Characteristic value

at 1mA test current

Version .................................................................. PTC

Imax ..................................................................... 5 mA
Measurement range ...............................-50 to +150ºC
Nominal voltage ................................................. 5 VDC
Nominal resistance (at 25ºC) ................................. 2 kΩ
Insulation resistance ...................................... >100 kΩ
Tightening torque ............................................... 30 Nm

&KDUJHDLUSUHVVXUHWHPSHUDWXUHVHQVRU
%

Pin 1 ..................................................... Supply, ground

Pin 3 ......................................................Supply, 5 VDC
Pin 2 ..............................Charge-air temperature signal
Pin 4 ................................... Charge-air pressure signal

6HQVRUIRUFKDUJHDLUWHPSHUDWXUH 6HQVRUIRUFKDUJHDLUSUHVVXUH
Temperature [°C] Resistance [Ω] (pin 2-1) Charge-air pressure kPa Voltage [V] (pin 4-1)
-45 39260 50 0.5
-20 13850 80 0.9
0 5500 110 1.3
20 2420 140 1.7
40 1166 170 2.1
60 609 200 2.5
80 340 230 2.9
100 202 260 3.3
120 127 290 3.7
130 102 320 4.1
350 4.5

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+HDWLQJIODQJH(

Nominal voltage ...............................................12 VDC

Current at 10V ........................................ approx. 147 A
Power ........................................................ 2.1 kW ±0.1

3&8FRQWUROXQLWLQMHFWLRQSXPS$

Pin 6 ................................ Ground supply (from EEM2)

Pin 7 ......................................12V supply (from EEM2)
Nominal voltage ...............................................12 VDC
(Minimum voltage) ............................................. 7 VDC
Current consumption (constant) ..................... max. 8 A
Pin 1 .............................................................CAN LOW
Pin 2 ............................................................CAN HIGH
Pin 5 .. Signal, engine emergency stop in event of CAN
fault
Pin 8 ........................Signal „engine - upper dead point“
127( 'RQRWWRXFKWKHFRQWDFWVRQWKHSOXJLQFRQQHF
WLRQWKLVDSSOLHVWRERWKWKH3&8DQGWKHSOXJ
)XHOGHOLYHU\SXPS0

Nominal voltage ...............................................12 VDC

Current consumption ..................................... max. 6 A
)XHOGHOLYHU\SUHVVXUH
at idling speed ........................................ 1.0 to 1.3 bar
at nominal power .................................... 1.0 to 1.1 bar

7HVWVZLWFKIXHOGHOLYHU\SUHVVXUH%

Contact ................................................ normally closed

Switching point ............................... p > 0.05 to 0.2 bar

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 4009-185

)XHOWDQNOHYHOWUDQVPLWWHU%

'LHVHOOHYHO 5HVLVWDQFHLQΩ
0 10 ± 2.5
1/2 95 ± 5
1 180 ± 12

5HYHUVLEOHIDQ$

Air compressor
Pin 2, 4 supply .................................................. ground
Pin 3 activation ................................................ 12 VDC
Current consumption ........................................... 5.6 A
Solenoid valve
Pin 2, 4 supply .................................................. ground
Pin 1 activation ................................................ 12 VDC
Current consumption ........................................... 0.5 A
Coil resistance .....................................................24 Ω

&RRODQWKHDWHU

Voltage ................................................................ 230 V

Power .............................................................. 1100 W

:HEDVWRFRRODQWKHDWHU

Voltage .................................................................. 12 V
Power .................................................................. 45 W
Warm current ...................................................... 5 kW
perm. Operating overpressure .......................... 2.5 bar

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&RPSRQHQWVWUDQVPLVVLRQ
6\VWHPSUHVVXUHVHQVRU%

Measurement range ......................................0 - 50 bar

Pin1 supply ....................................................... 5 VDC
Pin2 supply ...................................................... ground
Current consumption .................................. max. 3 mA
Pin3 Signal .......................................................... VDC
at 0 bar ....................................... 5% of supply voltage
at 50 bar ................................... 95% of supply voltage
Calibration point .................................................30 bar
Precision ........................................ <1% at -40 to +125°C
Insulation resistance ...................................... >100 kΩ

/XEULFDWLQJSUHVVXUHVHQVRU%

Measurement range .......................................0 - 20 bar

Pin1 supply ....................................................... 5 VDC
Pin2 supply ...................................................... ground
Current consumption .................................. max. 5 mA
Pin3 Signal ......................................................... VDC
at 0 bar ....................................... 5% of supply voltage
at 20 bar ................................... 95% of supply voltage
Calibration point ...................................................5 bar
Precision ........................................ <1% at -40 to +125°C
Insulation resistance ...................................... >100 kΩ

6SHHGVHQVRUV%%%%%

All sensors have the same electrical values, but

different lengths.
B24, B25, B35 ................................................ 77.3mm
B26, B27.......................................................... 99,1mm
Frequency range ..................................... 10 to 6000Hz
Signal REF..................................................... >0.8 VAC
Nominal resistance ................................. 1050 ± 100 Ω
Insulation resistance .......................................>100 kΩ

3RWHQWLRPHWHUDFFHOHUDWRUSHGDO5
(double potentiometer)
Power supply, FMGR box ........................5 to 6.5 VDC
Total resistance 2X .......................................4 kΩ ± 20%
Signal, protective resistor 2X ...................1k7 Ω ± 20%
Signal current ................................................ >100 µA
1 = Ground
2 = Supply
3 = Signal, FMGR box (falling)
4 = Signal, FMGR box and EEM2 box (ascending)
R measured 1-2 ............................................ 2 kΩ ± 20%
R measured 1-3 ................................ 1k7Ω to 3k7Ω ± 20%
R measured 1-4 ...............................3k7Ω to 1k7Ω ± 20%

Setting regulation for external voltage source of 5 VDC:

Accelerator position 0 ..................................... 0.8 VDC
Accelerator position max................................. 4.2 VDC
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66ZLWFKSUHVVXUHILOWHU

Contact ................................................ normally closed

Supply ............................................................... ground
Switching point at ∆p ........................................ > 5 bar

)XOOORDGSRWHQWLRPHWHU5

The full-load potentiometer is combined with a switch

for the indicator lamp.
Contact .................................................. normally open
Pin 1 supply ............................................ 5 to 6.5 VDC
Pin 2 supply ...................................................... ground
Pin 3 Signal ........................................................... VDC
Pin1 - 2 Resistance ................................... 4.7 k Ω± 10%
Pin1 - 3 Resistance .............................. 0 - 4.7 kΩ± 10%

%7HPSHUDWXUHVHQVRUWUDQVPLVVLRQRLO Characteristic value

at 1mA test current

Version .................................................................. PTC

Imax ..................................................................... 5 mA
Measurement range ...............................-50 to +150ºC
Nominal voltage ................................................. 5 VDC
Nominal resistance (at 25ºC) ................................. 2 kΩ
Insulation resistance ...................................... >100 kΩ
Tightening torque ............................................... 30 Nm

%$QJOHRIURWDWLRQVHQVRUFOXWFK

Pin 2, supply from FMGR ..........................5 +1.5 VDC

Pin 1 .................................................................Ground
Pin 3 ....................................................... Signal (VDC)
Pedal not depressed ..................................... 0.7 VDC
Pedal fully depressed .................................... 4.2 VDC
Load resistance ...............................................> 200 Ω

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&OXWFKVZLWFK6

Contact ...................................................normally open

Clocked supply (GSV 2)...................................3.1 VDC
(measured with DMM)
Cyclic frequency .................................................50 Hz
Switching current .................................... max. 500 mA
Switching power ......................................... max. 10 W
Continuous current ................................. max. 300 mA
Resistance (switch operated) ....................approx. 4 Ω
Insulation resistance .......................................>100 kΩ

66ZLWFKVHDW

Contact ...................................................normally open

6ROHQRLGYDOYHV<<<<
<<<

Supply (cyclic) .............................................. from SGR

Cyclic frequency ...............................................200 Hz
Voltage (measured with DMM) ........................7.1 VDC
Resistance .................................................. 2.5 Ω ± 0.06
Duty cycle .......................................................... 100 %
Insulation resistance .......................................>100 kΩ

6ROHQRLGYDOYHVSDUNLQJLQWHUORFN<<

Supply (cyclic) .............................................. from SGR

Cyclic frequency ...............................................200 Hz
Voltage (measured with DMM) .........................10 VDC
Resistance .................................................. 10 Ω ± 10 %
Duty cycle .......................................................... 100 %
Insulation resistance .......................................>100 kΩ

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6ROHQRLGYDOYHVIRUEUDNHRLOFRROLQJ<
<

Nominal voltage ............................................... 12 VDC

Current consumption ..............................max. 1.54 mA
Resistance ................................................... 8 Ω ± 10%
Insulation resistance ...................................... >100 kΩ

&RPSRQHQWVGLIIHUHQWLDOORFN
6ROHQRLGYDOYHIRUGLIIHUHQWLDOORFN<

Duty cycle ......................................................... 100 %

Nominal voltage .............................................. 12 VDC
Resistance ........................................8 Ω ± 10% at 20°C
Insulation resistance ...................................... >100 kΩ
Interference suppression .............Z-diodes, antiparallel

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4009-190

&RPSRQHQWVIURQW372
%6SHHGVHQVRUIURQW372VKDIW

Design ....................................................... Hall sensor

Operating range .....................................1Hz to 25 kHz
Pin A (+ supply) ................................................12VDC
Pin C (supply) .................................................. Ground
Current consumption ................................ max. 15 mA
Pin B............................................Signal (square-wave)
Insulation resistance .......................................>100 kΩ

<6ROHQRLGYDOYHIURQW372VKDIW
Proportional
Duty cycle .......................................................... 100 %
Nominal voltage ...............................................12 VDC
Resistance ................................... 4.98 Ω ± 10% at 20°C
Imax .......................................................................1.5 A
Insulation resistance ...................................... >100 kΩ
Activation ...................................... PWM signal 100 Hz
Interference suppression ......................... BZW 06-28B

&RPSRQHQWVUHDU372
5HDU372VKDIWVSHHGVHQVRU%

Design ....................................................... Hall sensor

Pin 3 Supply ....................................................12 VDC
Pin 1 Supply ..................................................... ground
Current consumption ................................ max. 21 mA
Pin 2 ............................................Signal (square-wave)

<6ROHQRLGYDOYHUHDU372VKDIW
Proportional
Duty cycle .......................................................... 100 %
Nominal voltage ...............................................12 VDC
Resistance ................................... 4.98 Ω ± 10% at 20°C
Imax .......................................................................1.5 A
Insulation resistance ...................................... >100 kΩ
Activation ...................................... PWM signal 100 Hz
Interference suppression ......................... BZW 06-28B

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 4009-191

&RPSRQHQWVLQGLYLGXDOZKHHOVSUXQJIURQWD[OH
$QJOHRIURWDWLRQVHQVRU%%

Pin 2 (+ supply from E box A61) ...................... 12 VDC

Pin 1 (supply from E box A55) ..........................Ground
Pin 3 ......................................................... Signal (mA)
Signal, axle 20.25S
Vehicle lowered ................................................ > 5 mA
Vehicle raised .............................................. < 18.7 mA
Signal, axle 20.29S
Vehicle lowered ........................................ 7.8 ± 0.5 mA
Vehicle raised............................................ 16 ± 0.5 mA
127( 7KHDGMXVWPHQWLVPDGHE\WXUQLQJWKHVHQVRU

6ROHQRLGYDOYHV<<<

Duty cycle ........................................................ 100 %

Nominal voltage .............................................. 12 VDC
Resistance at 23°C ......................................... 8 Ω±10%
Insulation resistance ...................................... >100 kΩ
Interference suppression .............Z-diodes, antiparallel

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4009-192

&RPSRQHQWVEUDNH
6ZLWFKIRUEUDNHOLJKW66
Power ........................................................... max. 5 W
Current ....................................................... max. 0.5 A
Pin 1, clocked supply (GSV 2) ........................3.1 VDC
(measured with DMM)
Brake pedals not depressed:
Pin 1 - 2 ...........................................................Interrupt
Pin 1 - 3 ...........................................................Interrupt
Both brake pedals depressed (see graphic symbol):
Pin 1 - 2 ..................................................... approx. 4 Ω
Pin 1 - 3 ...........................................................Interrupt
One brake pedal depressed (steering brake):
Pin 1 - 2 ...........................................................Interrupt
Pin 1 - 3 ..................................................... approx. 4 Ω

6ZLWFKIRUKDQGEUDNH6

Contact ................................................ normally closed

Current ................................................... max. 500 mA
Pin 1, clocked supply (GSV 2) ........................3.1 VDC
(measured with DMM)

66ZLWFKHQJLQHEDFNSUHVVXUHEUDNH

Contact ...................................................normally open

Current ................................................... max. 500 mA

6ZLWFKIRUEUDNHIOXLGOHYHO6

Contact ...................................................normally open

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 4009-193

7UDQVPLWWHUFRPSUHVVHGDLULQGLFDWRU%

(for compressed air reservoir pressure indicator)

Flat plug-in rim (G) ............................................6.3 mm

Ground via housing (with ground connection)

3UHVVXUHEDU 5HVLVWDQFH>Ω] 3UHVVXUHEDU 5HVLVWDQFH>Ω]

0 10 6 124
2 52 8 155
4 88 10 184

6ROHQRLGYDOYHIRUWUDLOHUEUDNHÄ,WDO\³<

Duty cycle ......................................................... 100 %

Nominal voltage .............................................. 12 VDC
Resistance ............................................... 8.5 Ω ± 10%
Insulation resistance ...................................... >100 kΩ

3XVKEXWWRQIRU
WUDLOHUEUDNHÄ,WDO\³6

Contact ................................................ normally closed

Switching power ........................................max. 100 W
Switching point .............................................. 10±0.5 bar
Safety .......................................................pma 300 bar
Thread .............................................................. G 1/4“

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4009-194

&RPSRQHQWVUHYHUVHWUDYHOHTXLSPHQW
3RWHQWLRPHWHUDFFHOHUDWRUSHGDO5
(double potentiometer)
Power supply, FMGR box ........................5 to 6.5 VDC
Total resistance 2X .......................................4 kΩ ± 20%
Signal, protective resistor 2X ...................1k7 Ω ± 20%
Signal current ................................................ >100 µA
1 = Ground
2 = Supply
3 = Signal, FMGR box (falling)
4 = Signal, FMGR box and EEM2 box (ascending)
R measured 1-2 ............................................ 2 kΩ ± 20%
R measured 1-3 ................................ 1k7Ω to 3k7Ω ± 20%
R measured 1-4 ...............................3k7Ω to 1k7Ω ± 20%

Setting regulation for external voltage source of 5 VDC:

Accelerator position 0 ..................................... 0.8 VDC
Accelerator position max................................. 4.2 VDC
%$QJOHRIURWDWLRQVHQVRUFOXWFK

Pin 2, supply from FMGR .......................... 5 +1.5 VDC

Pin 1 ................................................................. Ground
Pin 3 ....................................................... Signal (VDC)
Pedal not depressed ...................................... 0.7 VDC
Pedal fully depressed .................................... 4.2 VDC
Load resistance ............................................... > 200 Ω

&OXWFKVZLWFK6

Contact ...................................................normally open

Clocked supply (GSV 2)...................................3.1 VDC
(measured with DMM)
Cyclic frequency .................................................50 Hz
Switching current .................................... max. 500 mA
Switching power ......................................... max. 10 W
Continuous current ................................. max. 300 mA
Resistance (switch operated) ....................approx. 4 Ω
Insulation resistance .......................................>100 kΩ

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 4009-195

6HDWVZLWFK6

Contact .................................................. normally open

6ZLWFKUHYHUVLEOHVHDW6

Contact ................................................ normally closed

Current ....................................................max. 500 mA
Pin 3, supply +15 ............................................ 12 VDC
Pin 4, signal to ....................... K5/60, K5/61 and K5/62

6ZLWFKUHYHUVLEOHVHDW6

Contact .................................................. normally open

Current ....................................................max. 500 mA
Pin 1, clocked supply (GSV 3) ........................ 3.1 VDC
(measured with DMM)
Pin 2, signal to FMGR reverse travel equipment active

6ZLWFKEUDNHSHGDO6

Contact .................................................. normally open

Current ....................................................max. 500 mA
Pin 1, clocked supply (GSV 2) ........................ 3.1 VDC
(measured with DMM)

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4009-196

&RPSRQHQWVK\GUDXOLFV
&RQWUROVZLWFKIRUVXSSO\SXPSSUHVVXUH6

(for indicating the contamination level of the pressure

filter)

Contact ................................................ normally closed

Switching point ......................................... p > 1+0.2 bar

-R\VWLFN$
(proportional control)
Measured values for Hall element in ORQJLWXGLQDO
GLUHFWLRQ
Supply voltage .................................................. 5 VDC
Cable, interrupt/short circuit ...................... 0 - 0.2 VDC
Signal- play............................................. 0.2 - 1.1 VDC
Signal- lowering max. ...........................1.1 - 1.51 VDC
Signal- lowering /proportional ..............1.51 -2.33 VDC
Signal- neutral .....................................2.33 - 2.67 VDC
Signal- raising /proportional ................2.67 - 3.49 VDC
Signal- raising max. ..............................3.49 - 4.1 VDC
Signal- raising /latched ........................... 4.1 -4.8 VDC
Signal- short circuit + .............................. 4.8 - 5.0 VDC
Load resistance ...........................................> 20 kOhm
-R\VWLFN$
(proportional control)
Measured values for Hall element in ODWHUDOGLUHFWLRQ
Supply voltage .................................................. 5 VDC
Cable, interrupt/short circuit ...................... 0 - 0.2 VDC
Signal- lowering max. ............................. 0.2 -0.5 VDC
Signal- lowering /proportional ................0.5 -2.33 VDC
Signal- neutral .....................................2.33 - 2.67 VDC
Signal- raising /proportional ..................2.67 - 4.5 VDC
Signal- raising max. ............................... 4.5 - 4.8 VDC
Signal- short circuit + .............................. 4.8 - 5.0 VDC
Load resistance ...........................................> 20 kOhm

&RQWUROOHYHU%
(proportional control)
Measured values for Hall element
Supply voltage .................................................. 5 VDC
Cable, interrupt/short circuit ...................... 0 - 0.2 VDC
Signal- play............................................. 0.2 - 1.1 VDC
Signal- lowering max. ...........................1.1 - 1.51 VDC
Signal- lowering /proportional ..............1.51 -2.33 VDC
Signal- neutral .....................................2.33 - 2.67 VDC
Signal- raising /proportional ................2.67 - 3.49 VDC
Signal- raising max. ..............................3.49 - 4.1 VDC
Signal- raising /latched ........................... 4.1 -4.8 VDC
Signal- short circuit + .............................. 4.8 - 5.0 VDC
Load resistance ...........................................> 20 kOhm

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 4009-197

3RWHQWLRPHWHUIRU$8;FRQWUROYDOYHV
55555
± 10%
R Potentiometer ........................................... 5 kΩ

Potentiometer R20/1, R20/3

R measured, pin 4 - 5 .............................. 0 - 5 kΩ ± 10%

Potentiometer R20/2, R20/4

R measured, pin 1 - 2 .............................. 0 - 5 kΩ ± 10%

Potentiometer R20/5
R measured, pin 1 - 2 .............................. 0 - 5 kΩ ± 10%

7HUPLQDWLQJUHVLVWRU
± 5%
Resistance A - B 120 .......................................W

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4009-198

&RPSRQHQWV('&
$QJOHRIURWDWLRQVHQVRUIRU('&%

Pin 3, supply ....................................................10 VDC

Pin 1, supply ...................................................... ground
Pin 2 (signal) .......................... approx. 2.5 to 7.5 VDC
Load resistance ................................................ > 3 k Ω
127( 7KHDGMXVWPHQWLVPDGHE\WXUQLQJWKHVHQVRU

3RZHUVHQVRU%%

Nominal load....................................................... 60 KN

Pin 2 (+ supply from E box A55) ......................10 VDC

Pin 2 (supply from E box A55) ......................... Ground
Pin 2 (signal) .........................................2.5 to 7.5 VDC
Sensor not loaded ................................. approx. 5 VDC
Load resistance .............................................. > 10 k Ω

3RWHQWLRPHWHU5

Pin 1 - 2 (resistance).................................. 4.7 kΩ ±20%

Pin 1 - 3 (resistance) ............................ 0 - 4.7 kΩ ±20%

3RWHQWLRPHWHU5555

Pin 1 - 2 (resistance).................................. 4.7 kΩ ±20%

Pin 1 - 3 (resistance).................................... 0 − 4.7 κW

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 4009-199

6ROHQRLGYDOYHVIRU('&<DQG<

Proportional solenoid ...................................... 12 VDC

I max ..................................................................... 3.5 A
Current control ..................... Impulse width modulation
Ohmic resistance R .................................. approx.1.7 Ω
Interference suppression .......................... in E box A55

+HDWLQJYDOYH<

Nominal voltage .................................................... 12 V

Voltage range ........................................ 10.2 to 13.8 V
Power consumption ........................................... 14.4 W
Resistance ......................................... approx. 10 Ohm
Heating power .............................................. 5 to 6 kW
Activation temperature ....................................... < 5° C
Deactivation temperature ................................ > 10° C

5DGDUVHQVRU%
Mounting angle ....................................................... 35°
Output signal ....................................... 131 impulses/ m
Pin 1(+ supply) ................................................. 12 VDC
Pin 2 (supply) .................................................... ground
Pin 3 (signal, square-wave) ............. 505 Hz at 14 km/h
Pin 4 Available (connected to term. 3)
127( $OO FKDQJHV LQ EHDP DQJOH LQ UHODWLRQ WR WKH
JURXQGGLVWRUWWKHVLJQDOYDOXH
$77(17,217XUQWKHLJQLWLRQVZLWFKWRSRVLWLRQEHIRUH
ZRUNLQJLQWKHEHDPUDQJHRIWKHVHQVRU

&RPSRQHQWVIURQWSRZHUOLIW
$QJOHRIURWDWLRQVHQVRU
PDQDJHPHQWIURQWSRZHUOLIW%

Pin 3, supply ................................................... 10 VDC

Pin 1, supply ..................................................... ground
Pin 2 (signal) ........................... approx. 2.5 to 7.5 VDC
Load resistance ................................................. > 3 kΩ
127( 7KHDGMXVWPHQWLVPDGHE\WXUQLQJWKHVHQVRU

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4009-200

&RPSRQHQWVDLUFRQGLWLRQLQJV\VWHP
$LUFRQGLWLRQLQJWHPSHUDWXUHFRQWURO$
X4/44 - Pin 4 (supply) ......................................12 VDC
X4/44 - Pin 2 (supply) ...................................... Ground
X4/44 - Pin 1............................................ Output signal
(Activation of magnetic coupling, compressor)
X4/73 - Pin 1 - 2....................... Temperature sensor R9
X4/73 - Pin 3............................................Sheathing R9
X4/75 - Pin 1 - 2...............................Potentiometer R10
................................................... (Temperature setting)
X4/10 - Pin 3 - 4 ................... Switch, air cond. ON/OFF

6ZLWFKLQJ SRLQWV PDJQHWLF FRXSOLQJ FRPSUHVVRU

<
Potentiometer R10 (temperature setting) in position
minimum cooling
Resistance of R9 > 18 kΩ (compressor switches off)
minimum cooling
Resistance of R9 < 16 kΩ (compressor switches on)
maximum cooling
Resistance of R9 > 27 kΩ (compressor switches off)
maximum cooling
Resistance of R9 < 25 kΩ (compressor switches on)
6SHHGFRQWUROEORZHUPRWRU$
(only for air conditioning optional equipment)

X3/40 - Pin 4 (supply) ......................................12 VDC

X3/40 - Pin 2 (supply) ...................................... Ground

X4/74 - Pin 1 - 3...................Supply, potentiometer R11

X4/74 - Pin 2............................... Signal - speed setting

X2/20 - Pin A/B ......... Plug connection for blower motor

3RWHQWLRPHWHUIRUDLUFRQGLWLRQLQJURRI
PRXQWHGEORZHU5
(for setting the speed of the roof blower motor)

Pin 1 - 3 (resistance)................................... 10 k Ω ±20%

Pin 1 - 2 (resistance).............................. 0 - 10 k Ω ±20%

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 4009-201

53RWHQWLRPHWHUDLUFRQGLWLRQLQJ
WHPSHUDWXUH
for setting temperature with integrated switch (air
conditioning - ON/OFF)

Resistance (nominal)................................... 10 KΩ±20%

Pin 1 - 2 (resistance) ............................. 0 - 10 KΩ±20%
Pin 3 - 4 .............................................. Switch ON/OFF
Contact .................................................. normally open

3XVKEXWWRQIRUDLUFRQGLWLRQLQJV\VWHP6

Thread ..................................................... 3/8"-24 UNF

Nominal voltage .............................................. 12 VDC

Contact - high pressure ....................... normally closed

Opens at .............................................. p > 34 ±1.9 bar
Closes at ........................................... p < 28.4 ±1.9 bar

Contact - low pressure .......................... normally open

Closes at .............................................. p > 2.1 ±0.2 bar
Opens at ............................................. p < 1.9 ±0.3 bar

7HPSHUDWXUHVHQVRUIRUDLUFRQGLWLRQLQJ
V\VWHP5

Version ................................................................. NTC

Resistance 1 - 2 ......................... approx. 11 kΩ at 20°C

Switching points of magnetic coupling, compressor Y13

see page 200

$LUFRQGLWLRQLQJFRPSUHVVRUFRXSOLQJ<

Nominal voltage .............................................. 12 VDC

Minimum feed voltage .................................... 7.5 VDC
Current ...................................................... 3.6 to 4.2 A
Power .................................................................. 43 W
Resistance ................................................ 2.9 to 3.6 Ω
Coupling air gap ...............................................0.6 mm

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4009-202

&RPSRQHQWVFDE
0LUURUKHDWLQJ(DQG(

Nominal voltage ...............................................12 VDC

Current at 12V ......................................... approx. 1.7 A
Power ...................................................... approx. 20 W
Resistance ..................................................7.2 Ω ± 20%

0LUURUKHDWLQJDQGDGMXVWPHQW$$

Mirror adjustment
Pin 2 ........................................ +15/1 adjusting motor 1
Pin 1 .................................... Ground, adjusting motor 1
Pin 3 ........................................ +15/1 adjusting motor 2
Pin 4 ................................... Ground, adjusting motor 2
Mirror heating E18/1 and E18/2
pin 5 .................................................... activation +15/1
Pin 6 ..................................................... Supply, ground

&RQWUROXQLWPLUURUDGMXVWPHQW$

Pin 2 .......................................................... Supply 15/1

Pin 1 ..................................................... Supply, ground
Pin 9 ............................................................Lighting 58
Mirror, left
Pin 3 .......................... Activation 15/1 adjusting motor 1
Pin 5 .......................... Activation 15/1 adjusting motor 2
Pin 8 ............. Ground supply, adjusting motors 1 and 2
Mirror, right
Pin 4 .......................... Activation 15/1 adjusting motor 1
Pin 6 .......................... Activation 15/1 adjusting motor 2
Pin 8 ............. Ground supply, adjusting motors 1 and 2

+HDWHGZLQGVFUHHQIURQW(

Nominal voltage ...............................................12 VDC

Current at 12V ....................................... approx. 17.5 A
Power ............................................ approx. 210 W ±10%
spec. Heating power ........................approx. 4 W / dm2

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 4009-203

+HDWHGVFUHHQUHDU(

Nominal voltage .............................................. 12 VDC

Current at 12V....................................... approx. 12,5 A
Power ........................................... approx. 150 W ±10%
spec. Heating power...................... approx. 2.8 W / dm2

(OHFWURQLFVIRU;HQRQZRUNOLJKW
$$

Sva 6-92970 EN Edition 07-2005

 Chapter
4009A

CONNECTORS, WIRING HARNESSES ,

ELECTRICAL AND ELECTRONIC COMPONENTS

4009A

CNH Österreich GmbH Sva 6-93290 EN © 2006 CNH Österreich GmbH

Technical Documentation January 2006
A - 4300 St. Valentin, Steyrer Strasse 32
 4009A-3

CONTENTS
WIRING HARNESS DESIGNATION ..................................................................................................................... 7

MAIN CONNECTOR ............................................................................................................................................. 8

CONTROLLER AND PRINT´S ............................................................................................................................ 11

FLYING FUSES AND RELAYS .......................................................................................................................... 13

SOCKETS ........................................................................................................................................................... 14

DESIGNATION AND COLOUR CODING OF CABLESEL ................................................................................. 16

Abbreviations ............................................................................................................................................. 17

ENGINE HOOD WIRING HARNESS .................................................................................................................. 18

INJECTORS - ENGINE WIRING HARNESS ...................................................................................................... 21

ENGINE WIRING HARNESS .............................................................................................................................. 24

1. Additional line for 2nd Magneton alternator 95 A ................................................................................... 37
2. Additional line for 7-pin trailer socket and power socket at front............................................................ 37
3. Additional line for angle of rotation sensor at front................................................................................. 37
4. Additional line for speed sensor for front PTO ....................................................................................... 37
5. Additional line for reverse fan................................................................................................................. 37
6. Additional line for battery - ground ......................................................................................................... 38
7. Additional line for battery - starter + ....................................................................................................... 38
8. Additional line for electrical main switch - battery + ............................................................................... 38
9. Additional line for electrical main switch - starter + ................................................................................ 38
10. Additional line for main switch - battery + ........................................................................................... 39
11. Additional line for main switch - starter + ............................................................................................. 39

SENSORS - ENGINE WIRING HARNESS ......................................................................................................... 47

INSTRUMENTS WIRING HARNESS ................................................................................................................. 52

1. Additional line for 2nd alternator ............................................................................................................ 63
2. Additional line for independent suspension, sprung front axle............................................................... 63

RIGHT CAB WIRING HARNESS ........................................................................................................................ 68

1. Additional line for Molex bridge 2-pin ..................................................................................................... 84
2. Additional line for mobile phone precaution ........................................................................................... 84
3. Additional line for raise/lower ................................................................................................................. 84
4. Additional line for hydraulic trailer brake ................................................................................................ 85
5. Additional line for hydraulic trailer brake solenoid valve ........................................................................ 85
6. Additional line for standard signal socket T1.......................................................................................... 85
7. Additional line for standard signal socket T2.......................................................................................... 85
8. Additional line for radar sensor .............................................................................................................. 85
9. Additional line for power socket, additional monitor for cab ................................................................... 85
10. Additional line for additional marker light, wide tyres ........................................................................... 85

Sva 6-93290 EN Edition 01-2006

4009A-4
CONTROL PANEL, RIGHT WIRING HARNESS ................................................................................................ 92
1. Additional line for nominal value and EDC lighting potentiometer.......................................................... 99
2. Additional line for lifting limitation potentiometer .................................................................................... 99
3. Additional line for mixing potentiometer ................................................................................................. 99
4. Additional line for lowering speed potentiometer.................................................................................... 99
5. Additional line for slip control potentiometer........................................................................................... 99
6. Additional line for limit load potentiometer.............................................................................................. 99
7. Additional line for potentiometer for panel lighting ................................................................................. 99

CARTRIDGE WIRING HARNESS .................................................................................................................... 102

1. Plug connection for Linde electronics - hydrostat................................................................................. 107

CAB ON LEFT WIRING HARNESS .................................................................................................................. 109

1. Additional line for 2nd rear power socket ............................................................................................. 113

ROOF SUPPLY WIRING HARNESS ................................................................................................................ 115

ROOF WIRING HARNESS ............................................................................................................................... 118

1. Additional line for front left and right turn signal / side marker light and work lamps............................ 128
2. Additional line for front left and right side marker light (wide tyres)...................................................... 129
3. Additional line for front left and right side marker light and additional light .......................................... 129
4. Additional line for auxiliary headlight and work lamp............................................................................ 129
5. Additional line for licence plate lights ................................................................................................... 129
6. Additional line for all-round light bar ..................................................................................................... 129
7. Additional line for 6 work lamps............................................................................................................ 131
8. Additional line for electrical mirror adjustment and heating.................................................................. 131
9. Additional line for air conditioning system ............................................................................................ 131
10. Additional line for solenoid, all-round light, standard socket .............................................................. 131
11. Additional line for all-round light ......................................................................................................... 131
12. Additional line for wiper, hinged windscreen, front ............................................................................. 131
13. Additional line for blower ventilation ................................................................................................... 133
14. Additional line for front heated windscreen ........................................................................................ 133
15. Additional line for rear heated windscreen ......................................................................................... 133
16. Additional line for mirror heating......................................................................................................... 133
17. Additional line for Xenon work lamp ................................................................................................... 133

ELECTRICAL REMOTE CONTROL VALVES WIRING HARNESS ................................................................. 152

1. Additional line for external button, powerlift, front ................................................................................ 155
2. Additional line for external button for front remote control valves ........................................................ 155

REVERSE TRAVEL EQUIPMENT WIRING HARNESS ................................................................................... 158

1. Additional line for wash tank extension ................................................................................................ 165
2. Additional line for rear wiper extension ................................................................................................ 165

ISO BUS WIRING HARNESS ........................................................................................................................... 168

Sva 6-93290 EN Edition 01-2006

 4009A-5

ARMREST WIRING HARNESS ........................................................................................................................ 174

1. Additional line for multicontroller .......................................................................................................... 178
2. Additional line for AUX5 button ............................................................................................................ 178
3. Additional line for rapid retraction button............................................................................................. 179
4. Additional line for manual accelerator slider ....................................................................................... 179
5. Additional line for AUX control lever..................................................................................................... 179
6. Additional line for AUX joystick ............................................................................................................ 179
7. Additional line for potentiometers AUX1 and 2 .................................................................................... 179
8. Additional line for potentiometers AUX3 and 4 .................................................................................... 179
9. Additional line for potentiometer AUX5 ............................................................................................... 179
10. Additional line for lighting .................................................................................................................. 179
11. Additional line for EDC stop button .................................................................................................... 179
12. Additional line for shift button (floating position)................................................................................. 179

COMPONENTS ................................................................................................................................................ 185

Armrest..................................................................................................................................................... 185
Central print A12 ...................................................................................................................................... 186
Engine print A14....................................................................................................................................... 188
Roof print A13 .......................................................................................................................................... 190
EDC print A16 .......................................................................................................................................... 191
Print ARU A30.......................................................................................................................................... 192
Relay ........................................................................................................................................................ 193
Engine and fuel system components ....................................................................................................... 195
Transmission components ....................................................................................................................... 200
Differential lock components .................................................................................................................... 203
Front PTO shaft components ................................................................................................................... 204
Rear PTO shaft components.................................................................................................................... 204
Individual wheel, sprung front axle components ...................................................................................... 205
Brake components ................................................................................................................................... 206
Reversing facility components ................................................................................................................. 208
Hydraulics components............................................................................................................................ 210
EDC components ..................................................................................................................................... 212
Front power lift components..................................................................................................................... 213
Air conditioning system components........................................................................................................ 214
Cab components ...................................................................................................................................... 216

Sva 6-93290 EN Edition 01-2006

4009A-6

Blank page

Sva 6-93290 EN Edition 01-2006

 4009A-7

WIRING HARNESS DESIGNATION

HL Engine hood wiring harness CA Cartridge wiring harness

EF Injectors - engine wiring harness CL Cab wiring harness, left
EM Engine wiring harness RS Roof supply wiring harness
ES Sensors - engine wiring harness RM Roof wiring harness
AV Electrical remote control valves wiring
CI Instruments wiring harness
harness
CR Cab wiring harness, right RD Reverse travel equipment wiring harness
CD Control panel wiring harness, right IB ISO BUS wiring harness
AR Armrest wiring harness

Sva 6-93290 EN Edition 01-2006

4009A-8

MAIN CONNECTOR

X2/2 Plug connection for main beam headlight, X10/18 Plug connection for engine wiring harness -
engine hood instruments wiring harness
X2/3 Plug connection for dipped headlight, X12/1 Plug connection for engine -
engine hood engine print wiring harness
X3/28 Plug connection for work lamp, X16/1 Plug connection for EEM3 engine control
engine hood and horn unit - injectors engine wiring harness
X36/1 Plug connection for EEM3 engine control
X4/4 Plug connection for ID module
unit - sensors engine wiring harness
X10/3 Plug connection for instruments - X89/1 Plug connection for engine - EEM3 engine
engine print wiring harness control unit wiring harness

Sva 6-93290 EN Edition 01-2006

 4009A-9

A4/1 FMGR plug connection (white) X10/9 Plug connection for cab, right - control panel
A4/2 FMGR plug connection (dark grey) wiring harness

A4/3 FMGR plug connection (blue) X16/21 SGR plug connection

X18/4 Plug connection for cab, right - armrest
A4/4 FMGR plug connection (grey)
wiring harness
X24/5 Plug connection for cab, right - control panel
CN3a ECCU2 plug connection
wiring harness [5]
CN3b ECCU2 plug connection X55 Plug connection for EDC box
CN4 Plug connection for ISO-BUS

Sva 6-93290 EN Edition 01-2006

4009A-10

X6/6 Plug connection for instruments -

W1/4 Radio start plug connection
central print wiring harness
X2/4 Screw - plug connection for X10/8 Plug connection for central print -
potential 15/2, central print cab, left wiring harness
X4/45 Plug connection for sprung front axle X10/11 Plug connection for roof print supply [11]
X4/51 Plug connection for „Italy“ trailer brake -
X14/14 Plug connection for roof supply [14]
central print
X14/15 Plug connection for central print -
X4/59/a Plug connection for LIMP HOME [A]
Roof supply wiring harness [15]
X18/1 Plug connection for instruments -
X4/59/b Plug connection for LIMP HOME [A]
central print wiring harness
X24/1 Plug connection for instruments -
X4/59/c Plug connection for LIMP HOME [B]
central print wiring harness
X5/1 Screw - plug connection, potential 31, X24/2 Plug connection for cab, right -
central print central print wiring harness

Sva 6-93290 EN Edition 01-2006

 4009A-11

CONTROLLER AND PRINT´S

A1 ADIC A23 Linde electronics

A3 EEM3 control unit A30 Print ARU
A7 ID module A61 Electronics, sprung front axle
A14 Engine print A65 KEY PADS
A21 SGR transmission controller

Sva 6-93290 EN Edition 01-2006

4009A-12

A4 FMGR A22 Blower - control

A12 Central print A55 EDC control unit
A13 Roof print A60 ECCU2
A16 EDC print A64 Work lamp panel
A18 Electronics for Xenon work lamp, right P6 Display (for reverse travel equipment)
A19 Electronics for Xenon work lamp, left P8 ICU
A20 Air conditioning - control

Sva 6-93290 EN Edition 01-2006

 4009A-13

FLYING FUSES AND RELAYS

Fuses
F200 Main fuse ............................................. 150 A F200 Main fuse..............................................200 A
(with 2 alternators)

Relay
K4/2/2 Time relay, interior light K5/80 Relay for potential 15 ISO-BUS
K5/37 Relay for Italy trailer brake K5/81 Relay for ECU power ISO-BUS
K5/42 Relay D+ 2nd alternator K5/82 Relay for power socket ISO-BUS
K5/60 Relay for coupling (reverse travel equipment) K6/7 Relay for rear heated windscreen
K5/61 Relay for front accelerator pedal (reverse K6/8 Relay for front heated windscreen
travel equipment) K8/2 Heating flange relay 300A
K5/62 Relay for rear accelerator pedal (reverse Q2 Relay for electrical battery main switch
travel equipment) V8/1 Diode group, ISO-BUS

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SOCKETS

X2/1 Socket, 2-pin 30/31 [2/1] X14/30 Power socket for cab 30 A
X10/1 Trailer socket, 7-pin, rear X15 Power socket, front 40 A
X10/2 Trailer socket, 7-pin, front X29 Standard signal socket
X14/1 Power socket 1, rear 40 A X85 Socket for LBS, ISO-BUS
X14/20 Power socket 2, rear 40 A

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 4009A-15
Socket X2/1
30 12 V potential 30 (7.5 A)
31 Ground

Trailer socket X10/1, X10/2

1/L Turn signal, left
2/54g Not assigned
3/31 Ground
4/R Turn signal, right
5/58R Side marker light, right
6/54 Brake light (not assigned with X10/2)
7/58L Side marker light, left

Power socket X14/1, X14/20, X14/30, X15

30 12 V potential 30 (40 A, 30 A only with X14/30)
82 12 V potential 15/2 (10 A)
31 Ground

Standard signal socket X29

1 Speed of radar 130 pulse/m (standard)
(actual speed) 505 Hz at 14 km/h
2 Speed of transmission sensor 130 pulse/m (standard)
(theoretical speed)
3 PTO shaft, rear 6 pulse/rev (standard)
4 REAR POWER LIFT: Stroke height >50% = 12V,
<50% = 0 V (in basic setting)
5 Not assigned
6 12 V potential 15/2
7 Ground

Socket for LBS, ISO-BUS X85

1 Ground (40 A)
2 Ground (25 A)
3 Potential 30 (40 A)
4 Potential 30 (25 A)
5 Not assigned
6 CAN PWR
7 CAN GND
8 CAN H
9 CAN L

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4009A-16

DESIGNATION AND COLOUR CODING OF CABLESEL

All cables of a connector on a wiring harness are designated by colour.
Below you will find a list of the colours used and their code letters.

Cable colours or coding according to standard 05449

Code letter Colour Type of use Code letter Colour Type of use
A red potential 30 H orange VDC stabilised by electric box
(continuous current)
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown ground above a box
D yellow potential 15 Si (safety) M ground strip
E grey potential 58 lighting N pink electric signals
F green signal line P colourless reserve
G violet potential 15 (15/1 or 15/2) S black ground directly at ground point
switched current downstream of
start switch

NOTE: The „CAN H“ and „CAN L“ cables do not correspond to the aforementioned standard.
„CAN H“ is yellow in colour and „CAN L“ green.

Cable codes
The individual wiring harnesses, the arrangement of
connectors on the wiring harness and their precise
location are described in detail on the following pages.
The precise pin assignment and cable codes of the
individual cables are also specified.

The cable codes are structured as follows:

1. Number of connector bush (PIN)
2. Abbreviation - wiring harness
3. Code letter - cable colour
4. Cable number

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Abbreviations
ADIC.......................................................................................................................... Analogue / digital instrument
ARU.............................................................................................................................................................. Armrest
AUX.........................................................................................................................................Remote control valve
BB light...................................................................................................................... Turn signal / side marker light
DMM..............................................................................................................................................Digital multimeter
ECCU2 ....................................................................................................................................... Central control unit
EDC...............................................................................................................................Electronic power lift control
EEM3 ..........................................................................................................................................Engine control unit
FMGR........................................................................................................... Vehicle/engine/transmission controller
GSV .................................................................................................................................................... Cyclic supply
HTS ............................................................................................. Field end management (headland management)
ICU ..........................................................................................................................................Performance monitor
KEY PADS ........................................................................................ Function keys for analogue/digital instrument
NTC...................................................................................................................... Negative temperature coefficient
PCB............................................................................... Printed circuit board (relay switching, terminal resistance)
PTC ....................................................................................................................... Positive temperature coefficient
SBB light .................................................................................................... Tail light, turn signal / side marker light
SGR .................................................................................................................................... Transmission controller

NOTE: The name in the square brackets [xx] is inscribed on the plug.

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ENGINE HOOD WIRING HARNESS

X1/31/2 Plug connection for

E1 Headlight, left Fig. 1
engine print ground point Fig. 3
X2/2 Plug connection for main beam
E2 Headlight, right Fig. 2
headlight, engine hood Fig. 4
X2/3 Plug connection for dipped
E61 Work lamp, left Fig. 1
headlight, engine hood Fig. 5
X3/28 Plug connection for work lamp,
E62 Work lamp, right Fig. 2
engine hood and horn [WKL] Fig. 6
H1 Signal horn Fig. 1

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Connector positions and pin assignments

Fig. 1

Fig. 2

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Fig. 3

Fig. 4

Fig. 5

Fig. 6

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INJECTORS - ENGINE WIRING HARNESS

X16/1 Plug connection for

Y23 Screw connection for injector,
EEM3 engine control unit-
3rd cylinder Fig. 5
injectors engine wiring harness Fig. 1
X2/21 Plug connection for solenoid valve, Y24 Screw connection for injector,
high pressure pump Fig. 2 4th cylinder Fig. 6
Y21 Screw connection for injector, Y25 Screw connection for injector,
1st cylinder Fig. 3 5th cylinder Fig. 7
Y22 Screw connection for injector, Y26 Screw connection for injector,
2nd cylinder Fig. 4 6th cylinder Fig. 8

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Connector positions and pin assignments

Fig. 1

Fig. 2

Fig. 3

Fig. 4
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 4009A-23

Fig. 5

Fig. 6

Fig. 7

Fig. 8

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ENGINE WIRING HARNESS

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 4009A-25

(2) Screw connection for ground point, X1/50 Screw connection for engine print,
engine control unit Fig. 1 potential 50 Fig. 11
(11) Ground point, X2/13 Plug connection for electric
engine cable carrier, rear Fig. 2 battery main switch [BHS] Fig. 12
K8/2.30 Screw connection for relay, X3/12 Plug connection for sensor
heating flange 300A Fig. 3 „water in fuel“ Fig. 13
X3/28 Plug connection for work lamp,
M13 Fuel delivery pump Fig. 4
engine hoodand horn [ENG-HOOD] Fig. 14
S3 Test switch for air filter Fig. 5 X4/4 Plug connection for ID module Fig. 15
X10/18 Plug connection for engine
S22 Test switch for coolant level Fig. 6 wiring harness -
instruments wiring harness Fig. 16
X12/1 Plug connection for engine -
S30 Pressure switch, air conditioning Fig. 7
engine print wiring harness Fig. 17
X89/1 Plug connection for engine -
X1/30/1 Screw connection for engine print,
EEM3 engine
potential 30 Fig. 8
control unit wiring harness Fig. 18
Y13 Plug connection for
X1/30/EEMScrew connection for engine print,
magnetic coupling, air
potential 30 Fig. 9
conditioning compressor Fig. 19
X1/31/1 Screw connection for engine print,
potential 31 Fig. 10

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Q2/85 Screw connection for electrical

(16) Ground point, starter Fig. 20
battery main switch, control circuit Fig. 25
Q2/86 Screw connection for electrical
F200 Screw connection for main fuse Fig. 21
battery mainswitch, control circuit Fig. 26
X1/5 Plug connection for potential 30,
G2/2B+ Screw connection for alternator B+ Fig. 22 ADIC, ICU, radio,
hazard warning light system Fig. 27
M1.30 Screw connection for starter,
X2/17 Plug connection for alternator D+ Fig. 28
potential 30 Fig. 23
M1.50 Plug connection for starter,
terminal 50 Fig. 24

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 4009A-27
Connector positions and pin assignments

Fig. 1

Fig. 2

Fig. 3

Fig. 4
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4009A-28

Fig. 5

Fig. 6

Fig. 7

Fig. 8

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Fig. 9

Fig. 10

Fig. 11

Fig. 12

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Fig. 13

Fig. 14

Fig. 15

Fig. 16

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Fig. 17

Fig. 18

Fig. 19

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Fig. 20

Fig. 21

Fig. 22

Fig. 23

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Fig. 24

Fig. 25

Fig. 26

Fig. 27

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Fig. 28

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Blank page

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 4009A-37

1. Additional line for 2nd Magneton alternator 95 A

D+ Plug connection for 2nd alternator, G2/2/2 B+Screw connection for alternator,
G2/2/2 Magneton 95A [D+] Fig. 101 Magneton 95A Fig. 103
F200 Screw connection for main fuse, X12/1 Plug connection for engine -
potential 30 Fig. 102 engine print wiring harness Fig. 104

2. Additional line for 7-pin trailer socket and power socket at front
(12) Ground point, X4/20 Plug connection for 7-pin trailer
engine cable carrier, front Fig. 105 socket, front [7/3] Fig. 109
X1/15/1 Plug connection for engine print,
X10/2 Trailer socket, 7-pin, front Fig. 110
power socket, front, potential 15 Fig. 106
X1/30/SOCScrew connection for engine print,
X15 Power socket, front Fig. 110
power socket, potential 30 Fig. 107
X1/31/2 Plug connection for 7-pin trailer socket,
front, potential 31, engine print Fig. 108

3. Additional line for angle of rotation sensor at front

B19 Plug connection for angle X3/22 Plug connection for angle of
of rotation sensor Fig. 111 rotation sensor [POS] Fig. 112

4. Additional line for speed sensor for front PTO

X3/21 Plug connection for front PTO
B8 Plug connection for speed sensor Fig. 113
shaft speed sensor [FPTO] Fig. 114

5. Additional line for reverse fan

X4/64 Plug connection for reverse fan,
X4/66 Plug connection for reverse fan Fig. 116
engine print [FAN] Fig. 115

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4009A-38

6. Additional line for battery - ground

(1) Screw connection for
G1- Battery terminal Fig. 118
battery ground - starter Fig. 117

7. Additional line for battery - starter +

X1/5 Plug connection for potential 30,
G1+ Battery terminal Fig. 119 ADIC, ICU, radio,
hazard warning light system Fig. 121
M1.30 Starter Fig. 120

8. Additional line for electrical main switch - battery +

X1/5 Plug connection for potential 30,
G1+ Battery terminal Fig. 122 ADIC, ICU, radio,
hazard warning light system Fig. 121
Q2/30 Electrical main switch Fig. 123

9. Additional line for electrical main switch - starter +

M1.30 Starter Fig. 124 Q2/30A Electrical main switch Fig. 125

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 4009A-39

10. Additional line for main switch - battery +

X1/5 Plug connection for potential 30,
G1+ Battery terminal Fig. 122 ADIC, ICU, radio,
hazard warning light system Fig. 121
Q1 Main switch Fig. 126

11. Additional line for main switch - starter +

M1.30 Starter Fig. 124 Q1 Main switch Fig. 127

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Connector positions and pin assignments

Fig. 101

Fig. 102

Fig. 103

Fig. 104

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 4009A-41

Fig. 105

Fig. 106

Fig. 107

Fig. 108

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4009A-42

Fig. 109

Fig. 110

Fig. 111

Fig. 112

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 4009A-43

Fig. 113

Fig. 114

Fig. 115

Fig. 116

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4009A-44

Fig. 117

Fig. 118

Fig. 119

Fig. 120

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Fig. 121

Fig. 122

Fig. 123

Fig. 124

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4009A-46

Fig. 125

Fig. 126

Fig. 127

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SENSORS - ENGINE WIRING HARNESS

(12) Ground point, engine cable carrier, X2/36 Plug connection for
front Fig. 1 fuel temperature sensor Fig. 8
X3/37 Plug connection for oil
E10/1+ Screw connection for heating flange Fig. 2
pressure sensor Fig. 9
X3/38 Plug connection for rail
E10/1- Screw connection for heating flange Fig. 3
pressure sensor Fig. 10
K8/2 Screw connection for relay, (87) X3/39 Plug connection for
heating flange Fig. 4 fuel delivery pressure sensor Fig. 11
X2/19 Plug connection for heating X3/40 Plug connection for
flange relay Fig. 5 camshaft position sensor Fig. 12
X2/22 Plug connection for X4/29 Plug connection for charger pressure,
coolant temperature sensor Fig. 6 charged air temperature sensor Fig. 13
X36/1 Plug connection for EEM3
X2/28 Plug connection for engine
engine control unit - sensors
speed sensor Fig. 7
engine wiring harness Fig. 14

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4009A-48
Connector positions and pin assignments

Fig. 1

Fig. 2

Fig. 3

Fig. 4
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 4009A-49

Fig. 5

Fig. 6

Fig. 7

Fig. 8

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4009A-50

Fig. 9

Fig. 10

Fig. 11

Fig. 12

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 4009A-51

Fig. 13

Fig. 14

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4009A-52

INSTRUMENTS WIRING HARNESS

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 4009A-53

(11) Ground point, X2/46 Plug connection for potential 58/31,

engine cable carrier, rear Fig. 1 sprung front axle [GE.VA] Fig. 13
X2/87 Plug connection for right cab
B17 Angle of rotation sensor, coupling Fig. 2 wiring harness -instruments
ISO-BUS wiring harness Fig. 14
X4/14 Plug connection for brake light,
CN1 Plug connection for ADIC Fig. 3
Optistop Fig. 15
CN2 Plug connection for ADIC Fig. 3 X4/50 Plug connection for heating Fig. 16
CN3 Plug connection for ADIC Fig. 4 X4/59/a Plug connection for LIMP HOME [A] Fig. 17
D+ 2nd alternator G2/2/2 [D+] Fig. 5 X4/59/b Plug connection for LIMP HOME [A] Fig. 17
X4/59/c Plug connection for LIMP HOME
S1 Start switch Fig. 6
black [B] Fig. 17
S2/1 Light switch [LICHT] Fig. 7 X4/63 Plug connection for keypads Fig. 4
X5/1 Screw - plug connection for
S2/5 Hazard warning switch [WARN] Fig. 7
potential 31, central print Fig. 18
S2/61 Parking interlock switch X5/55 Plug connection for parallel wiper,
[PARKBREMSE] Fig. 7 front Fig. 19
X6/3 Plug connection for instruments -
S2/74 Reverse fan pushbutton Fig. 7
steering column wiring harness [3] Fig. 20
S2/76 Switch, electrical battery X6/6 Plug connection for instruments
main switch [BATT] Fig. 7 wiring harness - central print [6] Fig. 18
X6/10 Plug connection for left cab wiring
S13 Test switch for brake fluid Fig. 8 harness - instruments wiring
harness[10] Fig. 19
S46 Coupling switch 80% Fig. 2 X6/11 Plug connection for standard signal Fig. 19
X10/3 Plug connection for engine print -
S50/1 Blower switch 1-2-3 Fig. 7
instruments wiring harness Fig. 21
X10/14 Plug connection for instruments
X1/8 Screw connection for central print
wiring harness - supply for roof
supply, potential 30, start switch Fig. 9
wiring harness [14] Fig. 19
X10/18 Plug connection for instruments
X1/11 Screw connection for central print,
wiring harness - engine wiring
potential 30 Fig. 9
harness [INSTR] Fig. 22
X1/26 Plug connection for potential 15/2, X14/8 Plug connection for instruments
15 A blower heating Fig. 9 wiring harness - steering column [8] Fig. 20
X1/30/2 Screw connection for engine print, X18/1 Plug connection for instruments
potential 30 Fig. 10 wiring harness - central print [1] Fig. 23
X2/2 Plug connection for X24/1 Plug connection for instruments
main beam headlight, engine hood Fig. 11 wiring harness - central print [1] Fig. 23
X24/3 Plug connection for instruments
X2/3 Plug connection for dipped headlight,
wiring harness - right cab
engine hood Fig. 12
wiring harness [3] Fig. 24

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4009A-54
Connector positions and pin assignments

Fig. 1

Fig. 2

Fig. 3

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 4009A-55

Fig. 4

Fig. 5

Fig. 6

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4009A-56

Fig. 7

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 4009A-57

Fig. 8

Fig. 9

Fig. 10

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4009A-58

Fig. 11

Fig. 12

Fig. 13

Fig. 14

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 4009A-59

Fig. 15

Fig. 16

Fig. 17

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4009A-60

Fig. 18

Fig. 19

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 4009A-61

Fig. 20

Fig. 21

Fig. 22

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4009A-62

Fig. 23

Fig. 24

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 4009A-63

1. Additional line for 2nd alternator

K5/42 Relay D+ 2nd alternator Fig. 101 S1 Start switch Fig. 102
X2/4/2 Plug connection for central print,
L20/1 Telltale, 2nd alternator Fig. 102
potential 15/2 Fig. 103
X5/1 Screw - plug connection for
L20/2 Telltale, 2nd alternator Fig. 102
potential 31, central print Fig. 103

2. Additional line for independent suspension, sprung front axle

S2/15/1 Switch for sprung front axle X2/46 Plug connection for potential 58/31,
UP/DOWN [VA auf/ab] Fig. 104 sprung front axle [VA] Fig. 106
S2/15/2 Switch for sprung front axle X4/45 Plug connection for sprung front
IN/OUT [VA ein] Fig. 104 axle [45] Fig. 107
X2/45 Plug connection for right cab
X12/20 Plug connection for control block,
wiring harness - additional line
sprung front axle [VA] Fig. 108
for sprung front axle [45] Fig. 105

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4009A-64
Connector positions and pin assignments

Fig. 101

Fig. 102

Fig. 103

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 4009A-65

Fig. 104

Fig. 105

Fig. 106

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4009A-66

Fig. 107

Fig. 108

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 4009A-67

Blank page

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4009A-68

RIGHT CAB WIRING HARNESS

(11) Ground point,

B7 Rear PTO shaft speed sensor Fig. 4
engine cable carrier, rear Fig. 1
A4/1 FMGR plug connection - white [1] Fig. 2 B9/1 Rotary angle sensor EDC [LAGES] Fig. 5
A4/2 FMGR plug connection -
B10/1 Power sensor, left Fig. 6
dark grey [2] Fig. 2
A4/3 FMGR plug connection - blue [3] Fig. 2 B10/2 Power sensor, right Fig. 7
A4/4 FMGR plug connection - grey [4] Fig. 2 CN1a ECCU2 plug connection Fig. 8
A60_GNDScrew connection for ground point
CN2/E ECCU2 plug connection Fig. 8
ECCU2 Fig. 8
B3 Sensor for compressed air Fig. 3 CN3a Plug connection for ECCU2 Fig. 9

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X4/70 Plug connection for

CN3b Plug connection for ECCU2 Fig. 9
accelerator pedal [70] Fig. 27
X4/72 Plug connection for external
E9 Work lamp, fender, right Fig. 10
pushbutton, front AUX brown [EHR] Fig. 28
X4/83 Plug connection for
FL Front loader cable Fig. 11
remote control valves [83] Fig. 29
P8/1 Plug connection for X4/85/a Plug connection for cab wiring
ICU CAN [DISP] Fig. 12 harness, right - ISO BUS preparationFig. 29
S14/1 External pushbutton, LOWER, left X4/85/b Plug connection for cab wiring
[SENKEN] Fig. 13 harness, right - ISO BUS preparation Fig. 29
S14/2 External pushbutton, LOWER, right X6/2 Plug connection for engine print,
[SENKEN] Fig. 10 supply for EDC [2] Fig. 30
S15/1 External pushbutton, RAISE, left X6/15 Plug connection for mobile phone
[HEBEN] Fig. 13 socket, left Fig. 24
S15/2 External pushbutton, RAISE, right X9/17 Socket for diagnosis service tool
[HEBEN] Fig. 10 [DIAGNOSE] Fig. 31
S17/1 External pushbutton, PTO shaft, X10/9 Plug connection for right cab wiring
rear left Fig. 13 harness - control panel Fig. 32
S17/2 External pushbutton, PTO shaft, X14/4 Plug connection for EDC print -
rear right Fig. 14 control unit Fig. 33
S18/1 External push button AUX BLUE,
X16/21 Plug connection for SGR [A21] Fig. 34
pressure in - [ATS] Fig. 15
S18/2 External push button AUX BLUE, X18/4 Plug connection for right cab
pressure in + [ATH] Fig. 15 wiring harness - armrest Fig. 35
X24/2 Plug connection for right cab
S20 Engine back pressure brake switch Fig. 16
wiring harness - central print [2] Fig. 18
X24/3 Plug connection for instruments
S23 Test switch for
wiring harness - right cab
charge pressure 1bar Fig. 17
wiring harness [3] Fig. 36
X2/4/1 Plug connection for central print, X24/5 Plug connection for right cab
potential 15/2 Fig. 18 wiring harness - control panel [5] Fig. 32
X2/12 Plug connection for raise/lower Fig. 19 X55 Plug connection for EDC box Fig. 37
X2/45 Plug connection for right cab wiring Y4 Solenoid valve for front PTO shaft
harness - sprung front axle [45] Fig. 20 [PTO VO] Fig. 38
X2/87 Plug connection for right cab
Y5 Solenoid valve for rear PTO shaft
wiring harness - instruments
PTO] Fig. 39
wiring harness ISO BUS Fig. 21
X3/21 Plug connection for front PTO Y6 Solenoid valve for EDC, RAISE,
shaft speed sensor [FPTO] Fig. 22 grey [HEBEN] Fig. 40
X3/22 Plug connection for angle of rotation Y7 Solenoid valve for EDC, LOWER,
sensor, front power lift [POS] Fig. 23 black [SENKEN] Fig.41
X4/25 Plug connection for handbrake Y8 Solenoid valve for AUX
switch [25] Fig. 24 heating valve [HEIZ] Fig. 42
X4/60R Plug connection for Y10 Solenoid valve for
SBB light. right Fig. 14 differential lock [DIFF] Fig. 39
X4/61 Plug connection for Grammer seat Fig. 25 Y11 Solenoid valve for brake oil cooling 1Fig. 43
X4/69 Plug connection for external button
Y12 Solenoid valve for brake oil cooling 2Fig. 44
for front power lift [HPL Fig. 26

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Connector positions and pin assignments

Fig. 1

Fig. 2

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Fig. 3

Fig. 4

Fig. 5

Fig. 6

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4009A-72

Fig. 7

Fig. 8

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Fig. 9

Fig. 10

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4009A-74

Fig. 11

Fig. 12

Fig. 13

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Fig. 14

Fig. 15

Fig. 16

Fig. 17

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4009A-76

Fig. 18

Fig. 19

Fig. 20

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Fig. 21

Fig. 22

Fig. 23

Fig. 24

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4009A-78

Fig. 25

Fig. 26

Fig. 27

Fig. 28

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 4009A-79

Fig. 29

Fig. 30

Fig. 31

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4009A-80

Fig. 32

Fig. 33

Fig. 34

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 4009A-81

Fig. 35

Fig. 36

Fig. 37

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4009A-82

Fig. 38

Fig. 39

Fig. 40

Fig. 41

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 4009A-83

Fig. 42

Fig. 43

Fig. 44

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4009A-84

1. Additional line for Molex bridge 2-pin

X2/14 Plug connection for air conditioning Fig. 101

2. Additional line for mobile phone precaution

X6/15 Plug connection for mobile
E11/1 Mobile phone socket, left Fig. 102
phone socket, left [13] Fig. 103

3. Additional line for raise/lower

S28 Raise/lower changeover switch Fig. 104 X2/12 Raise/lower plug connection Fig. 105

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4. Additional line for hydraulic trailer brake

K5/37 Relay for Italy trailer brake
[ITALY] Fig. 106 X4/52 Plug connection for additional line,
Italy trailer brake, trailer brake
X4/51 Plug connection for „Italy“ trailer valve [MGV] Fig. 108
brake, central print [ITALB] Fig. 107

5. Additional line for hydraulic trailer brake solenoid valve

S50 Trailer brake valve pushbutton Fig. 109 Y50 Trailer brake solenoid valve Fig. 109
X4/52 Plug connection for additional line,
taly trailer brake,
trailer brake [MGV] Fig. 110

6. Additional line for standard signal socket T1

X6/8 Plug connection for standard
X29 Standard signal socket Fig. 112
signal socket [NORMS] Fig. 111

7. Additional line for standard signal socket T2

X6/11 Plug connection for standard
X6/8 Plug connection for standard
signal socket, instruments
signal socket [NORMS] Fig. 113
wiring harness [NORMS] Fig. 114

8. Additional line for radar sensor

X3/1 Plug connection for radar sensor,
X3/2 Plug connection for radar sensor Fig. 116
central print [1] Fig. 115

9. Additional line for power socket, additional monitor for cab

X1/60 Screw connection for X5/1 Screw - plug connection for
power socket, cab 30 A Fig. 117 potential 31, central print Fig. 118
X2/4/2 Plug connection for central print,
X14/30 Power socket for cab 30 A Fig. 119
potential 15/2 Fig. 118

10. Additional line for additional marker light, wide tyres

X2/84L Plug connection for X4/60L Plug connection for
additional lights Fig. 120 SBB light, left Fig. 122
X2/84R Plug connection for X4/60R Plug connection for
additional lights Fig. 121 SBB light, right Fig. 123

Sva 6-93290 EN Edition 01-2006

4009A-86
Connector positions and pin assignments

Fig. 101

Fig. 102

Fig. 103

Fig. 104

Sva 6-93290 EN Edition 01-2006

 4009A-87

Fig. 105

Fig. 106

Fig. 107

Fig. 108

Sva 6-93290 EN Edition 01-2006

4009A-88

Fig. 109

Fig. 110

Fig. 111

Fig. 112

Sva 6-93290 EN Edition 01-2006

 4009A-89

Fig. 113

Fig. 114

Fig. 115

Fig. 116

Sva 6-93290 EN Edition 01-2006

4009A-90

Fig. 117

Fig. 118

Fig. 119

Fig. 120

Sva 6-93290 EN Edition 01-2006

 4009A-91

Fig. 121

Fig. 122

Fig. 123

Sva 6-93290 EN Edition 01-2006

4009A-92

CONTROL PANEL, RIGHT WIRING HARNESS

Sva 6-93290 EN Edition 01-2006

 4009A-93

E11 Cigarette lighter, right [E11] Fig. 1 S2/70/1 Switch for front PTO shaft [PTO VO] Fig. 8
H2/1 LED for diagnosis Fig. 2 S2/70/2 Switch for rear PTO shaft [PTO HI] Fig. 8
S2/71 Switch for rear PTO shaft
H2/2 LED for slip Fig. 3
management [PTO M] Fig. 8
H2/3 LED for raise Fig. 2 S2/73 Switch for slip control [ASR] Fig. 3
H2/4 LED for lower Fig. 2 X2/1 Socket, 2-pin 30/31 [2/1] Fig. 1
S2/7/3 Switch for X3/23 Plug connection for load
hydraulic master [MASTER] Fig. 4 limit potentiometer Fig. 10
X4/2 Plug connection for LED for
S2/15/5 Raise / lower pushbutton [INNEN] Fig. 4
diagnosis / slip [2] Fig. 9
X4/3 Plug connection for LED for
S2/15/6 Switch for HTS [HTS] Fig. 5
raise / lower [3] Fig. 9
S2/15/7 Switch for speed reduction X6/13 Plug connection for EDC print -
[DREHZAHLABSENKUNG] Fig. 5 cigarette lighter, 2-pin socket [13] Fig. 11
S2/56 Switch for differential lock X10/4 Plug connection for EDC print -
management [DIFF HI] Fig. 6 armrest (GSV) [4] Fig. 9
S2/58/1 Switch for speed ranges X10/9 Plug connection for right cab
[RANGE] Fig. 7 wiring harness, control panel [9] Fig. 12
S2/58/2 Switch for manual mode X24/5 Plug connection for right cab
[MAN.MOD] Fig. 7 wiring harness - control panel [5] Fig. 12
S2/59 Switch for all-wheel drive
management [4 WD] Fig. 6

Sva 6-93290 EN Edition 01-2006

4009A-94
Connector positions and pin assignments

Fig. 1

Fig. 2

Fig. 3

Sva 6-93290 EN Edition 01-2006

 4009A-95

Fig. 4

Fig. 5

Sva 6-93290 EN Edition 01-2006

4009A-96

Fig. 6

Fig. 7

Sva 6-93290 EN Edition 01-2006

 4009A-97

Fig. 8

Fig. 9

Sva 6-93290 EN Edition 01-2006

4009A-98

Fig. 10

Fig. 11

Fig. 12

Sva 6-93290 EN Edition 01-2006

 4009A-99

1. Additional line for nominal value and EDC lighting potentiometer

X5/6 Plug connection for nominal value and lighting potentiometer Fig. 101

2. Additional line for lifting limitation potentiometer

X3/17 Plug connection for lift limitation potentiometer Fig. 102

3. Additional line for mixing potentiometer

X3/18 Plug connection for EDC mixing potentiometer Fig. 103

4. Additional line for lowering speed potentiometer

X3/16 Plug connection for lowering speed potentiometer Fig. 104

5. Additional line for slip control potentiometer

X3/19 Plug connection for slip control potentiometer Fig. 105

6. Additional line for limit load potentiometer

X3/23 Plug connection for limit load potentiometer Fig. 106

7. Additional line for potentiometer for panel lighting

X2/6 Plug connection for EDC print - lighting, potentiometer EDC Fig. 107

Sva 6-93290 EN Edition 01-2006

4009A-100
Connector positions and pin assignments

Fig. 101

Fig. 102

Fig. 103

Fig. 104

Sva 6-93290 EN Edition 01-2006

 4009A-101

Fig. 105

Fig. 106

Fig. 107

Sva 6-93290 EN Edition 01-2006

4009A-102

CARTRIDGE WIRING HARNESS

A21/2 Plug connection for SGR grey Fig. 1 S49/1 Switch for pressure filter 5bar Fig. 4
A21/3 Plug connection for SGR black Fig. 1 X5 Plug connection for pressure filter Fig. 5
A21/4 Plug connection for SGR green Fig. 1 X6/1 Plug connection for Linde electronics Fig. 6
A21/5 Plug connection for SGR brown Fig. 1 Y41 Solenoid valve, coupling 1 Fig. 3
A21/6 Plug connection for speed sensor,
Y42 Solenoid valve, coupling 2 Fig. 3
black planetary carrier 1 / 2, B35 Fig. 8
A21/7 Plug connection for speed sensor,
Y43 Solenoid valve, coupling 3 Fig. 3
grey cartridge input B24 Fig. 8
A21/8 Plug connection for speed sensor,
Y44 Solenoid valve, coupling 4 Fig. 3
brown planetary carrier 3 / 4, B25 Fig. 8
A21/9 Plug connection for speed sensor,
Y45 Solenoid valve, coupling, forwards Fig. 3
green cartridge output B26 Fig. 8
A21/10 Plug connection for speed sensor,
Y46 Solenoid valve, coupling, reverse Fig. 7
orange cartridge output B27 Fig. 8
B32 Temperature sensor, gear oil Fig. 2 Y57 Solenoid valve, parking interlock On Fig. 7
B47 Pressure sensor, transmission
Y58 Solenoid valve, parking interlock Off Fig. 7
system pressure Fig. 3
B51 Pressure sensor, transmission
Y59 All-wheel solenoid valve Fig. 7
lubrication pressure Fig. 3

Sva 6-93290 EN Edition 01-2006

 4009A-103
Connector positions and pin assignments

Fig. 1

Fig. 2

Sva 6-93290 EN Edition 01-2006

4009A-104

Fig. 3

Sva 6-93290 EN Edition 01-2006

 4009A-105

Fig. 4

Fig. 5

Fig. 6

Sva 6-93290 EN Edition 01-2006

4009A-106

Fig. 7

Fig. 8

Sva 6-93290 EN Edition 01-2006

 4009A-107

1. Plug connection for Linde electronics - hydrostat

A23 Plug connection for X6/9 Plug connection for Linde
Linde electronics Fig. 101 electronics - hydrostat A24 Fig. 103
X6/1 Plug connection for
Linde electronics Fig. 102

Sva 6-93290 EN Edition 01-2006

4009A-108
Connector positions and pin assignments

Fig. 101

Fig. 102

Fig. 103

Sva 6-93290 EN Edition 01-2006

 4009A-109

CAB ON LEFT WIRING HARNESS

(11) Ground point, engine cable carrier, X4/20 Plug connection for wiring harness, cab,
rear Fig. 1 left - 7-pin trailer socket, front [7/3] Fig. 7
X4/60L Plug connection for SBB light,
B2/1 Sensor for tank content, left Fig. 2
rear left Fig. 3
X6/10 Plug connection for left cab
E8 Work lamp, fender, left Fig. 3 wiring harness - instruments
wiring harness [10] Fig. 8
M5 Plug connection for motor for
X10/1 Trailer socket, 7-pin, rear Fig. 9
windscreen washing system, rear [R] Fig. 4
M6 Plug connection for motor for X10/8 Plug connection for wiring harness,
windscreen washing system, front [F] Fig. 4 cab, left - central print [8] Fig. 6
X1/6/2 Plug connection for
X14/1 Power socket 1, rear 40 A Fig. 9
1st power socket 40 A Fig. 5
X2/4/1 Plug connection for central print,
potential 15/2 Fig. 6

Sva 6-93290 EN Edition 01-2006

4009A-110
Connector positions and pin assignments

Fig. 1

Fig. 2

Fig. 3

Fig. 4

Sva 6-93290 EN Edition 01-2006

 4009A-111

Fig. 5

Fig. 6

Fig. 7

Fig. 8

Sva 6-93290 EN Edition 01-2006

4009A-112

Fig. 9

Sva 6-93290 EN Edition 01-2006

 4009A-113

1. Additional line for 2nd rear power socket

X1/6/1 Plug connection for X5/1 Screw - plug connection for
2nd power socket 40 A Fig. 101 potential 31, central print Fig. 101
X2/4/1 Plug connection for central print,
X14/20 Power socket 2, rear 40 A Fig. 102
potential 15/2 Fig. 101

Sva 6-93290 EN Edition 01-2006

4009A-114
Connector positions and pin assignments

Fig. 101

Fig. 102

Sva 6-93290 EN Edition 01-2006

 4009A-115

ROOF SUPPLY WIRING HARNESS

(11) Ground point,

X14/14 Plug connection for roof supply [14] Fig. 3
engine cable carrier, rear Fig. 1
X1/30/2 Screw connection for engine print, X14/15 Plug connection for central print -
potential 30 Fig. 2 wiring harness for roof supply [15] Fig. 5
X10/11 Plug connection for roof print X16/4 Screw connection for potential 30,
supply [11] Fig. 3 supply for roof print Fig. 3
X10/14 Plug connection for instruments
X16/5 Screw connection for roof print
wiring harness - supply for roof
ground point Fig. 3
wiring harness [14] Fig. 4

Sva 6-93290 EN Edition 01-2006

4009A-116
Connector positions and pin assignments

Fig. 1

Fig. 2

Fig. 3

Sva 6-93290 EN Edition 01-2006

 4009A-117

Fig. 4

Fig. 5

Sva 6-93290 EN Edition 01-2006

4009A-118

ROOF WIRING HARNESS

(7) Roof ground point, front left Fig. 1 E19 Interior light Fig. 8
(8) Roof ground point, front right Fig. 2 E20 Spot light Fig. 9
A6/A Plug connection for radio Fig. 5 K4/2/2 Time relay, interior light Fig. 10
M4/2 Plug connection for rear
A6/B Plug connection for loudspeaker Fig. 5
wiper motor Fig. 10
B14 Loudspeaker, left Fig. 6 P8 Plug connection for ICU Fig. 11
B15 Loudspeaker, right Fig. 7 P8/2 Plug connection for ICU CAN Fig. 11

Sva 6-93290 EN Edition 01-2006

 4009A-119

X4/65 Plug connection for roof print,

S2/17 Switch for auxiliary headlight Fig. 12
wiper motor, rear [65] Fig. 16
S2/30 Switch for wiper/washing system, X4/65L Plug connection for licence
rear [Wi.hi] Fig. 12 plate lights, roof, left Fig. 6
X4/65R Plug connection for
S2/63/2 Switch for 4+2 front work lamps Fig. 12
licence plate lights, roof, right Fig. 7
X5/7 Socket for auxiliary headlight and
S24/1 Switch for door contact, left Fig. 13
work lamp, front left Fig. 1
X5/8 Socket for auxiliary headlight and
S24/2 Switch for door contact, right Fig. 14
work lamp, front right Fig. 2
X4/1 Plug connection for wiper motor, X6/12L Plug connection for turn signal / side
hinged screen, front [Wi-VO] Fig. 15 marker light, front left [BB-L] Fig. 19
X4/17 Plug connection for roof print, X6/12R Plug connection for turn signal / side
wiper motor, front [17] Fig. 16 marker light, front right [BB-R] Fig. 20
X4/21 Plug connection for work lamp X6/23 Plug connection for roof print,
outside right at rear Fig. 7 wiper motor, rear [23] Fig. 16
X4/22 Plug connection for work lamp X10/12 Plug connection for roof wiring
inside right at rear Fig. 17 harness - roof print [12] Fig. 16
X4/23 Plug connection for work lamp X10/13 Plug connection for
at rear outside left Fig. 6 roof wiring harness - roof print [13] Fig. 16
X4/24 Plug connection for work lamp X14/14 Plug connection for
inside left at rear Fig. 18 roof supply [14] Fig. 21
X4/33 Socket for all-round light, left, X16/5 Screw connection for roof print
magnetic Fig. 3 ground point Fig. 16
X4/34 Socket for all-round light, right, X19/1 Plug connection for
magnetic Fig. 4 all-round light, left Fig. 3
X4/38 [X4/ASW] Plug connection for roof X19/2 Plug connection for
print, work lamp at front Fig. 16 all-round light, right Fig. 4
X4/40 [X4/ESW] Plug connection for X24/6 Plug connection for
roof print, auxiliary headlight Fig. 16 work lamp panel Fig. 12

Sva 6-93290 EN Edition 01-2006

4009A-120
Connector positions and pin assignments

Fig. 1

Fig. 2

Sva 6-93290 EN Edition 01-2006

 4009A-121

Fig. 3

Fig. 4

Fig. 5

Sva 6-93290 EN Edition 01-2006

4009A-122

Fig. 6

Fig. 7

Sva 6-93290 EN Edition 01-2006

 4009A-123

Fig. 8

Fig. 9

Fig. 10

Sva 6-93290 EN Edition 01-2006

4009A-124

Fig. 11

Fig. 12

Sva 6-93290 EN Edition 01-2006

 4009A-125

Fig. 13

Fig. 14

Fig. 15

Sva 6-93290 EN Edition 01-2006

4009A-126

Fig. 16

Fig. 17

Sva 6-93290 EN Edition 01-2006

 4009A-127

Fig. 18

Fig. 19

Fig. 20

Fig. 21

Sva 6-93290 EN Edition 01-2006

4009A-128

1. Additional line for front left and right turn signal / side marker light and
work lamps
E3/17/30Plug connection for turn signal, side
E36 Work lamp, at front right on turn
marker and doorway lights,
signal / side marker light Fig. 102
front, left Fig. 101
E6/14 Plug connection for turn signal X6/12L Plug connection for turn signal
side marker lights, front, right Fig. 102 side marker lights, front, left Fig. 103
E35 Work lamp, at front left on turn X6/12R Plug connection for turn signal
signal / side marker light Fig. 101 side marker lights, front, right Fig. 104

Sva 6-93290 EN Edition 01-2006

 4009A-129

2. Additional line for front left and right side marker light (wide tyres)
E3/17 Plug connection for turn signal side E6/14 Plug connection for turn signal
marker lights, front, left Fig. 105 side marker lights, front, right Fig. 107
E3/17 Plug connection for turn signal side E6/14 Plug connection for turn signal
marker lights, front, left Fig. 106 side marker lights, front, right Fig. 108

3. Additional line for front left and right side marker light and additional
light
E3/1 Additional front left E6/1 Additional front right
side marker light Fig. 109 side marker light Fig. 111
E3/17 Plug connection for turn signal E6/14 Plug connection for turn signal
side marker lights, front, left Fig. 105 side marker lights, front, right Fig. 107
E3/17 Plug connection for turn signal E6/14 Plug connection for turn signal
side marker lights, front, left Fig. 110 side marker lights, front, right Fig. 112

4. Additional line for auxiliary headlight and work lamp

(7) Roof ground point, front left Fig. 113 E22 Auxiliary headlight, right Fig. 116
E33 Work lamp on roof,
(8) Roof ground point, front right Fig. 114
front centre left [M] Fig. 115
X5/7 Socket for auxiliary headlight E34 Work lamp on roof, front,
and work lamp, front left Fig. 113 centre, right [M] Fig. 116
X5/8 Socket for auxiliary headlight E37 Work lamp on roof, front,
and work lamp, front right Fig. 114 outside, left [A] Fig. 115
E38 Work lamp on roof, front,
E21 Auxiliary headlight, left Fig. 115
outside, right [A] Fig. 116

5. Additional line for licence plate lights

X4/65L Plug connection for licence
E5/3 Licence plate lights, roof, left Fig. 117
plate lights, roof, left Fig. 118
X4/65R Plug connection for licence
E5/4 Licence plate lights, roof, right Fig. 117
plate lights, roof, right Fig. 119

6. Additional line for all-round light bar

X4/38 (X4/ASW) Plug connection for X4/40 (X4/ESW) Plug connection for
supply, lighting, all-round light bar Fig. 120 supply, lighting, all-round light bar Fig. 120
X19/1 Plug connection for all-round
light, left Fig. 121

NOTE: The plug connection (supply) of the all-round light bar is either plugged into roof print X4/38 or X4/40.

Sva 6-93290 EN Edition 01-2006

4009A-130

Sva 6-93290 EN Edition 01-2006

 4009A-131

7. Additional line for 6 work lamps

E38 Work lamp on roof, front, outside,
(7) Roof ground point, front left Fig. 122
right [A] Fig. 125
E44 Work lamp on roof, at front inside
(8) Roof ground point, front right Fig. 123
left [I] Fig. 124
E33 Work lamp on roof, E45 Work lamp on roof, at front inside
front centre left [M] Fig. 124 right [I] Fig. 125
E34 Work lamp on roof, front, X5/7 Socket for auxiliary headlight
centre, right [M] Fig. 125 and work lamp, front left Fig. 122
E37 Work lamp on roof, front, X5/8 Socket for auxiliary headlight
outside, left [A] Fig. 124 and work lamp, front right Fig. 123

8. Additional line for electrical mirror adjustment and heating

X6/24 Plug connection for electric mirror,
S2/19 Switch for heated mirror [HEIZSP] Fig. 126
right [SPIEGEL] Fig. 128
X3/80 Plug connection for mirror X6/25 Plug connection for electric mirror,
adjustment, roof print [X3/13] Fig. 127 left [SPIEGEL] Fig. 129
X4/15 Plug connection for heated mirror, X9/1 Plug connection for switch for
roof print [15] Fig. 127 mirror adjustment Fig. 126
X4/39 Plug connection for switch for
heated mirror, roof print [39] Fig. 127

9. Additional line for air conditioning system

X2/9 Plug connection for roof print X4/73 Plug connection for
supply for blower Fig. 130 temperature sensor Fig. 132
X2/20 Plug connection for air X4/74 Plug connection for
conditioning blower motor Fig. 131 blower potentiometer Fig. 132
X4/44 Plug connection for supply for X4/75 Plug connection for air
air conditioning control Fig. 130 conditioning control potentiometer Fig. 132

10. Additional line for solenoid, all-round light, standard socket

X4/33 Socket for all-round light, left Fig. 133 X4/34 Socket for all-round light, right Fig. 134

11. Additional line for all-round light

X19/1 Plug connection for
A5/1 All-round light, left Fig. 135
all-round light, left Fig. 135
X19/2 Plug connection for
A5/2 All-round light, right Fig. 136
all-round light, right Fig. 136

12. Additional line for wiper, hinged windscreen, front

X4/1 Plug connection for wiper motor,
M2/2 Wiper motor, front Fig. 137
hinged screen, front Fig. 138

Sva 6-93290 EN Edition 01-2006

4009A-132

Sva 6-93290 EN Edition 01-2006

 4009A-133

13. Additional line for blower ventilation

X2/9 Plug connection for roof print
M10 Motor blower, roof Fig. 139
supply for blower Fig. 141
S50/2 Blower switch 1-2-3, roof Fig. 140

14. Additional line for front heated windscreen

X2/90 Plug connection for roof print,
E25 Heated windscreen, front Fig. 142
front heated windscreen [90] Fig. 145
K6/8 Relay for front heated windscreen X4/41 Plug connection for switch for front
[HZS VO] Fig. 143 heated windscreen roof print [41] Fig. 145
S2/16/2 Switch for front heated windscreen X16/5 Screw connection for roof print
[HZS VO] Fig. 144 ground point Fig. 145
X1/24 Screw connection for potential 30,
roof print, heated windscreens Fig. 145

15. Additional line for rear heated windscreen

X2/91 Plug connection for roof print,
E26 Heated windscreen, rear Fig. 146
rear heated windscreen [91] Fig. 149
K6/7 Relay for rear heated windscreen X4/42 Plug connection for switch for rear
[HZS HI] Fig. 147 heated windscreen, roof print [42] Fig. 149
S2/16/1 Switch for rear heated windscreen X16/5 Screw connection for roof print
[HZS HI] Fig. 148 ground point Fig. 149
X1/24 Screw connection for potential 30,
roof print, heated windscreens Fig. 149

16. Additional line for mirror heating

X4/15 Plug connection for heated mirror,
E18/1 Heated mirror, left Fig. 150
roof print [15] Fig. 153
X4/39 Plug connection for switch for
E18/2 Heated mirror, right Fig. 151
heated mirror, roof print[39] Fig. 153
S2/19 Switch for heated mirror [HEIZSP] Fig. 152

17. Additional line for Xenon work lamp

X2/26 Plug connection for electronics, X4/21 Plug connection for work lamp
Xenon, input, right Fig. 154 outside right at rear Fig. 154
X2/27 Plug connection for electronics, X4/22 Plug connection for work lamp
Xenon, input, left Fig. 155 inside right at rear Fig. 154
X4/10 Plug connection for electronics, X4/23 Plug connection for work lamp
Xenon, output, right Fig. 154 outside left at rear Fig. 155
X4/11 Plug connection for electronics, X4/24 Plug connection for work lamp
Xenon, output, left Fig. 155 inside left at rear Fig. 155

Sva 6-93290 EN Edition 01-2006

4009A-134
Connector positions and pin assignments

Fig. 101

Fig. 102

Fig. 103

Fig. 104

Sva 6-93290 EN Edition 01-2006

 4009A-135

Fig. 105

Fig. 106

Fig. 107

Fig. 108

Sva 6-93290 EN Edition 01-2006

4009A-136

Fig. 109

Fig. 110

Fig. 111

Fig. 112

Sva 6-93290 EN Edition 01-2006

 4009A-137

Fig. 113

Fig. 114

Sva 6-93290 EN Edition 01-2006

4009A-138

Fig. 115

Fig. 116

Sva 6-93290 EN Edition 01-2006

 4009A-139

Fig. 117

Fig. 118

Fig. 119

Fig. 120

Sva 6-93290 EN Edition 01-2006

4009A-140

Fig. 121

Fig. 122

Sva 6-93290 EN Edition 01-2006

 4009A-141

Fig. 123

Fig. 124

Sva 6-93290 EN Edition 01-2006

4009A-142

Fig. 125

Fig. 126

Sva 6-93290 EN Edition 01-2006

 4009A-143

Fig. 127

Fig. 128

Fig. 129

Sva 6-93290 EN Edition 01-2006

4009A-144

Fig. 130

Fig. 131

Fig. 132

Sva 6-93290 EN Edition 01-2006

 4009A-145

Fig. 133

Fig. 134

Fig. 135

Fig. 136

Sva 6-93290 EN Edition 01-2006

4009A-146

Fig. 137

Fig. 138

Fig. 139

Fig. 140

Sva 6-93290 EN Edition 01-2006

 4009A-147

Fig. 141

Fig. 142

Fig. 143

Fig. 144

Sva 6-93290 EN Edition 01-2006

4009A-148

Fig. 145

Fig. 146

Fig. 147

Sva 6-93290 EN Edition 01-2006

 4009A-149

Fig. 148

Fig. 149

Fig. 150

Sva 6-93290 EN Edition 01-2006

4009A-150

Fig. 151

Fig. 152

Fig. 153

Sva 6-93290 EN Edition 01-2006

 4009A-151

Fig. 154

Fig. 155

Sva 6-93290 EN Edition 01-2006

4009A-152

ELECTRICAL REMOTE CONTROL VALVES WIRING HARNESS

X3/10 Plug connection for terminal

X4/92 Plug connection for AUX3 Fig. 3
resistance Fig. 1
X4/83 Plug connection for remote
X4/93 Plug connection for AUX4 Fig. 4
control valves [EHS] Fig. 2
X4/90 Plug connection for AUX1 Fig. 3 X4/94 Plug connection for AUX5 Fig. 4
X4/91 Plug connection for AUX2 Fig. 3

Sva 6-93290 EN Edition 01-2006

 4009A-153
Connector positions and pin assignments

Fig. 1

Fig. 2

Fig. 3

Sva 6-93290 EN Edition 01-2006

4009A-154

Fig. 4

Sva 6-93290 EN Edition 01-2006

 4009A-155

1. Additional line for external button, powerlift, front

S14/3 External button, power lift, X4/69 Plug connection for external
front LOWER [HPL - L] Fig. 101 button for front power lift [HPL] Fig. 102
S15/3 External button, power lift,
front RAISE [HPL - R] Fig. 101

2. Additional line for external button for front remote control valves
S19/1 External button, AUX BROWN
pressure in - [EHR - L] Fig. 103 X4/72 Plug connection for external
pushbutton,
S19/2 External button, AUX BROWN front AUX brown [EHR] Fig. 104
pressure in + [EHR - R] Fig. 103

Sva 6-93290 EN Edition 01-2006

4009A-156
Connector positions and pin assignments

Fig. 101

Fig. 102

Fig. 103

Fig. 104

Sva 6-93290 EN Edition 01-2006

 4009A-157

Blank page

Sva 6-93290 EN Edition 01-2006

4009A-158

REVERSE TRAVEL EQUIPMENT WIRING HARNESS

Sva 6-93290 EN Edition 01-2006

 4009A-159

A4/1 FMGR plug connection - white [1] Fig. 1 S2/61/1 Parking interlock switch [PARK] Fig. 7
A4/1 FMGR plug connection -
S2/75 Button for horn [HORN] Fig. 7
dark grey[1] Fig. 2
A4/2 FMGR plug connection -
S4/4/1 Switch for forwards - reverse [V/R] Fig. 7
dark grey [2] Fig. 1
A4/2 FMGR plug connection -
S5/1 Switch for brake light [BREMSL] Fig. 8
dark grey [2] Fig. 2
A4/4 FMGR plug connection - grey [4] Fig. 1 S46/1 Coupling switch 80% [KUPPL] Fig. 8
A4/4 FMGR plug connection - X4/25 Plug connection for handbrake
dark grey [4] Fig. 2 switch [HANDBREMSE] Fig. 9
B17/1 Angle of rotation sensor, coupling X4/25/1 Plug connection for handbrake
[DW-KUPPL] Fig. 3 switch [HANDBREMSE] Fig. 10
X4/70/1 Plug connection for accelerator
Horn Plug connection for horn Fig. 4
pedal [FAHRPEDAL] Fig. 10
X6/15 Plug connection for mobile phone
K5/60 Relay for coupling [KUPPLUNG] Fig. 5
socket, left Fig. 9
K5/61 Relay for front accelerator pedal X6/15 Plug connection for mobile phone
[FAHRPEDAL1] Fig. 5 socket, left Fig. 10
K5/62 Relay for rear accelerator pedal X6/58 Plug connection for seat switch
[FAHRPEDAL1] Fig. 5 [SITZ RF] Fig. 11
P6 Plug connection for reverse travel
equipment display[DISPLAY] Fig. 6

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Connector positions and pin assignments

Fig. 1

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Fig. 2

Fig. 3

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Fig. 4

Fig. 5

Fig. 6

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Fig. 7

Fig. 8

Fig. 9

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Fig. 10

Fig. 11

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1. Additional line for wash tank extension

M5 Plug connection for motor for M6 Plug connection for motor for
windscreen washing system, rear Fig. 101 windscreen washing system, front Fig. 101
M5 Plug connection for motor for M6 Plug connection for motor for
windscreen washing system, rear Fig. 102 windscreen washing system, front Fig. 102

2. Additional line for rear wiper extension

M4/2 Plug connection for motor, M4/2 Plug connection for wiper motor,
rear angled wiper Fig. 103 hinged screen, front Fig. 104

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Connector positions and pin assignments

Fig. 101

Fig. 102

Fig. 103

Fig. 104

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Blank page

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ISO BUS WIRING HARNESS

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X2/87 Plug connection for right cab

(11) Ground point,
wiring harness - instruments
engine cable carrier, rear Fig. 1
ISO-BUS wiring harness Fig. 8
CN4 Plug connection for X3/85 Plug connection for
ECCU2 ISO-BUS Fig. 2 terminal resistance ISO-BUS Fig. 9
X4/85/a Plug connection for cab wiring
K5/80 Relay for potential 15 ISO-BUS Fig. 3
harness, right - ISO BUS preparation Fig. 10
X4/85/b Plug connection for cab wiring
K5/81 Relay for ECU power ISO-BUS Fig. 3
harness, right - ISO BUS preparation Fig. 10
X4/86 Plug connection for socket LBS
K5/82 Relay for power socket ISO-BUS Fig. 4
ISO-BUS Fig. 7
V8/1 Diode group, ISO-BUS Fig. 4 X9/17 Socket for diagnosis service tool Fig. 11
X1/30/ISOScrew connection for engine print, X12/8 Plug connection for virtual terminal
potential 30 Fig. 5 ISO-BUS Fig. 12
X2/11 Plug connection for engine print
X85 Socket for LBS, ISO-BUS Fig. 13
ISO-BUS Fig. 6
X2/86 Plug connection for socket LBS
ISO-BUS Fig. 7

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Connector positions and pin assignments

Fig. 1

Fig. 2

Fig. 3

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Fig. 4

Fig. 5

Fig. 6

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Fig. 7

Fig. 8

Fig. 9

Fig. 10

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Fig. 11

Fig. 12

Fig. 13

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ARMREST WIRING HARNESS

S28/1 Pushbutton, front power lift

X30/1 Plug connection for supply, armrest Fig. 5
management Fig. 1
X6/27 Plug connection for console for ARU
X30/7 Plug connection for ARU CAN BUS Fig. 6
seat switch (reverse travel equipment)Fig. 2
X30/9 Plug connection for ARU -
X6/58 Plug connection for seat switch
lighting, switch for front power
[SITZ RF] Fig. 3
lift management Fig. 7
X18/4 Plug connection for right cab
wiring harness - armrest Fig. 4

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Connector positions and pin assignments

Fig. 1

Fig. 2

Fig. 3

Fig. 4

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Fig. 5

Fig. 6

Fig. 7

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Blank page

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1. Additional line for multicontroller

X4 Plug connection for X30/11 Plug connection for supply -
multicontroller print Fig. 101 multicontroller print Fig. 103
X21 Plug connection for
multicontroller print Fig. 102

2. Additional line for AUX5 button

X30/6 Plug connection for ARU -
S34 Button for AUX5 Fig. 104
AUX5 button Fig. 105

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3. Additional line for rapid retraction button

X30/2 Plug connection for ARU - rapid retraction button Fig. 106

4. Additional line for manual accelerator slider

X30/3 Plug connection for ARU - manual accelerator slider Fig. 107

5. Additional line for AUX control lever

X30/4 Plug connection for ARU - AUX control lever Fig. 108

6. Additional line for AUX joystick

X30/5 Plug connection for ARU - AUX joystick Fig. 109

7. Additional line for potentiometers AUX1 and 2

X30/16 Plug connection for ARU - potentiometers R20/1 and R20/2 Fig. 110

8. Additional line for potentiometers AUX3 and 4

X30/15 Plug connection for ARU - potentiometers R20/3 and R20/4 Fig. 111

9. Additional line for potentiometer AUX5

X30/12 Plug connection for ARU - potentiometer R20/5 Fig. 112

10. Additional line for lighting

X30/13 Plug connection for ARU lighting Fig. 113

11. Additional line for EDC stop button

X30/14 Plug connection for ARU, button for EDC stop Fig. 114

12. Additional line for shift button (floating position)

X30/19 Plug connection for shift button Fig. 115

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Connector positions and pin assignments

Fig. 101

Fig. 102

Fig. 103

Fig. 104

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Fig. 105

Fig. 106

Fig. 107

Fig. 108

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Fig. 109

Fig. 110

Fig. 111

Fig. 112

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Fig. 113

Fig. 114

Fig. 115

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Blank page

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COMPONENTS
Armrest

A29 Joystick for 2 AUX R20/4 Potentiometer for 4th AUX

A30 Print ARU R20/5 Potentiometer for 5th AUX
A31 Multicontroller II S2/72 Rapid retraction button
B28 Manual accelerator slider S28/1 Pushbutton, front power lift management
B52 Shift lever for AUX (black) S33 EDC stop button
R20/1 Potentiometer for 1st AUX S34 Button for 5th AUX
R20/2 Potentiometer for 2nd AUX S35 Joystick button
R20/3 Potentiometer for 3rd AUX

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Central print A12

List of plugs
W1/4 Radio start plug connection X4/45 Plug connection for sprung front axle
X1/6/1 Screw connection for 2nd power socket 40 A X4/51 Plug connection for „Italy“ trailer brake
X1/6/2 Screw connection for 1st power socket 40 A X5/1 Screw - plug connection for potential 31
X1/8 Screw connection for start switch supply X6/5 Reserve
X1/11 Screw connection for potential 30 X6/6 Plug connection for instruments
X1/26 Plug connection for potential 15/2, wiring harness
heating blower X10/8 Plug connection for wiring harness, cab, left
X1/60 Screw connection for power socket, X14/15 Plug connection for wiring harness
cab 30 A, potential 30 for roof supply (15)
X2/4/1 Screw - plug connection for potential 15/2 X18/1 Plug connection for instruments
X2/4/2 Screw - plug connection for potential 15/2 wiring harness
X3/1 Radar sensor plug connection X24/1 Plug connection for instruments
X3/5 Plug connection for reserve wiring harness
X24/2 Plug connection for right cab wiring harness

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Fuses
F1 Start switch supply ................................. 20 A reverse fan, potential 15/2......................10 A
F2 Power socket for cab, potential 30 ........ 25 A F30 Supply for engine print, potential 15/2......5 A
F3 1st power socket for potential 30 ........... 40 A F31 Supply for radar sensor, potential 15/2.....5 A
F4 2nd power socket for potential 30.......... 40 A F32 Supply for PTO sensors, potential 15/2..10 A
F5 Supply, indicator, potential 15/1 ............. 15 A F33 Supply for hazard warning light,
F6 ADIC, keypads potential 15/1 .................. 5 A potential 30.............................................10 A
F7 Relay 56a, potential 30.......................... 15 A F34 Work lamp on roof, right 56b .................7.5 A
F8 Reserve, potential 30............................... 5 A F35 Work lamp on roof, left 56b ...................7.5 A
F9 SGR, potential 30 .................................. 10 A F36 Headlight, engine hood, right 56b .........7.5 A
F10 Supply for ECCU2, potential 30............... 5 A F37 Headlight, engine hood, left 56b............7.5 A
F11 Relay for worklight, mudguard, F38 Trailer socket, potential 58L
potential 30 ............................................ 10 A front and rear ...........................................5 A
F12 Light switch, potential30 ........................ 10 A F39 Trailer socket, potential 58R
F13 Cigarette lighter, 2-pin socket, front and rear............................................5 A
diagnosis socket, EDC print, F40 Supply for steering column switch,
potential 30 ........................................... 7.5 A potential 15/1..........................................15 A
F14 FMGR, potential 30 .............................. 7.5 A F41 Reserve for supply, potential 15/1 X6/5.7.5 A
F15 Reserve, potential 15/2.......................... 10 A F42 Reserve for supply, potential 15/1 X6/5....5 A
F16 Reserve, potential 15/2............................ 5 A F43 Reserve for supply, potential 15/1 X6/5....5 A
F17 Blower for heating, potential 15/2 .......... 20 A F44 Reserve for supply, potential 15/1 ............5 A
F18 SGR, potential 15/1 ................................. 5 A F45 Supply for roof, ICU potential 15/1 ...........5 A
F19 Supply for ARU, EDC potential 15/1........ 5 A F46 Relay, brake light, Optistop,
F20 Supply for ARU, EDC potential 15/1........ 5 A potential 15/1..........................................10 A
F21 Supply for D+ relay, ECCU2, EDC .......... 5 A F47 Supply for AUX potential 15/1 ..................5 A
F22 Reserve for supply, terminal 30 X6/5....... 5 A F48 Supply for seat, „Italy“ trailer brake,
F23 Reserve for supply, terminal 30 X6/5....... 5 A potential 15/1..........................................20 A
F24 58 L Parking light, rear left ADIC, F49 Supply for potential 15/1 EDC box ...........5 A
switch lighting for instrument panel, F50 Supply for potential 15/1 ECCU2 ...........25 A
front and rear trailer sockets, F51 Supply for potential 15/1 FMGR .............10 A
ISO BUS ............................................... 7.5 A F52 Trailer socket for turn signal,
F25 58 R Parking light, rear right, ARU, right front and rear.................................7.5 A
switch lighting for control panel, F53 Trailer socket for turn signal,
mobile phone socket............................. 7.5 A left front and rear ..................................7.5 A
F26 Parallel wiper, horn, interval relay, F54 Reserve for supply, potential 30 X6/5.......5 A
potential 15/2 ........................................ 7.5 A F55 Trailer socket for brake light,
F27 Sprung front axle, potential 30............... 10 A front and rear .........................................10 A
F28 Sprung front axle, potential 15/2.............. 5 A
F29 Supply to front and rear power sockets,
standard signal socket,

Relay

K2 Indicator relay K5/10 Relay, light, potential 58

K3 Interval relay K5/11 Relay, potential D+ supply
K5/5 Switchover relay for main beam K5/12 Relay, brake light, Optistop
K5/6 Switchover relay for dipped beam K5/43 Relay for D+ cut-off
K5/7/1 Relay, potential 15/1 supply K5/56a Relay for main beam
K5/7/2 Relay, potential 15/2 supply K5/56b Relay for dipped beam
K5/9 Relay, work lamp, fender

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Engine print A14

List of plugs
X1/CL Plug connection for central lubrication X1/30/SOC.F
X1/HEATPlug connection for heating GND Screw connection for power socket,
X1/15/1 Plug connection for power socket, front, front, potential 30
potential 15 X1/31/1 Screw connection for potential 31
X1/15/ABS X1/31/2 Screw connection for potential 31
Plug connection for ABS, potential 15 X1/50 Screw connection for starter, potential 50
X1/15FUEL X2/11 Plug connection for ISO-BUS, potential 30 Si
Plug connection for filter heating, potential 15 X2/13 Plug connection for electric battery
X1/30/1 Screw connection for potential 30 main switch
X1/30/2 Screw connection for potential 30 X2/WKL Plug connection for work lamp,
X1/30/ABS engine hood, reserve
Screw connection for ABS, potential 30 X4/64 Plug connection for reverse fan
X1/30/EEM X6/2 Plug connection for supply for EDC
Screw connection for engine control unit, X10/3 Plug connection for instruments -
potential 30 engine print wiring harness
X1/30/ISO X12/1 Plug connection for engine -
Screw connection for ISO-BUS, engine print wiring harness
potential 30

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Fuses
F201 Work lamps, engine hood ...................... 15 A F213 Electrical battery main switch,
F202 Work lamps, engine hood, reserve ........ 15 A potential 30...............................................5 A
F203 Supply for EEM3, potential 30 ............... 30 A F214 Fuel filter heating, potential 15 ...............10 A
F204 Central lubrication, potential D+ ............. 5 A F215 Supply for ABS, potential 15 ....................5 A
F205 Air conditioning compressor .................... 5 A F216 Power socket, front, potential 15 ............15 A
F206 Reserve (potential 15) ............................. 5 A F217 Supply for hazard warning light,
F207 Supply for EEM3, potential 15 ................. 5 A potential 30............................................ 15 A
F208 Fuel delivery pump ................................ 10 A F218 Supply for ABS, potential 30 ................. 25 A
F209 Reserve (potential 30) .......................... 7.5 A F219 ISO bus for potential 30......................... 20 A
F210 Supply for EDC, potential 30 ................ 7.5 A F220 ISO bus for potential 30......................... 25 A
F211 Supply for reverse fan, potential 30 ...... 10 A F221 Power socket, front, potential 30 ........... 40 A
F212 ADIC, ICU, radio memory, F222 ISO bus for potential 30......................... 40 A
potential 30 ........................................... 10 A

Relay
K4/BATT Time relay, main electrical battery switch K6/WKL-ERelay for work lamp, engine hood
K5/FAN Relay for reverse fan relay K6/HEAT Relay for heating blower
K5/LP Relay for fuel delivery pump relay K8/50 Relay for starter
K5/IGN Relay for engine, potential 15

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Roof print A13

List of plugs
X1/24 Screw connection for potential 30, X4/44 Plug connection for supply for air
heated windscreens conditioning control
X2/9 Plug connection for supply for blower X4/65 Plug connection for rear wiper motor
X2/14 Plug connection for air conditioning X4/ASW [X4/38] Plug connection for work lamp at front
X2/90 Plug connection for front heated windscreen X4/ASW [X4/38] Plug connection for supply,
X2/91 Plug connection for rear heated windscreen lighting, all-round light bar
X3/80 Plug connection for mirror adjustment [X3/13] X4/ESW [X4/40] Plug connection for auxiliary headlight
X4/15 Plug connection for heated mirror X4/ESW [X4/40] Plug connection for supply,
X4/16 Plug connection for reserve lighting, all-round light bar
X4/17 Plug connection for front wiper motor X6/23 Plug connection for rear wiper motor
X4/39 Plug connection for switch for heated mirror X10/11 Plug connection for roof print supply [11]
X4/41 Plug connection for switch for front X10/12 Plug connection for roof wiring harness [12]
heated windscreen X10/13 Plug connection for roof wiring harness [13]
X4/42 Plug connection for switch for rear X16/4 Screw connection for potential 30,
heated windscreen supply for roof print
X16/5 Screw connection for potential 31, roof print

Fuses
F60 Side marker light, front left, F69 All-round light, ASW panel supply
licence plate lights, roof ........................... 3 A for potential 30........................................15 A
F61 Side marker light front right, F70 2 rear work lamps ..................................10 A
ICU switch lighting for roof, spot F71 Heated mirror ........................................7.5 A
light, radio and ASW panel lighting, F72 Supply for radio, interior light,
activation of all work lamps...................... 5 A ASW panel supply for potential 30 ...........5 A
F63 Rear wiper ............................................ 7.5 A F74 Reserve for potential 30 .........................25 A
F64 Front wiper for hinged windscreen........ 7.5 A F76 Heated windscreen, rear ........................25 A
F65 Control, air conditioning system............... 5 A F77 Heated windscreen, front ......................25 A
F66 Blower / air conditioning system ............ 20 A F100 Electrically adjustable mirror ....................5 A
F67 4 front work lamps (outside) .................. 15 A F101 ASW panel supply for 4 front
F68 4 rear work lamps, ASW panel work lamps, work lamp on BB light ........25 A
supply for potential 30 .......................... 10 A F102 4+2 front work lamps .............................15 A
F103 Air conditioning pushbutton ......................5 A

Relay
K5/29 Supply for potential, terminal 15 K5/32 Supply, D+ air conditioning
K5/30 4 rear work lamps (outside) K5/33 4+2 front work lamps
K5/31 4 front work lamps (outside) K5/36 Reserve

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EDC print A16

List of plugs
X2/6 Plug connection for lighting, X4/2 Plug connection for LED for diagnosis / slip [2]
potentiometer EDC X4/3 Plug connection for LED for raise / lower [3]
X3/16 Plug connection for lowering speed X5/6 Plug connection for nominal value and
potentiometer lighting potentiometer
X3/17 Plug connection for lift X6/13 Plug connection for cigarette lighter and
limitation potentiometer socket, 2-pin (13)
X3/18 Plug connection for EDC X10/4 Plug connection for EDC print armrest
mixing potentiometer (GSV) [4]
X3/19 Plug connection for X14/4 Plug connection for EDC print - control panel
slip control potentiometer

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Print ARU A30

List of plugs
X30/1 Plug connection for supply, armrest X30/11 Plug connection for supply,
X30/2 Plug connection for ARU - rapid multicontroller print
retraction button X30/12 Plug connection for ARU -
X30/3 Plug connection for ARU - manual potentiometer for R20/5
accelerator slider X30/13 Plug connection for ARU lighting
X30/4 Plug connection for ARU - AUX control lever X30/14 Plug connection for ARU, button for EDC stop
X30/5 Plug connection for ARU - AUX joystick X30/15 Plug connection for ARU - potentiometers
X30/6 Plug connection for ARU - AUX5 button R20/3 and R20/4
X30/7 Plug connection for ARU CAN BUS X30/16 Plug connection for ARU - potentiometers
X30/8 Plug connection for ARU reserve R20/1 and R20/2
X30/9 Plug connection for ARU - lighting, switch for
front power lift management

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Relay
Miniature relay
(K6/7, K6/8, K6/WKL-E, K6/HEAT)

Contacts ................................................. normally open

Activation period ............................................... 100 %
Nominal voltage .............................................. 12 VDC
Load............................................................. max. 30 A
Resistance 85 - 86 ....................................... 65 Ω ± 10%

Miniature relay
(K5/7/1, K5/7/2, K5/12, K5/80, K5/81)

Contacts ..........................................................changer
Activation period ............................................... 100 %
Nominal voltage .............................................. 12 VDC
Load.........................................................max. 20/30 A
Resistance 85 - 86 ....................................... 65 Ω ± 10%

Micro relay
(K5/5, K5/6, K5/9, K5/10, K5/11, K5/29, K5/30, K5/31,
K5/33, K5/37, K5/42, K5/43, K5/56a, K5/56b, K5/60,
K5/61, K5/62, K5/LP, K5/FAN, K5/IGN)

Contacts ..........................................................changer
Activation period ............................................... 100 %
Nominal voltage .............................................. 12 VDC
Load.........................................................max. 15/25 A
Resistance 1 - 2 ................................ 80 Ω±10% at 23°C
Interference suppression resistance ................... 680 Ω

Power relay
(K5/32, K5/82, K8/50)

Contact ................................................. normally open

Activation period ............................................... 100 %
Nominal voltage .............................................. 12 VDC
Load............................................................. max. 70 A
Resistance 1 - 2 ....................................................80 Ω
Interference suppression resistance ....................560 Ω

Time relay (with delay)

(K4/2/2, K4/BATT)

Contacts ..........................................................changer
Retention period ................................................ 40 sec.
Activation period ............................................... 100 %
Nominal voltage .............................................. 12 VDC
Load............................................................. max. 10 A

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Indicator relay
(K2)

Nominal voltage ...............................................12 VDC

Frequency ........................... 90 indicator code/ min ± 30

Interval relay
(K3)

Nominal voltage ...............................................12 VDC

Interval period.............................................. 6 sec. ± 1.5

Power relay
(K8/2)

Contacts .................................................normally open

Nominal voltage ...............................................12 VDC
Load ............................................................ max. 300A
Resistance 1 - 2 (at 20°C)............................ 37.5 Ω ± 6.5%
(including interference-suppression resistance)

Electrical battery main switch

(Q2)

Nominal voltage ...............................................12 VDC

Operating current ....................................... max. 250 A
Nominal consumption during normal operations....0.4 A
Type of protection .................................................IP 65

Diode group
(V8/1)

Nominal voltage ...............................................12 VDC

Nominal current ...................................................1.5 A
Locking voltage..................................................1000 V

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Engine and fuel system components

Oil pressure sensor B37

Design................................................. pressure sensor

PIN 3 supply ...................................................... 5 VDC
PIN 1 supply ..................................................... ground
PIN 2................................................................... signal
Tightening torque ............................................... 25 Nm

Engine speed sensor B20

Design ................................................ inductive sensor

PIN 1................................................................. ground
PIN 2................................................................... signal
Tightening torque ............................................... 25 Nm

Camshaft position sensor B40

Design ................................................ inductive sensor

PIN 1 supply ..................................................... ground
PIN 2................................................................... signal
PIN 3............................................................. sheathing
Tightening torque ................................................. 8 Nm

Manual accelerator slider B28

Design.......................................................Hall element
PIN 1 supply ...................................................... 5 VDC
PIN 4 supply...................................................... ground
Current consumption ..................................max. 15 mA
PIN 2 signal........................................................... VDC
Load resistance ......................................min. 4.5 kOhm
Insulation resistance ........................................ >100kΩ

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Test switch for air filter S3

Contact ...................................................normally open

Shift point ..................... > 65±3 mbar negative pressure

Charge-air pressure / temperature sensor

B29

PIN 3 supply ..................................................... 5 VDC

PIN 1 supply ..................................................... ground
PIN 2 signal .................. charged air temperature (NTC)
PIN 4 signal ....................................... charger pressure
Tightening torque .............................................. 3.3 Nm

Charged air temperature sensor Charger pressure sensor

Temperature [°C] Resistance [Ω] (PIN 2-1) Charger pressure [kPa] Voltage [V] (PIN 4-1)
-45 39260 50 0.5
-20 13850 80 0.9
0 5500 110 1.3
20 2420 140 1.7
40 1166 170 2.1
60 609 200 2.5
80 340 230 2.9
100 202 260 3.3
120 127 290 3.7
130 102 320 4.1
350 4.5

Heating flange E10/1

Nominal voltage ...............................................12 VDC

Current at 10V ........................................ approx. 147 A
Power ........................................................ 2.1 kW ±0.1

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Control switch, coolant level S22

(Reed switch)

Contact .................................................. normally open

Nominal voltage .............................................. 12 VDC

Sensor for coolant temperature B22

Design................................................................... NTC
PIN 2 supply ...................................................... 5 VDC
PIN 1................................................................... signal
Measurement range ...............................-50 to +150ºC
Nominal resistance (at 20ºC) ........................2.5 kΩ± 6%
Insulation resistance ...................................... >100 kΩ
Tightening torque ............................................... 20 Nm

Fuel tank level transmitter B2/1

Diesel level Resistance in Ω

0 10 ± 2.5
1/2 95 ± 5
1 180 ± 12

Fuel delivery pump M13

Nominal voltage .............................................. 12 VDC

Current consumption ...................................... max. 6 A
Fuel delivery pressure
at idling speed ........................................ 1.0 to 1.3 bar
at nominal rating .................................... 1.0 to 1.1 bar

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Water in fuel sensor B23

Fuel delivery pressure sensor B39

Design .................................................pressure sensor

PIN 3 supply ..................................................... 5 VDC
PIN 1 supply ..................................................... ground
PIN 2 ...................................................................signal
Tightening torque ............................................... 25 Nm

Fuel temperature sensor B36

Design ...................................................................NTC
PIN 2 supply ..................................................... 5 VDC
PIN 1 ...................................................................signal
Measurement range ............................... -50 to +150ºC
Nominal resistance (at 20ºC) ....................... 2.5 kΩ± 6%
Insulation resistance .......................................>100 kΩ
Tightening torque ............................................... 20 Nm

Solenoid valve, high-pressure pump Y20

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Rail pressure sensor B38

PIN 3 supply ...................................................... 5 VDC

PIN 1 supply .................................................... ground
PIN 2 ................................................................. signal
Tightening torque ............................................ 140 Nm

Solenoid valves, injectors

Y21, Y22, Y23, Y24, Y25, Y26

Type ............................................................. CRIN2-2V

Number of blowholes.................................................. 5
Tightening torque of retaining bolts .................... 40 Nm
Tightening torque of retaining nuts for cable ..... 1.5 Nm

Reverse fan A62

Air compressor
PIN 2, 4 supply.................................................. ground
PIN 3 activation ................................................ 12 VDC
Current consumption ............................................ 5.6 A
Solenoid valve
PIN 2, 4 supply.................................................. ground
PIN 1 activation ................................................ 12 VDC
Current consumption ............................................ 0.5 A
Coil resistance ......................................................24 Ω

Coolant heater

Voltage ............................................................... 230 V

Power .............................................................. 1100 W

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Transmission components
System pressure sensor B47

Measurement range ......................................0 - 50 bar

PIN 1 supply ..................................................... 5 VDC
PIN 2 supply .................................................... ground
Current consumption .................................. max. 3 mA
PIN 3 signal ......................................................... VDC
at 0 bar ..................................5% of the supply voltage
at 50 bar ..............................95% of the supply voltage
Calibration point .................................................30 bar
Precision ........................................ <1% at -40 to +125°C
Insulation resistance ....................................... >100 kΩ

Lubrication pressure sensor B51

Measurement range ......................................0 - 20 bar

PIN 1 supply ..................................................... 5 VDC
PIN 2 supply .................................................... ground
Current consumption .................................. max. 3 mA
PIN 3 signal ........................................................ VDC
at 0 bar ..................................5% of the supply voltage
at 20 bar ..............................95% of the supply voltage
Calibration point....................................................5 bar
Precision ........................................ <1% at -40 to +135°C
Insulation resistance ....................................... >100 kΩ
Tightening torque ............................................... 20 Nm

Speed sensors B24, B25, B26, B27, B28

All sensors have the same electrical values, but

different lengths.
B24, B25, B35 ................................................. 77.3mm
B26, B27.......................................................... 99.1mm
Frequency range...................................... 10 to 6000Hz
Signal ..................................................Ueff = >0.8 VAC
Nominal resistance (at 20ºC) ......................1050 ± 100 Ω
Insulation resistance .......................................>100 kΩ

Potentiometer, accelerator pedal R8

(double potentiometer)
Voltage supply of FMGR box.....................5 to 6.5 VDC
Total resistance 2x ........................................4 kΩ ± 20%
Protective resistor signal 2x .........................1k7Ω ± 20%
Signal current ................................................ >100 µA
1 = Ground
2 = Supply
3 = Signal, FMGR box (falling)
4 = Signal - FMGR box and EEM3 box (rising)
R measured 1-2 ............................................ 2 kΩ ± 20%
R measured 1-3 ................................ 1k7Ω to 3k7Ω ± 20%
R measured 1-4 ...............................3k7Ω to 1k7Ω ± 20%

Setting regulation for external voltage source of 5 VDC:

Accelerator pedal position 0............................ 0.8 VDC
Accelerator pedal position max. ...................... 4.2 VDC
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Pressure filter switch S49/1

Contact ................................................ normally closed

Supply ............................................................... ground
Switching point at ∆p ........................................ > 5 bar

Limit load potentiometer R23

The full-load potentiometer is combined with a switch

for the indicator lamp.
Contact .................................................. normally open
PIN 1 supply ............................................ 5 to 6.5 VDC
PIN 2 supply...................................................... ground
PIN 3 signal........................................................... VDC
PIN1 - 2 resistance .................................... 4.7 kΩ± 10%
PIN1 - 3 resistance ............................... 0 - 4.7 kΩ± 10%

Temperature sensor, gear oil B32 Characteristic value

at 1mA test current

Version .................................................................. PTC

Imax ..................................................................... 5 mA
Measurement range ...............................-50 to +150ºC
Nominal voltage ................................................. 5 VDC
Nominal resistance (at 25ºC) ................................. 2 kΩ
Insulation resistance ...................................... >100 kΩ
Tightening torque ............................................... 30 Nm

Angle of rotation sensor, clutch B17

PIN 2 supply of FMGR ................................ 5 +1.5 VDC

PIN 1................................................................. ground
PIN 3 ....................................................... signal (VDC)
Pedal not depressed ...................................... 0.7 VDC
Pedal fully depressed .................................... 4.2 VDC
Load resistance ................................................> 200 Ω

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Clutch switch 80% S46

Contact ...................................................normally open

Cyclic supply (GSV 2) ......................................3.1 VDC
(measured with DMM)
Cyclic frequency ..................................................50 Hz
Switching current ..................................... max. 500 mA
Switching power .......................................... max. 10 W
Continuous current .................................. max. 300 mA
Resistance (switch operated) ......................approx. 4 Ω
Insulation resistance .......................................>100 kΩ

Seat switch S8

Contact ...................................................normally open

Solenoid valves Y41, Y42, Y43, Y44,

Y45, Y46, Y59

Supply (cyclic) from .............................................. SGR

Cyclic frequency ................................................200 Hz
Voltage (measured with DMM) .........................7.1 VDC
Inner resistance ........................................... 2.5 Ω ± 0.06
Activation period ................................................. 100 %
Insulation resistance .......................................>100 kΩ
Current consumption ............................................28 A
Tightening torque ............................................... 30 Nm

Solenoid valves, parking interlock Y57, Y58

Supply (cyclic) from .............................................. SGR

Cyclic frequency ................................................200 Hz
Voltage (measured with DMM) ..........................10 VDC
Inner resistance ...................................................... 7 Ω
Activation period ................................................. 100 %
Insulation resistance .......................................>100 kΩ
Current consumption ...........................................1.2 A
Tightening torque ............................................... 30 Nm

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Solenoid valves, brake oil cooling Y11, Y12

Nominal voltage .............................................. 12 VDC

Current consumption ..................................max. 1.54 A
Resistance .................................................. 8 Ω ± 10%
Insulation resistance ...................................... >100 kΩ

Differential lock components

Differential lock solenoid valve Y10

Activation period ................................................ 100 %

Nominal voltage .............................................. 12 VDC
Resistance ........................................8 Ω ± 10% at 20°C
Insulation resistance ....................................... >100 kΩ
Interference suppression .............Z-diodes, antiparallel

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 Front PTO shaft components
Front PTO shaft speed sensor B8

Design ........................................................ Hall sensor

Operating range ....................................1 Hz to 25 kHz
PIN A (+ supply) ...............................................12 VDC
PIN C (supply) ................................................... ground
Current consumption ................................. max. 15 mA
PIN B .................................................... signal (square)
Insulation resistance .......................................>100 kΩ

Front PTO shaft solenoid valve Y4

Proportional
Activation period ................................................. 100 %
Nominal voltage ...............................................12 VDC
Resistance ................................... 4.98 Ω ± 10% at 20°C
Imax .......................................................................1.5 A
Insulation resistance ....................................... >100 kΩ
Activation ...................................... PWM signal 100 Hz
Interference suppression ......................... BZW 06-28B

Rear PTO shaft components

Rear PTO shaft speed sensor B7

Design ........................................................ Hall sensor

PIN 3 supply ....................................................12 VDC
PIN 1 supply ..................................................... ground
Current consumption ................................. max. 21 mA
PIN 2 .................................................... signal (square)

Rear PTO shaft solenoid valve Y5

Proportional
Activation period ................................................. 100 %
Nominal voltage ...............................................12 VDC
Resistance ................................... 4.98 Ω ± 10% at 20°C
Imax .......................................................................1.5 A
Insulation resistance ....................................... >100 kΩ
Activation ...................................... PWM signal 100 Hz
Interference suppression ......................... BZW 06-28B
 4009A-205

Individual wheel, sprung front axle components

Angle of rotation sensor B33/1, B33/2

PIN 2 (+supply from E-box A61) ....................... 12 VDC

PIN 1 (supply from E-box A61)) ......................... ground
PIN 3 ......................................................... signal (mA)
Signal, axle 20.25S
Vehicle lowered ................................................ > 5 mA
Vehicle raised .............................................. < 18.7 mA
Signal, axle 20.29S
Vehicle lowered ....................................... 7.8 ± 0.5 mA
Vehicle raised............................................ 16 ± 0.5 mA
NOTE: The adjustment is made by turning the sensor.

Solenoid valves Y14, Y15, Y16

Activation period ................................................ 100 %

Nominal voltage .............................................. 12 VDC
Resistance at 23°C ......................................... 8 Ω±10%
Insulation resistance ....................................... >100 kΩ
Interference suppression ..............Z-diodes, antiparallel

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Brake components
Brake light switches S5, S25
Power ............................................................ max. 5 W
Current ........................................................ max. 0.5 A
PIN 1 cyclic supply (GSV 2) ............................ 3.1 VDC
(measured with DMM)
Brake pedals not depressed:
PIN 1 - 2 ..........................................................interrupt
PIN 1 - 3 ..........................................................interrupt
Both brake pedals depressed (see graphic symbol):
PIN 1 - 2 .................................................... approx. 4 Ω
PIN 1 - 3 ..........................................................interrupt
One brake pedal depressed (steering brake):
PIN 1 - 2 ..........................................................interrupt
PIN 1 - 3 .................................................... approx. 4 Ω

Switch for handbrake S21

Contact ................................................ normally closed

Current .................................................... max. 500 mA
PIN 1 cyclic supply (GSV 3) ............................ 3.1 VDC
(measured with DMM)

Engine back pressure brake switch S20

Contact ...................................................normally open

Current .................................................... max. 500 mA

Switch for brake fluid level S13

Contact ...................................................normally open

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 4009A-207
Transmitter, compressed air indicator B3

(for compressed air reservoir pressure indicator)

Flat plug-in rim (G) ............................................6.3 mm

Ground via housing (with ground connection)

Pressure [bar] Resistance [Ω] Pressure [bar] Resistance [Ω]

0 10 6 124
2 52 8 155
4 88 10 184

Solenoid valve for trailer brake „Italy“ Y50

Activation period ................................................ 100 %

Nominal voltage .............................................. 12 VDC
Resistance ................................................ 8.5 Ω ± 10%
Insulation resistance ...................................... >100 kΩ

Pushbutton for
trailer brake „Italy“ S50

Contact ................................................ normally closed

Switching power .........................................max. 100 W
Shift point ...................................................... 10±0.5 bar
Safety .......................................................pma 300 bar
Thread ............................................................... G 1/4“

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Reversing facility components

Potentiometer, accelerator pedal R8/1
(double potentiometer)
Voltage supply of FMGR box.....................5 to 6.5 VDC
Total resistance 2x ........................................4 kΩ ± 20%
Protective resistor signal 2x .........................1k7Ω ± 20%
Signal current ................................................ >100 µA
1 = Ground
2 = Supply
3 = Signal, FMGR box (falling)
4 = Signal - FMGR box and EEM3 box (rising)
R measured 1-2 ............................................ 2 kΩ ± 20%
R measured 1-3 ................................ 1k7Ω to 3k7Ω ± 20%
R measured 1-4 ...............................3k7Ω to 1k7Ω ± 20%

Setting regulation for external voltage source of 5 VDC:

Accelerator pedal position 0............................ 0.8 VDC
Accelerator pedal position max. ...................... 4.2 VDC
Angle of rotation sensor, clutch B17/1

PIN 2 supply of FMGR ................................. 5 +1.5 VDC

PIN 1 ................................................................. ground
PIN 3 ....................................................... signal (VDC)
Pedal not depressed .......................................0.7 VDC
Pedal fully depressed .................................... 4.2 VDC
Load resistance ............................................... > 200 Ω

Clutch switch 80% S46/1

Contact ...................................................normally open

Cyclic supply (GSV 2) ......................................3.1 VDC
(measured with DMM)
Cyclic frequency ..................................................50 Hz
Switching current ..................................... max. 500 mA
Switching power .......................................... max. 10 W
Continuous current .................................. max. 300 mA
Resistance (switch operated) ......................approx. 4 Ω
Insulation resistance .......................................>100 kΩ

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 4009A-209
Seat switch S8

Contact .................................................. normally open

Reversible seat switch S8/1

Contact ................................................ normally closed

Current .....................................................max. 500 mA
PIN 3 supply +15............................................. 12 VDC
PIN 4 signal closed ................. K5/60, K5/61 and K5/62

Reversible seat switch S8/2

Contact .................................................. normally open

Current .....................................................max. 500 mA
PIN 1 cyclic supply (GSV 3) ........................... 3.1 VDC
(measured with DMM)
PIN 2 signal to FMGR reverse travel equipment active

Switch, brake pedal S5/1

Contact .................................................. normally open

Current .....................................................max. 500 mA
PIN 1 cyclic supply (GSV 2) ........................... 3.1 VDC
(measured with DMM)

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Hydraulics components
Supply pump pressure control switch S23

(for indicating the contamination level of the pressure

filter)

Contact ................................................ normally closed

Shift point ................................................ p > 1+0.2 bar

Joystick A29
(proportional control)
Measurements for Hall element in
longitudinal direction
Supply voltage .................................................. 5 VDC
Line interrupt/short-circuit ......................... 0 - 0.2 VDC
Signal- play............................................. 0.2 - 1.1 VDC
Signal- lowering max. ............................1.1 - 1.51 VDC
Signal- lowering / proportional .............1.51 - 2.33 VDC
Signal- Neutral .....................................2.33 - 2.67 VDC
Signal- raising / proportional ................2.67 - 3.49 VDC
Signal- raising max. ...............................3.49 - 4.1 VDC
Signal- raising/ latched ........................... 4.1 - 4.8 VDC
Signal- short circuit + .............................. 4.8 - 5.0 VDC
Load resistance ...........................................> 20 kOhm
Joystick A29
(proportional control)
Measurements for Hall element in transverse direction
Supply voltage .................................................. 5 VDC
Line interrupt/short-circuit ......................... 0 - 0.2 VDC
Signal- lowering max. ............................. 0.2 - 0.5 VDC
Signal- lowering / proportional ...............0.5 - 2.33 VDC
Signal- Neutral .....................................2.33 - 2.67 VDC
Signal- raising / proportional ................2.67 - 3.49 VDC
Signal- raising max. ................................ 4.5 - 4.8 VDC
Signal- short circuit + .............................. 4.8 - 5.0 VDC
Load resistance ...........................................> 20 kOhm

Control lever B52

(proportional control)
Measured values for Hall element
Supply voltage .................................................. 5 VDC
Line interrupt/short-circuit ......................... 0 - 0.2 VDC
Signal- play............................................. 0.2 - 1.1 VDC
Signal- lowering max. ............................1.1 - 1.51 VDC
Signal- lowering / proportional .............1.51 - 2.33 VDC
Signal- Neutral .....................................2.33 - 2.67 VDC
Signal- raising / proportional ................2.67 - 3.49 VDC
Signal- raising max. ...............................3.49 - 4.1 VDC
Signal- raising/ latched ........................... 4.1 - 4.8 VDC
Signal- short circuit + .............................. 4.8 - 5.0 VDC
Load resistance ...........................................> 20 kOhm

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Potentiometer, AUX remote control valves
R20/1, R20/2, R20/3, R20/4, R20/5
± 10%
Potentiometer (resistance) ........................... 5 kΩ

Potentiometer R20/1, R20/3

R measured PIN 4 - 5.............................. 0 - 5 kΩ ± 10%

Potentiometer R20/2, R20/4

R measured PIN 1 - 2.............................. 0 - 5 kΩ ± 10%

Potentiometer R20/5
R measured PIN 1 - 2.............................. 0 - 5 kΩ ± 10%

Terminal resistance

Resistance A - B ..........................................120 Ω ± 5%

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EDC components
Angle of rotation sensor EDC B9/1

PIN 3 supply ....................................................10 VDC

PIN 1 supply ..................................................... ground
PIN 2 signal ............................. approx. 2.5 to 7.5 VDC
Load resistance ................................................ > 3 kΩ
NOTE: The adjustment is made by turning the sensor.

Power sensor B10/1, B10/2

Nominal load....................................................... 60 KN

PIN 3 (+ supply from E-box A55) ......................10 VDC

PIN 1 (supply from E-box A55) .......................... ground
PIN 2 (signal).........................................2.5 to 7.5 VDC
Sensor not loaded.................................. approx. 5 VDC
Load resistance ............................................... > 10 kΩ

Potentiometer R6/1

PIN 1 - 2 (resistance) ................................. 4.7 kΩ ±20%

PIN 1 - 3 (resistance) ............................ 0 - 4.7 kΩ ±20%

Potentiometer R6/2, R6/3, R6/4, R6/5

PIN 1 - 2 (resistance) ................................. 4.7 kΩ ±20%

PIN 1 - 3 (resistance) ............................ 0 - 4.7 kΩ ±20%

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Solenoid valves EDC Y6 and Y7

Proportional solenoid ...................................... 12 VDC

I max ..................................................................... 3.5 A
Current control ..................... impulse width modulation
Ohmic resistance R .................................. approx.1.7 Ω
Interference suppression .......................... in E-box A55

Heating valve Y8

Nominal voltage .................................................... 12 V

Voltage range ........................................ 10.2 to 13.8 V
Power consumption ........................................... 14.4 W
Resistance ......................................... approx. 10 ohms
Heating output............................................... 5 to 6 kW
Activation temperature ....................................... < 5° C
Deactivation temperature ................................. > 10° C

Radar sensor B16

Mounting angle ....................................................... 35°
Output signal ............................................ 131 pulse/ m
PIN 1(+ supply) ................................................ 12 VDC
PIN 2 (supply) ................................................... ground
PIN 3 (square signal) ....................... 505 Hz at 14 km/h
NOTE: Every change of the beam angle in relation to the
ground mutilates the signal value.
CAUTION: Before working in the sensor's beam area, the
start switch must be moved into the „0“ position

Front power lift components

Angle of rotation sensor
management - front power lift B19

PIN 3 supply .................................................... 10 VDC

PIN 1 supply ..................................................... ground
PIN 2 signal.............................. approx. 2.5 to 7.5 VDC
Load resistance ................................................. > 3 kΩ
NOTE: The adjustment is made by turning the sensor.

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Air conditioning system components

Air conditioning temperature control A20
X4/44 - PIN 4 (supply) ......................................12 VDC
X4/44 - PIN 2 (supply) ....................................... ground
X4/44 - PIN 1 ............................................ output signal
(Activation of magnetic coupling, compressor)
X4/73 - PIN 1 - 2 ....................... temperature sensor R9
X4/73 - PIN 3 ........................................... sheathing R9
X4/75 - PIN 1 - 2 .............................. potentiometer R10
................................................... (Temperature setting)
X4/75 - PIN 3 - 4 ........ air conditioning switch - ON/OFF

Switching points, magnetic coupling, compressor

Y13
Potentiometer R10 (temperature setting) in position-
Minimum cooling
resistance of R9 > 18 kΩ ((compressor switches off)
Minimum cooling
resistance of R9 < 16 kΩ (compressor switches on)
Maximum cooling
resistance of R9 > 27 kΩ (compressor switches off)
Maximum cooling
resistance of R9 < 25 kΩ (compressor switches on)
Speed control, blower motor A22
(only for air conditioning optional equipment)

X2/9 - PIN 1 (supply) ........................................12 VDC

X2/9 - PIN 2 (supply) ......................................... ground

X4/74 - PIN 1 - 3 ................... potentiometer supply R11

X4/74 - PIN 2 .................................speed setting signal

X2/20 - PIN A/B ......... plug connection for blower motor

Potentiometer for air conditioning - roof

blower R11
(for setting the speed of the roof blower motor)

PIN 1 - 3 (resistance) .................................. 10 KΩ ±20%

PIN 1 - 2 (resistance) ............................. 0 - 10 KΩ ±20%

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Potentiometer for air conditioning -
temperature R10
for setting the temperature, with integrated switch (air
cond. ON/OFF)

Resistance (nominal)................................... 10 KΩ±20%

PIN 1 - 2 (resistance) ............................ 0 - 10 KΩ±20%
PIN 3 - 4............................................... switch ON/OFF
Contact .................................................. normally open

Pressure switch, air conditioning S30

Thread ..................................................... 3/8“-24 UNF

Nominal voltage .............................................. 12 VDC

Contact - high pressure ........................ normally closed

opens at ............................................... p > 34 ±1.9 bar
closes at ............................................ p < 28.4 ±1.9 bar

Contact - low pressure ........................... normally open

closes at .............................................. p > 2.1 ±0.2 bar
opens at .............................................. p < 1.9 ±0.3 bar

Temperature sensor, air conditioning R9

Version ................................................................. NTC

Resistance 1 - 2 ......................... approx. 11 kΩ at 20°C

Switching points of magnetic coupling, compressor Y13

see Page 214

Air conditioning compressor coupling Y13

Nominal voltage .............................................. 12 VDC

Minimum feed voltage .................................... 7.5 VDC
Current ...................................................... 3.6 to 4.2 A
Power .................................................................. 43 W
Resistance ............................................... 2.9 to 3.6 Ω
Coupling gap ....................................................0.6 mm

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Cab components
Mirror heating E18/1 and E18/2

Nominal voltage ...............................................12 VDC

Current at 12V ......................................... approx. 1.7 A
Power ...................................................... approx. 20 W
Resistance ...................................................7.2 Ω ± 20%

Mirror heating and adjustment A41, A42

Mirror heating
PIN 2 ....................................... +15/1 adjusting motor 1
PIN 1 .................................... ground, adjusting motor 1
PIN 3 ....................................... +15/1 adjusting motor 2
PIN 4 ................................... ground, adjusting motor 2
Mirror heating E18/1 and E18/2
PIN 5 ................................................... activation +15/1
PIN 6 ..................................................... supply, ground

Control unit, mirror adjustment A40

PIN 2 .......................................................... supply 15/1

PIN 1 ..................................................... supply, ground
PIN 9 ............................................................lighting 58
Mirror, left
PIN 3 ......................... activation 15/1 adjusting motor 1
PIN 5 ......................... activation 15/1 adjusting motor 2
PIN 7 .............supply, ground, adjusting motors 1 and 2
Mirror, right
PIN 4 ......................... activation 15/1 adjusting motor 1
PIN 6 ......................... activation 15/1 adjusting motor 2
PIN 8 .............supply, ground, adjusting motors 1 and 2

Heated windscreen, front E25

Nominal voltage ...............................................12 VDC

Current at 12V ....................................... approx. 17.5 A
Power output ................................ approx. 210 W ±10%
Spec. heating output .........................approx. 4 W / dm2

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Heated windscreen, rear E26

Nominal voltage .............................................. 12 VDC

Current at 12V....................................... approx. 12.5 A
Power output ................................ approx. 150 W ±10%
Spec. heating output ..................... approx. 2.8 W / dm2

Electronics for Xenon work lamp

A18, A19

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 4010
Chapter
4010

CIRCUIT DIAGRAM

CNH Österreich GmbH Sva 6-51402 EN © 2005 CNH Österreich GmbH

Technical Documentation December, 2005
A - 4300 St. Valentin, Steyrer Strasse 32

INDEX
Numerics
4 + 2 front work lamps ......................................... 31
A Display for reverse travel equipment ...................87
Additional front left light ....................................... 27
Additional front right light ..................................... 27
Additional rear left light ........................................ 27
Additional rear right light ..................................... 27
ADIC ........................................................ 53, 55, 57
Air conditioning .................................................... 45
Air cushion seat ................................................... 47
All-round light carrier ........................................... 39
All-round lights (can be plugged in) ..................... 37
All-round lights (magnetic) .................................. 41
Alternator Denso ................................................. 11
Alternator Magneton .............................................. 7
Alternator Magneton (2nd alternator) .................... 9
Angle of rotation sensor, coupling ....................... 75
Angle of rotation sensor, coupling with
reverse travel equipment ..................................... 77
Angle of rotation sensor, power lift, front ............. 97
Angle of rotation sensor, power lift, rear ....... 65, 67
Angled wiper, front .............................................. 49
Angled wiper, rear ............................................... 49
Armrest ................................................................ 69
Armrest, electronics .......... 107, 109, 111, 113, 115
ASR with radar sensor ........................................ 51
AUX valves ........................................................ 105
Auxiliary headlight and 4 work lamps .................. 29
B Horn for reverse travel equipment .......................79
BB light, left ................................................... 23, 25
BB light, left and right .......................................... 27
BB light, right ................................................. 23, 25
Blower (heating) .................................................. 21
Blower (roof) ........................................................ 47
Brake light ........................................................... 17
Brake light for reverse travel equipment ............. 19
Button, AUX 5 ................................................... 111
Button, EDC - stop and lighting ......................... 111
Button, raise/lower EDC ...................................... 71
Button, rapid retraction ...................................... 111
C LIMP HOME plug connection ........................85, 87
CAN BUS ............................................ 99, 101, 103
Cigarette lighter with socket on right, 2-pin ... 61, 63
Clutch switch 80% ............................................... 75
Clutch switch 80% for reverse travel equipment . 77
Control handle for AUX ..................................... 109
Control signal ...................................................... 69
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4010-3
D
D supply+ ............................................................15
Door contact switch .............................................35
Doorway lights .....................................................35
E
EDC signal 50% ..................................................73
EDC with raise/lower ...........................................67
EDC without raise/lower ......................................65
EEM2 - box with sensors and PCU .....................15
Electrical mirror adjustment .....................37, 39, 41
External button, AUX, front .................................97
External button, EDC ..........................................71
External button, power lift, front ..........................97
F
Filter heating (preparation) ............................53, 55
Front PTO shaft ...................................................91
Fuel delivery pump ......................................7, 9, 11
G
Gearbox electronics ......................................85, 87
H
Headlight .............................................................29
Heated windscreen, front ....................................43
Heated windscreen, rear .....................................43
Heating flange .............................................7, 9, 11
Heating flange, fuel delivery pump ......................13
Heating valve for hydraulic oil ...........................105
Horn ....................................................................49
I
ICU performance monitor ..............................85, 87
Indicator lights, EDC ...........................................73
Interface, wiring harness, cab, right ..................107
Interior light .........................................................35
ISO-BUS ........................................................... 117
J
Joystick with button ...........................................109
L
Licence plate lights, roof .....................................35
Limit load potentiometer ......................................75
Low beam, high beam .........................................29
M
Magneton alternator ............................................13
Manual accelerator slider ..................................109
Mirror heating ..........................................37, 39, 41
Multicontroller II .................................................115
Edition 12-2005
4010-4
P Supply for ADIC, ISO BUS ..................................55
Parallel wipers, front ............................................49 Supply, control panel, right ............................61, 63
Parking interlock switch .................................75, 79 Supply, ECCU2 ...................................................93
Potentiometer, accelerator pedal ........................75 Supply, ECCU2 for ISO BUS ..............................95
Potentiometer, accelerator pedal for Supply, EDC box ...........................................65, 67
reverse travel equipment .....................................77
Supply, EEM2 box ...............................................15
Potentiometer, AUX remote control valves .......113
Supply, FMGR ...............................................75, 77
Potentiometer, EDC ............................................73
Supply, potential 15/1 ............................7, 9, 11, 13
Potentiometer, limit load for reverse
Supply, potential 15/1 seat, trailer brake .............47
travel equipment ..................................................79
Supply, roof .........................................................43
Power lift, front, management .............................97
Switch for differential lock, all-wheel drive
Power lift, front, raise/lower .................................69
management .......................................................81
Power sensors ...............................................65, 67
Switch for differential lock, all-wheel drive
Power socket .......................................................51 management for reverse travel equipment ..........83
Power socket 1, rear ...........................................51 Switch for engine back pressure brake ...............75
Power socket 2, rear (preparation) ......................51 Switch for engine back pressure brake,
Power socket, front ..............................................51 handbrake for reverse travel equipment ..............79
Power supply and starter .............................7, 9, 11 Switch for handbrake, seat switch .......................75
Power supply, electrical battery main switch .......13 Switch for HTS ....................................................59
R Switch for reducing speed ...................................59
Radio preparation ................................................43 Switch for speed ranges, manual mode ..............81
Rear PTO shaft ...................................................91 Switch for speed ranges, manual mode for
reverse travel equipment .....................................83
Reserve .............................................................111
T
Reserve central print .....................................17, 19
Trailer brake ........................................................21
Reserve, EDC print .......................................61, 63
W
Reverse fan ...................................................17, 19
Warning light system .....................................23, 27
S
Warning light system for ISO BUS and
SBB light, left ...........................................23, 25, 27 electrical main battery switch ..............................25
SBB light, right .........................................23, 25, 27 WEBASTO engine preheating .............................35
Seat switch for reverse travel equipment ............79 Windscreen washing system, front ......................49
Sensors, cartridge switch ....................................89 Windscreen washing system, rear ......................49
Shuttle lever ..................................................85, 87 Work lamp at rear inside .....................................31
Socket, diagnosis ADIC .......................................57 Work lamp at rear outside ...................................31
Socket, front ........................................................51 Work lamp, BB light .............................................31
Socket, mobile phone, left ...................................61 Work lamp, engine hood .....................................35
Socket, mobile phone, left for Work lamp, fender ...............................................29
reverse travel equipment .....................................63
Work lamp, rear, XENON ....................................33
Socket, rear (trailer) .............................................51
Socket, standard signal .......................................57
Solenoid valves, brake oil cooling .................81, 83
Solenoid valves, cartridge ...................................89
Solenoid valves, raising, lowering .................65, 67
Speed sensors, cartridge ....................................89
Speed sensors, PTO, front and rear ...................59
Speed signal ........................................................71
Spot light .................................................37, 39, 41
Spring-mounted front axle .............................93, 95
Starter ..................................................................13
Steering column switch .......................................49
Supply for ADIC ...................................................53
Sva 6-51402 EN Edition 12-2005
 4010-5

Abbreviations
ADIC.................................................................................................................................. Analogue/ digital instrument
ARU................................................................................................................................................................... Armrest
AUX..............................................................................................................................................Remote control valve
BB light............................................................................................................................Turn signal / side marker light
DZG..................................................................................................... Signal for crankshaft position (top dead centre)
DMM...................................................................................................................................................Digital multimeter
ECCU2 ............................................................................................................................................ Central control unit
EDC.....................................................................................................................................Electronic power lift control
EEM2 ...............................................................................................................................................Engine control unit
FMGR................................................................................................................ Vehicle/engine/transmission controller
GSV ..........................................................................................................................................................Cyclic supply
HTS ...................................................................................................Field end management (headland management)
ICU ............................................................................................................................................... Performance monitor
KEY PAD´S ............................................................................................ Function keys for analogue/digital instrument
NTC............................................................................................................................ Negative temperature coefficient
PCB.................................................................................... Printed circuit board (relay switching, terminal resistance)
PCU............................................................................................................................... Electronic pumps - control unit
PTC ............................................................................................................................. Positive temperature coefficient
SBB light .......................................................................................................... tail light, turn signal / side marker light
SGR ..........................................................................................................................................Transmission controller

NOTE: The name in the square brackets [xx] is inscribed on the plug.

Sva 6-51402 EN Edition 12-2005

 Sheet 1 4010-6

Sva 6-51402 EN
Diagnosis LED
for pre-glowing

SS05N001

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A# Power supply and starter A12 Central print (Würth or Berifors) X1/21 Screw - plug connection for engine print,

Sva 6-51402 EN
A14 Engine print (Würth or Berifors) potential 31
B Heating flange
A50/1 Power module X2/5 Screw - plug connection for engine print,
C Fuel delivery pump Denso alternator, potential 15
E10/1 Heating flange
D Alternator Magneton F1 Fuse Supply for start switch X3/11 Plug connection for alternator
E Supply, potential 15/1 F89 FusePotential 15 for engine X5/1 Screw - plug connection, potential 31, central
F93 Fuse Supply for clock, ADIC, radio, print
potential 30 X18/1 Plug connection for instruments wiring
# Variants on sheets 2, 3, 4 F200 Main fuse harness - central print [1]
G1 Battery X20/1 Plug connection for engine wiring harness
G2/2 Magneton alternator 120A (Würth)
K5/7/1 Relay, potential 15/1 supply X23/1 Plug connection for instruments wiring
harness - engine wiring harness
K5/7/2 Relay, potential 15/2 supply
X24/1 Plug connection for instruments wiring
K8/1 Starter relay
harness - central print [1]
K8/2 Heating flange relay 300A
M1 Starter
M13 Fuel delivery pump
Ground points R27 Resistance
S1 Start switch
1 Battery X0/3/3 Weld point for instruments wiring harness,
11 Engine device carrier potential 31
13 Cab X0/3/ Weld point for instruments wiring harness,
16 Starter potential 31
X0/4/1 Weld point for engine wiring harness,
potential 31
X0/4/4 Weld point for engine wiring harness,
potential 31
X1/2 Plug connection for engine wiring harness,
terminal 50
X1/5 Plug connection for potential 30, clock / radio
X1/8 Plug connection for central print supply,
potential 30, start switch
X1/11 Plug connection for central print supply,
potential 30
X1/12 Plug connection for engine print, potential 30

Edition 12-2005
4010-7
 Sheet 2 4010-8

Sva 6-51402 EN
Diagnosis LED
for pre-glowing

SS05N002

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A# Power supply and starter A12 Central print (Würth or Berifors) X1/11 Plug connection for central print, potential 30

Sva 6-51402 EN
A14 Engine print (Würth or Berifors) X1/12 Plug connection for engine print, potential 30
B Heating flange
A50/1 Power module X1/21 Screw - plug connection for engine print,
C Fuel delivery pump potential 31
E10/1 Heating flange
D Alternator Magneton F1 Fuse, start switch supply X2/5 Screw - plug connection for engine print, Denso
(2nd alternator) F89 Fuse, potential 15 for engine alternator, potential 15
E Supply, potential 15/1 F93 Fuse, supply for clock, ADIC, radio, potential 30 X3/11 Plug connection for alternator
F200 Main fuse X5/1 Screw - plug connection, potential 31, central
G1 Battery print
# Variants on sheets 1, 3, 4 X18/1 Plug connection for instruments wiring harness
G2/2 Magneton alternator 120A
G2/2/2 2nd Magneton alternator 95A - central print [1]
K5/7/1 Relay, potential 15/1 supply X20/1 Plug connection for engine wiring harness
(Würth)
K5/7/2 Relay, potential 15/2 supply
K8/1 Starter relay X23/1 Plug connection for instruments wiring harness
- engine wiring harness
K8/2 Heating flange relay 300A
X24/1 Plug connection for instruments wiring harness
L20/1 Telltale, 2nd alternator
- central print [1]
L20/2 Telltale, 2nd alternator
Ground points M1 Starter
M13 Fuel delivery pump
1 Battery Q1 Master switch
11 Engine device carrier R27 Resistance
13 Cab S1 Start switch
16 Starter X0/3/3 Weld point for instruments wiring harness,
potential 31
X0/3/ Weld point for instruments wiring harness,
potential 31
X0/4/1 Weld point for engine wiring harness,
potential 31
X0/4/4 Weld point for engine wiring harness,
potential 31
X1/2 Plug connection for engine wiring harness,
terminal 50
X1/5 Plug connection for potential 30, clock / radio
X1/8 Plug connection for central print supply,
potential 30, start switch

Edition 12-2005
4010-9
 Sheet 3 4010-10

Sva 6-51402 EN
Diagnosis LED
for pre-glowing

SS05N003

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A# Power supply and starter A12 Central print (Würth or Berifors) X2/5 Screw - plug connection for engine print, Denso

Sva 6-51402 EN
A14 Engine print (Würth or Berifors) alternator, potential 15
B Heating flange
A50/1 Power module X3/11 Plug connection for alternator
C Fuel delivery pump X5/1 Screw - plug connection, potential 31, central
E10/1 Heating flange
D Alternator Denso F1 Fuse, start switch supply print
E Supply, potential 15/1 F89 Fuse, potential 15 for engine X18/1 Plug connection for instruments wiring harness
F93 Fuse, supply for clock, ADIC, radio, potential 30 - central print [1]
F200 Main fuse X20/1 Plug connection for engine wiring harness
# Variants on sheets 1, 2, 4 (Würth)
G1 Battery
G2/3 Denso alternator 140A X23/1 Plug connection for instruments wiring harness
K5/7/1 Relay, potential 15/1 supply - engine wiring harness
X24/1 Plug connection for instruments wiring harness
K5/7/2 Relay, potential 15/2 supply
- central print [1]
K8/1 Starter relay
K8/2 Heating flange relay 300A
M1 Starter
M13 Fuel delivery pump
R27 Resistance
Ground points S1 Start switch
X0/3/3 Weld point for instruments wiring harness,
1 Battery potential 31
11 Engine device carrier X0/3/ Weld point for instruments wiring harness,
13 Cab potential 31
16 Starter X0/4/1 Weld point for engine wiring harness,
potential 31
X0/4/4 Weld point for engine wiring harness,
potential 31
X1/2 Plug connection for engine wiring harness,
terminal 50
X1/5 Plug connection for potential 30, clock / radio
X1/8 Plug connection for central print supply,
potential 30, start switch
X1/11 Plug connection for central print, potential 30
X1/12 Plug connection for engine print, potential 30
X1/21 Screw - plug connection for engine print,
potential 31

Edition 12-2005
4010-11
 Sheet 4 4010-12

Sva 6-51402 EN
Diagnosis LED
for pre-glowing

SS05N004

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A# Power supply, electrical battery A12 Central print (Würth or Berifors) X0/38/3 Weld point for additional line, electrical battery

Sva 6-51402 EN
main switch A14 Engine print (Würth or Berifors) main switch, potential 30
A50/1 Power module X0/38/4 Weld point for additional line, electrical battery
B Starter
E10/1 Heating flange main switch, potential 31
C Heating flange, fuel delivery X1/2 Plug connection for engine wiring harness,
F1 Fuse, start switch supply
pump terminal 50
F87 Fuse, electrical battery main switch,
D Magneton alternator potential 30 X1/5 Plug connection for potential 30, clock / radio
E Supply, potential 15/1 F89 Fuse, potential 15 for engine X1/8 Plug connection for central print supply,
F200 Main fuse potential 30, start switch
G1 Battery X1/11 Plug connection for central print, potential 30
# Variants on sheets 1, 2, 3 X1/12 Plug connection for engine print, potential 30
G2/2 Magneton alternator 120A
K5/7/1 Relay, potential 15/1 supply X1/21 Screw - plug connection for engine print,
K5/7/2 Relay, potential 15/2 supply potential 31
K5/54 Relay, electrical battery main switch [54] X2/5 Screw - plug connection for engine print, Denso
K8/1 Starter relay alternator, potential 15
X2/46a Plug connection for potential 58/31, electrical
K8/2 Heating flange relay 300A
battery main switch [46a]
M1 Starter
X2/46b Plug connection for potential 58/31, electrical
Ground points M13 Fuel delivery pump
battery main switch [X2/46b]
Q2 Electrical battery main switch
X3/11 Plug connection for alternator
1 Battery R27 Resistance
X5/1 Screw - plug connection, potential 31, central
11 Engine device carrier S1 Start switch
print
13 Cab S2/76 Switch, electrical battery main switch [BATT.-
16 Starter HS]
X0/3/3 Weld point for instruments wiring harness,
potential 31
X0/3/ Weld point for instruments wiring harness,
potential 31
X0/4/1 Weld point for engine wiring harness,
potential 31
X0/4/4 Weld point for engine wiring harness,
potential 31
X0/38/1 Weld point for additional line, electrical battery
main switch, potential 58
X0/38/2 Weld point for additional line, electrical battery
main switch, potential 31

Edition 12-2005
4010-13
 Sheet 5 4010-14

Sva 6-51402 EN
12 V
12 V
12 V

12 V
12 V

5V
Ground
Ground
12 V
Ground

Ground
12 V
DZG
Ground

NTC 32 kOhm to
102 Ohm
1V to approx. 2V
Ground
0.7V to 9V
PTC 1 kOhm to
4.6 kOhm
Ground
CAN L
Emergency
shut-down
Ground
CAN H

12 V
Signal

Ground
SS05N005

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A D supply+ A2 EEM2 control unit X3/20 Plug connection for engine speed sensor

Sva 6-51402 EN
A2/2 PCU electronic pumps - control unit X4/71 Plug connection for charger pressure,
B EEM2 - box with sensors and
A12 Central print (Würth or Berifors) charged air temperature sensor
PCU
A14 Engine print (Würth or Berifors) X9/7 Plug connection for fuel injection pump [7]
C Supply, EEM2 box
A60 ECCU2 X18/1 Plug connection for instruments wiring harness
B20 Engine speed sensor - central print [1]
B21 Test switch, fuel delivery pressure X20/1 Plug connection for engine wiring harness
B22 Engine temperature sensor (Würth)
B23 Water in fuel sensor X23/1 Plug connection for instruments wiring harness
B29 Sensor for charger pressure/charged air - engine wiring harness
temperature X24/3 Plug connection for instruments wiring
CN3a ECCU2 plug connection harness - cab wiring harness on right [3]
F21 Fuse, supply for D+ relay ECCU2, EDC X70 Plug connection for engine control unit EEM2
F30 Fuse, supply for engine print, potential 15/2
F92 Fuse, supply for EEM2, potential 30
F94 Fuse, supply for EEM2, PCU potential 30
F97 Supply for EEM2, potential 15
Ground points K5/3 Relay, engine print, potential 15
K5/11 Relay, potential D+ supply
K5/42 Relay D+ 2nd alternator
S6 Engine oil pressure switch
W1/4 Radio start plug connection
X0/4/1 Weld point for engine wiring harness,
potential 31
X0/7/22 Weld point for wiring harness, cab, right D+
X1/3 Plug connection for fuel filter pressure sensor
X1/10 Screw connection for engine print, potential
30 EEM2
X1/11A Plug connection for central lubrication
X1/14 Screw connection for engine print, potential
30 EEM2, fuel delivery pump
X2/22 Plug connection for temperature sensor
EEM2 [22]
X3/12 Plug connection for “Water in fuel” sensor
X3/13 Plug connection for sensor B23

Edition 12-2005
4010-15
 Sheet 6 4010-16

Sva 6-51402 EN
signal
switch

Steering

Brake light
Brake light

brake switch

GSV2
SS05N006

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A# Brake light A4 FMGR X18/1 Plug connection for instruments wiring harness

Sva 6-51402 EN
A4/2 FMGR plug connection - dark grey [2] - central print [1]
B Reserve central print
A12 Central print (Würth or Berifors) X23/1 Plug connection for instruments wiring harness
C Reverse fan - engine wiring harness
A60 ECCU2
A62 Reverse fan X24/2 Plug connection for wiring harness, cab, right
# Variant on sheet 7 CN3a ECCU2 plug connection X24/3 Plug connection for instruments wiring harness
CN3b ECCU2 plug connection - cab wiring harness on right [3]
F8 Fuse, reserve, potential 30
F15 Fuse, reserve, potential 15/2
F46 Fuse, relay, brake light, Optistop,
potential 15/1
K5/12 Relay, brake light, Optistop
K5/16 Reverse fan relay
S2/74 Reverse fan pushbutton
S5 Brake light switch
S25 Steering brake switch
X0/3/1 Weld point for instruments wiring harness,
Ground points potential 58L
X0/3/2 Weld point for instruments wiring harness,
potential 15/1
X0/3/ Weld point for instruments wiring harness,
potential 31
X0/3/6 Weld point for instruments wiring harness,
potential GSV2
X0/4/1 Weld point for engine wiring harness,
potential 31
X0/30/1 Weld point for additional line, reverse fan,
potential 31
X0/30/2 Weld point for additional line, reverse fan,
potential +
X2/25 Plug connection for reverse fan [LU]
X3/5 Plug connection, reserve
X4/14 Plug connection for brake light, Optistop
X4/66 Plug connection for reverse fan [LU]
X10/8 Plug connection for wiring harness, cab, left -
central print [8]

Edition 12-2005
4010-17
 Sheet 7 4010-18

Sva 6-51402 EN
signal
switch

Steering

Brake light
Brake light

brake switch

GSV2
SS05N007

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A# Brake light for reverse travel A4 FMGR X2/25 Plug connection for reverse fan [LU]

Sva 6-51402 EN
equipment A4/2 FMGR plug connection - dark grey [2] X3/5 Plug connection, reserve
B Reserve central print A12 Central print (Würth or Berifors) X4/14 Plug connection for brake light, Optistop
A60 ECCU2 X4/66 Plug connection for reverse fan [LU]
C Reverse fan
A62 Reverse fan X10/8 Plug connection for wiring harness, cab, left -
CN3a ECCU2 plug connection central print [8]
# Variant on sheet 6 CN3b ECCU2 plug connection X18/1 Plug connection for instruments wiring harness
F8 Fuse, reserve, potential 30 - central print [1]
F15 Fuse, reserve, potential 15/2 X23/1 Plug connection for instruments wiring harness
F46 Fuse, relay, brake light, Optistop, - engine wiring harness
potential 15/1 X24/2 Plug connection for wiring harness, cab, right
K5/12 Relay, brake light, Optistop X24/3 Plug connection for instruments wiring harness
K5/16 Reverse fan relay - cab wiring harness on right [3]
S2/74 Reverse fan pushbutton
S5 Brake light switch
S5/1 Brake light switch for reverse travel
equipment [BREMSL]
Ground points S25 Steering brake switch
X0/3/1 Weld point for instruments wiring harness,
potential 58L
X0/3/2 Weld point for instruments wiring harness,
potential 15/1
X0/3/ Weld point for instruments wiring harness,
potential 31
X0/3/6 Weld point for instruments wiring harness,
potential GSV2
X0/4/1 Weld point for engine wiring harness,
potential 31
X0/27/12 Weld point for reverse travel equipment wiring
harness, brake
X0/27/9 Weld point for reverse travel equipment wiring
harness, GSV2
X0/30/1 Weld point for additional line, reverse fan,
potential 31
X0/30/2 Weld point for additional line, reverse fan,
potential +

Edition 12-2005
4010-19
 Sheet 8 4010-20

Sva 6-51402 EN
SS05N008

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A Trailer brake A12 Central print (Würth or Berifors)

Sva 6-51402 EN
F10 Fuse, supply, ECCU2, potential 30
B Blower (heating)
F17 Fuse, blower, heating, potential 15/2
F48 Fuse, supply for seat, “Italy” trailer brake,
potential 15/1
K5/37 Relay for Italy trailer brake
M3 Heating blower motor
S7 Switch for handbrake
S50 Trailer brake valve pushbutton
S50/1 Blower switch 1-2-3
X0/7/17 Weld point for wiring harness, cab, right,
handbrake
X0/15/1 Weld point for additional line, hydraulic trailer
brake, potential 31
X0/15/2 Weld point for additional line, hydraulic trailer
brake, potential 15/1
X1/26 Plug connection for potential 15/2, 15 A
heating blower
Ground points X4/25 Plug connection for handbrake switch [25]
11 Engine device carrier X4/50 Plug connection for heating
X4/51 Plug connection for “Italy” trailer brake,
central print [ITALB]
X4/52 Plug connection for additional line, Italy trailer
brake, trailer brake [MGV]
X24/2 Plug connection for wiring harness, cab, right
Y50 Trailer brake solenoid valve

Edition 12-2005
4010-21
 Sheet 9 4010-22

Sva 6-51402 EN
SS05N009

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections
A Warning light system
Sva 6-51402 EN
B SBB light, left
C SBB light, right
D BB light, left
E BB light, right
# Variants on sheets 10, 11
Ground points
8 Roof, front right
11 Engine device carrier
Edition 12-2005
Electrical equipment
A12 Central print (Würth or Berifors) X0/3/21 Weld point for instruments wiring harness,
A13 Roof print potential 15, turn signal
E3 Front left side marker light X0/3/3 Weld point for instruments wiring harness,
potential 31
E4 Rear left side marker light
E6 Front right side marker light X0/6/1 Weld point for wiring harness, cab, left,
E7 Rear right side marker light potential 31
E12 Brake light, left X0/7/18 Weld point for wiring harness, cab, right 58R
E13 Brake light, right X0/7/5 Weld point for wiring harness, cab, right,
potential 31
E14 Turn signal, front right
E15 Turn signal, rear right X0/28/12 Weld point for roof wiring harness, potential 31
E16 Turn signal, rear left X0/28/13 Weld point for roof wiring harness, potential 31
E17 Turn signal, front left X0/28/3 Weld point for roof wiring harness, potential 58
F5 Fuse, supply for turn signal, potential 15/1 X6/12L Plug connection for turn signal / side marker
F24 Fuse, parking light, rear left, ADIC, switch light, front left [BB-L]
lighting for instrument panel, front and rear X6/12R Plug connection for turn signal / side marker
trailer sockets, ISO BUS light, front right [BB-R]
F25 Fuse, parking light, rear right, ARU, switch X10/8 Plug connection for wiring harness, cab, left -
lighting for control panel, mobile phone central print [8]
X10/11 Plug connection for roof print supply
socket
F33 Fuse, supply for hazard warning light, X10/12 Plug connection for roof wiring harness
potential 30 X14/8 Plug connection for instruments wiring harness
F60 Fuse, side marker light, front left, licence - steering column [8]
plate lights, roof X14/14 Plug connection for roof supply [14]
F61 Fuse, side marker light front right, ICU switch X14/15 Plug connection for central print - wiring
lighting for roof, spot light, radio and ASW harness for roof supply [15]
panel lighting, activation of all work lamps X18/1 Plug connection for instruments wiring harness
K2 Indicator relay - central print [1]
K5/10 Relay, light, potential 58 X24/1 Plug connection for instruments wiring harness
S2/5 Hazard warning switch [WARN] - central print [1]
S4/2 Turn signal switch, steering column X24/2 Plug connection for wiring harness, cab, right
X0/3/1 Weld point for instruments wiring harness,
potential 58L
X0/3/10 Weld point for instruments wiring harness, turn
signal on right
X0/3/11 Weld point for instruments wiring harness, turn
signal on left
4010-23
 Sheet 10 4010-24

Sva 6-51402 EN
SS05N010

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections
A# Warning light system for ISO
Sva 6-51402 EN
BUS and electrical main battery
switch
B SBB light, left
C SBB light, right
D BB light, left
E BB light, right
# Variants on sheets 9, 11
Ground points
11 Engine device carrier
Edition 12-2005
Electrical equipment
A12 Central print (Würth or Berifors) X0/3/21 Weld point for instruments wiring harness,
A13 Roof print potential 15, turn signal
E3 Front left side marker light X0/3/3 Weld point for instruments wiring harness,
E4 Rear left side marker light potential 31
E6 Front right side marker light X0/6/1 Weld point for wiring harness, cab, left,
potential 31
E7 Rear right side marker light
E12 Brake light, left X0/7/18 Weld point for wiring harness, cab, right 58R
E13 Brake light, right X0/7/5 Weld point for wiring harness, cab, right,
E14 Turn signal, front right potential 31
E15 Turn signal, rear right X0/28/12 Weld point for roof wiring harness, potential 31
X0/28/13 Weld point for roof wiring harness, potential 31
E16 Turn signal, rear left
E17 Turn signal, front left X0/28/3 Weld point for roof wiring harness, potential 58
F5 Fuse, supply for turn signal, potential 15/1 X2/87 Plug connection for cab wiring harness on
F24 Fuse, parking light, rear left, ADIC, switch right - instruments wiring harness ISO-BUS
lighting for instrument panel, front and rear X6/12L Plug connection for turn signal / side marker
trailer sockets, ISO BUS light, front left [BB-L]
F25 Fuse, parking light, rear right, ARU, switch X6/12R Plug connection for turn signal / side marker
lighting for control panel, mobile phone socket light, front right [BB-R]
X10/8 Plug connection for wiring harness, cab, left -
F33 Fuse, supply for hazard warning light,
potential 30 central print [8]
F60 Fuse, side marker light, front left, licence plate X10/11 Plug connection for roof print supply
lights, roof X10/12 Plug connection for roof wiring harnessPlug
F61 Fuse, side marker light front right, ICU switch connection for roof wiring harness
lighting for roof, spot light, radio and ASW panel X14/8 Plug connection for instruments wiring harness
lighting, activation of all work lamps - steering column [8]
K2 Indicator relay X14/14 Plug connection for roof supply [14]
K5/10 Relay, light, potential 58 X14/15 Plug connection for central print - wiring
S2/5 Hazard warning switch [WARN] harness for roof supply [15]
S4/2 Turn signal switch, steering column X18/1 Plug connection for instruments wiring harness
X0/3/1 Weld point for instruments wiring harness, - central print [1]
potential 58L X24/1 Plug connection for instruments wiring harness
- central print [1]
X0/3/10 Weld point for instruments wiring harness, turn
signal on right X24/2 Plug connection for wiring harness, cab, right
X0/3/11 Weld point for instruments wiring harness, turn
signal on left
4010-25
 Sheet 11 4010-26

Sva 6-51402 EN
SS05N011

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections
A Warning light system
Sva 6-51402 EN
B Additional rear left light
C SBB light, left
D SBB light, right
E Additional rear right light
F Additional front left light
G BB light, left and right
H Additional front right light
# Variants on sheets 9, 10
Ground points
11 Engine device carrier
Edition 12-2005
Electrical equipment
A12 Central print (Würth or Berifors) X0/3/10 Weld point for instruments wiring harness, turn
A13 Roof print signal on right
E3 Front left side marker light X0/3/11 Weld point for instruments wiring harness, turn
signal on left
E3/1 Additional front left side marker light
E4 Rear left side marker light X0/3/21 Weld point for instruments wiring harness,
E6 Front right side marker light potential 15, turn signal
E6/1 Additional front right side marker light X0/3/3 Weld point for instruments wiring harness,
E7 Rear right side marker light potential 31
X0/6/1 Weld point for wiring harness, cab, left,
E12 Brake light, left
potential 31
E12/1 Additional rear left side marker light
E13 Brake light, right X0/7/18 Weld point for wiring harness, cab, right 58R
X0/7/5 Weld point for wiring harness, cab, right,
E13/1 Additional rear right side marker light
potential 31
E14 Turn signal, front right
X0/28/12 Weld point for roof wiring harness, potential 31
E15 Turn signal, rear right
X0/28/13 Weld point for roof wiring harness, potential 31
E16 Turn signal, rear left
X0/28/3 Weld point for roof wiring harness, potential 58
E17 Turn signal, front left
X6/12L Plug connection for turn signal / side marker
F5 Fuse, supply for turn signal, potential 15/1
light, front left [BB-L]
F24 Fuse, parking light, rear left, ADIC, switch
X6/12R Plug connection for turn signal / side marker
lighting for instrument panel, front and rear
light, front right [BB-R]
trailer sockets, ISO BUS
X10/8 Plug connection for wiring harness, cab, left -
F25 Fuse, parking light, rear right, ARU, switch
central print [8]
lighting for control panel, mobile phone socket
X10/11 Plug connection for roof print supply
F33 Fuse, supply for hazard warning light,
potential 30 X10/12 Plug connection for roof wiring harness
X14/8 Plug connection for instruments wiring harness
F60 Fuse, side marker light, front left, licence plate
- steering column [8]
lights, roof
X14/14 Plug connection for roof supply [14]
F61 Fuse, side marker light front right, ICU switch
lighting for roof, spot light, radio and ASW panel X14/15 Plug connection for central print - wiring
lighting, activation of all work lamps harness for roof supply [15]
K2 Indicator relay X18/1 Plug connection for instruments wiring harness
- central print [1]
K5/10 Relay, light, potential 58
X24/1 Plug connection for instruments wiring harness
S2/5 Hazard warning switch [WARN]
- central print [1]
S4/2 Turn signal switch, steering column
X24/2 Plug connection for wiring harness, cab, right
X0/3/1 Weld point for instruments wiring harness,
potential 58L
4010-27
 Sheet 12 4010-28

Sva 6-51402 EN
SS05N012

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A Auxiliary headlight and 4 work A12 Central print (Würth or Berifors) X0/5/1 Weld point for engine hood wiring harness,

Sva 6-51402 EN
lamps A13 Roof print potential 31
A64 Work lamp panel X0/6/1 Weld point for wiring harness, cab, left,
B Headlight
E1 Headlight, left potential 31
C Low beam, high beam X0/7/5 Weld point for wiring harness, cab, right,
E2 Headlight, right
D Work lamp, fender E8 Work lamp, fender, left potential 31
E9 Work lamp, fender, right X4/32 Plug connection for headlight
E21 Auxiliary headlight, left X4/40 [X4/ESW] Plug connection for roof print,
E22 Auxiliary headlight, right auxiliary headlight
E33 Work lamp on roof, front, centre, left [M] X5/7 Socket for auxiliary headlight and work lamp,
E34 Work lamp on roof, front, centre, right [M] front left
X5/8 Socket for auxiliary headlight and work lamp,
E37 Work lamp on roof, front, outside, left [A]
front right
E38 Work lamp on roof, front, outside, right [A]
X6/6 Plug connection for instruments wiring
F7 Fuse, relay 56a, potential 30
harness
F11 Fuse, relay, work lamp, fender, potential 30
X10/8 Plug connection for wiring harness, cab, left -
F12 Fuse, light switch, potential 30
central print [8]
F34 Fuse, headlight, roof, right 56b
X10/11 Plug connection for roof print supply
Ground points F35 Fuse, headlight, roof, left 56b X14/8 Plug connection for instruments wiring harness
F36 Fuse, headlight, engine hood, right 56b - steering column [8]
7 Roof, front left F37 Fuse, headlight, engine hood, left 56b X14/14 Plug connection for roof supply [14]
8 Roof, front right F40 Fuse, supply for steering column switch, X14/15 Plug connection for central print - wiring
11 Engine device carrier potential 15/1 harness for roof supply [15]
K5/5 Switchover relay for high beam X16/5 Screw connection for roof print ground point
K5/6 Switchover relay for low beam X18/1 Plug connection for instruments wiring harness
K5/9 Relay, work lamp, fender - central print [1]
K5/56a Relay for high beam X24/1 Plug connection for instruments wiring harness
K5/56b Relay for low beam - central print [1]
S2/1 Light switch [LICHT] X24/2 Plug connection for wiring harness, cab, right
S2/17 Switch for auxiliary headlight X24/6 Plug connection for work lamp panel
S4/1 High/low beam steering column switch
V3/9 Diode
X0/3/1 Weld point for instruments wiring harness,
potential 58L
X0/3/3 Weld point for instruments wiring harness,
potential 31

Edition 12-2005
4010-29
 Sheet 14 4010-30

Sva 6-51402 EN
SS05N014

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A Work lamp at rear outside A13 Roof print X4/21 Plug connection for work lamp outside right

Sva 6-51402 EN
A60 ECCU2 at rear
B Work lamp at rear inside
A64 Work lamp panel X4/22 Plug connection for work lamp inside right at
C# 4 + 2 front work lamps rear
CN3a ECCU2 plug connection
D Work lamp, BB light E23/1 Work lamp, roof, at rear, inside left X4/23 Plug connection for work lamp at rear outside
E23/2 Work lamp, roof, at rear, outside left left
E24/1 Work lamp, roof, at rear, inside right X4/24 Plug connection for work lamp inside left at
# Variant on sheet 17
E24/2 Work lamp, roof, at rear, outside right rear
E33 Work lamp, roof, at front centre left [M] X4/38 [X4/ASW] Plug connection for roof print, work
lamp at front
E34 Work lamp, roof, at front centre right [M]
E35 Work lamp, at front left on turn signal / side X5/7 Socket for auxiliary headlight and work lamp,
marker light front left
X5/8 Socket for auxiliary headlight and work lamp,
E36 Work lamp, at front right on turn signal / side
front right
marker light
X6/12L Plug connection for turn signal / side marker
E37 Work lamp on roof, front, outside, left [A]
light, front left [BB-L]
E38 Work lamp on roof, front, outside, right [A]
X6/12R Plug connection for turn signal / side marker
E44 Work lamp on roof, at front inside left [I]
light, front right [BB-R]
Ground points E45 Work lamp on roof, at front inside right [I]
X10/4 Plug connection for EDC print armrest (GSV)
F67 Fuse, 4 work lamps, front outside
X10/12 Plug connection for roof wiring harness
7 Roof, front left F68 Fuse, 4 rear work lamps, ASW panel supply
X10/13 Plug connection for roof wiring harness
8 Roof, front right for potential 30
X14/14 Plug connection for roof supply [14]
F70 Fuse, 2 rear work lamps
X16/4 Screw connection for potential 30, supply for
F101 Fuse, ASW panel supply for 4 front work
roof print
lamps, work lamp on BB light
X24/3 Plug connection for instruments wiring harness
F102 Fuse, 4+2 front work lamps
- cab wiring harness on right [3]
K5/30 Relay 4 rear work lamps (outside)
X24/6 Plug connection for work lamp panel
K5/31 Relay 4 front work lamps (outside)
K5/33 Relay 4+2 front work lamps
S2/63/2 Switch for 4+2 front work lamps
X0/28/12 Weld point for roof wiring harness, potential 31
X0/28/13 Weld point for roof wiring harness, potential 31
X0/28/14 Weld point for roof wiring harness, potential 31
X0/28/15 Weld point for roof wiring harness, potential 31
X0/28/2 Weld point for roof wiring harness, work lamp 2
X0/28/6 Weld point for roof wiring harness, work lamp 2

Edition 12-2005
4010-31
 Sheet 17 4010-32

Sva 6-51402 EN
SS05N017

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A Work lamp, rear, XENON A13 Roof print

Sva 6-51402 EN
A18 Electronics for Xenon work lamp, right
A19 Electronics for Xenon work lamp, left
# Variant on sheet 14
A64 Work lamp panel
E27 Work lamp, roof, at rear, XENON, left
E29 Work lamp, roof, at rear, XENON, right
F68 Fuse, 4 rear work lamps, ASW panel supply for
potential 30
F70 Fuse, 2 rear work lamps
K5/30 Relay 4 rear work lamps (outside)
X0/28/12 Weld point for roof wiring harness, potential 31
X0/28/15 Weld point for roof wiring harness, potential 31
X0/28/2 Weld point for roof wiring harness, work lamp 2
X4/21 Plug connection for work lamp outside right at
rear
X4/22 Plug connection for work lamp inside right at
rear
X4/23 Plug connection for work lamp outside left at
Ground points
rear
X4/24 Plug connection for work lamp inside left at rear
X10/12 Plug connection for roof wiring harness
X10/13 Plug connection for roof wiring harness
X16/4 Screw connection for potential 30, supply for
roof print
X24/6 Plug connection for work lamp panel

Edition 12-2005
4010-33
 Sheet 18 4010-34

Sva 6-51402 EN
ASW - engine hood

SS05N018

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A Work lamp, engine hood A13 Roof print X1/7 Plug connection for diagnosis, engine

Sva 6-51402 EN
A14 Engine print (Würth or Berifors) preheating [DIAG]
B WEBASTO engine preheating
A25 Engine preheater ECU X1/9 Screw connection for fuel filter heating
C Licence plate lights, roof A26 WEBASTO clock X1/16 Plug connection for clock timer - control unit,
D Door contact switch A50/2 Power module engine preheating [16]
A64 Work lamp panel X1/17 Screw connection for reverse fan
E Doorway lights
E5/3 Licence plate lights, roof, left X1/21 Screw - plug connection for engine print,
F Interior light E5/4 Licence plate lights, roof, right potential 31
E19 Interior light X1/22 Screw - plug connection for engine print,
E30 Doorway lights, left potential 31
E61 Work lamp, left X2/5 Screw - plug connection for engine print, Denso
alternator, potential 15
E62 Work lamp, right
X2/18 Plug connection for fuel delivery pump,
F89 Fuse, potential 15 for engine
engine preheating
F95 Fuse, reverse fan
X2/24 Plug connection for supply for engine
F98 Fuse, fuel filter heating, potential 30
preheating, potential 30
F104 Fuse, engine preheater, potential 30
X3/28 Plug connection for work lamp, engine hood
K4/2/2 Time relay, interior light and horn
M14 Fuel delivery pump, engine preheating X4/47 Plug connection for engine preheating
Ground points S24/1 Switch for door contact, left precaution [WEBASTO]
S24/2 Switch for door contact, right X4/53 Plug connection for engine preheating clock
X0/3/ Weld point for instruments wiring harness, X4/65L Plug connection for licence plate lights, roof,
potential 31 left
X0/3/9 Weld point for instruments wiring harness, X4/67 Plug connection for work lamp, front left
potential 30 X6/12L Plug connection for turn signal / side marker
X0/5/1 Weld point for engine hood wiring harness, light, front left [BB-L]
potential 31 X6/14 Plug connection for engine preheating ECU
X0/20/1 Weld point for additional line, Webasto heating, X10/11 Plug connection for roof print supply
potential 31
X10/13 Plug connection for roof wiring harness
X0/28/11 Weld point for roof wiring harness, potential 58
X10/14 Plug connection for wiring harness for roof
X0/28/12 Weld point for roof wiring harness, potential 31 supply
X0/28/13 Weld point for roof wiring harness, potential 31 X14/14 Plug connection for roof supply [14]
X0/28/14 Weld point for roof wiring harness, potential 31 X20/1 Plug connection for engine wiring harness
X0/28/15 Weld point for roof wiring harness, potential 31 (Würth)
X0/28/4 Weld point for roof wiring harness, potential 30 X23/1 Plug connection for instruments wiring harness
X0/28/5 Weld point for roof wiring harness, supply for - engine wiring harness
time relay X24/6 Plug connection for work lamp panel
X0/28/9 Weld point for roof wiring harness, potential 31

Edition 12-2005
4010-35
 Sheet 19 4010-36

Sva 6-51402 EN
SS05N019

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A Mirror heating A5/1 All-round light, left X6/24 Plug connection for electric mirror, right

Sva 6-51402 EN
A5/2 All-round light, right [SPIEGEL]
B Electrical mirror adjustment
A13 Roof print X9/1 Plug connection for switch for mirror
C Spot light adjustment
A40 Control unit - mirror adjustment
D All-round lights (can be plugged A41 Electric mirror heating and adjustment X10/12 Plug connection for roof wiring harness
in) A42 Electric mirror heating and adjustment X19/1 Plug connection for all-round light, left
A64 Work lamp panel X19/2 Plug connection for all-round light, right
# Variants on sheets 20, 21 E18/1 Heated mirror, left X24/6 Plug connection for work lamp panel
E18/2 Heated mirror, right
E20 Spot light
F69 Fuse, all-round light, ASW panel supply for
potential 30
F71 Fuse, heated mirror
F72 Fuse, supply for radio, interior light, ASW
panel supply for potential 30
F100 Fuse, electrically adjustable mirror
S2/19 Switch for heated mirror [HEIZSP]
Ground points X0/13/1 Weld point for additional line, mirror heating
supply
X0/13/2 Weld point for additional line, mirror heating
supply
X0/28/12 Weld point for roof wiring harness, potential 31
X0/28/13 Weld point for roof wiring harness, potential 31
X0/28/14 Weld point for roof wiring harness, potential 31
X0/28/15 Weld point for roof wiring harness, potential 31
X0/28/3 Weld point for roof wiring harness, potential 58
X0/28/4 Weld point for roof wiring harness, potential 30
X0/28/8 Weld point for roof wiring harness, all-round
lights
X3/80 Plug connection for mirror adjustment, roof
print [X3/13]
X4/15 Plug connection for heated mirror, roof
print [15]
X4/39 Plug connection for switch for heated mirror,
roof print [39]
X6/23 Plug connection for rear wiper motor

Edition 12-2005
4010-37
 Sheet 20 4010-38

Sva 6-51402 EN
SS05N020

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A Mirror heating A5/1 All-round light, left X6/24 Plug connection for electric mirror, right

Sva 6-51402 EN
A5/2 All-round light, right [SPIEGEL]
B Electrical mirror adjustment
A13 Roof print X9/1 Plug connection for switch for mirror adjustment
C Spot light X10/12 Plug connection for roof wiring harness
A40 Control unit - mirror adjustment
D All-round light carrier A41 Electric mirror heating and adjustment X19/1 Plug connection for all-round light, left
A42 Electric mirror heating and adjustment X19/2 Plug connection for all-round light, right
# Variants on sheets 19, 21 A64 Work lamp panel X24/6 Plug connection for work lamp panel
E18/1 Heated mirror, left
E18/2 Heated mirror, right
E20 Spot light
F69 Fuse, all-round light, ASW panel supply for
potential 30
F71 Fuse, heated mirror
F72 Fuse, supply for radio, interior light, ASW panel
supply for potential 30
F100 Fuse, electrically adjustable mirror
S2/19 Switch for heated mirror [HEIZSP]
Ground points X0/13/1 Weld point for additional line, mirror heating
supply
X0/13/2 Weld point for additional line, mirror heating
supply
X0/28/12 Weld point for roof wiring harness, potential 31
X0/28/13 Weld point for roof wiring harness, potential 31
X0/28/14 Weld point for roof wiring harness, potential 31
X0/28/15 Weld point for roof wiring harness, potential 31
X0/28/3 Weld point for roof wiring harness, potential 58
X0/28/4 Weld point for roof wiring harness, potential 30
X0/28/8 Weld point for roof wiring harness, all-round
lights
X3/80 Plug connection for mirror adjustment, roof
print [X3/13]
X4/15 Plug connection for heated mirror, roof print [15]
X4/39 Plug connection for switch for heated mirror,
roof print [39]
X6/23 Plug connection for rear wiper motor

Edition 12-2005
4010-39
 Sheet 21 4010-40

Sva 6-51402 EN
SS05N021

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A Mirror heating A5/1 All-round light, left X6/23 Plug connection for rear wiper motor

Sva 6-51402 EN
A5/2 All-round light, right X6/24 Plug connection for electric mirror, right
B Electrical mirror adjustment
A13 Roof print [SPIEGEL]
C Spot light X9/1 Plug connection for switch for mirror adjustment
A40 Control unit - mirror adjustment
D All-round lights (magnetic) A41 Electric mirror heating and adjustment X10/12 Plug connection for roof wiring harness
A42 Electric mirror heating and adjustment X24/6 Plug connection for work lamp panel
# Variants on sheets 19, 20 A64 Work lamp panel
E18/1 Heated mirror, left
E18/2 Heated mirror, right
E20 Spot light
F69 Fuse, all-round light, ASW panel supply for
potential 30
F71 Fuse, heated mirror
F72 Fuse, supply for radio, interior light, ASW panel
supply for potential 30
F100 Fuse, electrically adjustable mirror
S2/19 Switch for heated mirror [HEIZSP]
Ground points X0/13/1 Weld point for additional line, mirror heating
supply
X0/13/2 Weld point for additional line, mirror heating
supply
X0/28/12 Weld point for roof wiring harness, potential 31
X0/28/13 Weld point for roof wiring harness, potential 31
X0/28/14 Weld point for roof wiring harness, potential 31
X0/28/15 Weld point for roof wiring harness, potential 31
X0/28/3 Weld point for roof wiring harness, potential 58
X0/28/4 Weld point for roof wiring harness, potential 30
X0/28/8 Weld point for roof wiring harness, all-round
lights
X3/80 Plug connection for mirror adjustment, roof
print [X3/13]
X4/15 Plug connection for heated mirror, roof print [15]
X4/33 Socket for all-round light, left, magnetic
X4/34 Socket for all-round light, right, magnetic
X4/39 Plug connection for switch for heated mirror,
roof print [39]

Edition 12-2005
4010-41
 Sheet 22 4010-42

Sva 6-51402 EN
SS05N022

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A Radio preparation A6 Radio X2/91 Plug connection for roof print, rear heated

Sva 6-51402 EN
A6/A Radio plug connection windscreen [91]
B Supply, roof
A6/B Loudspeaker plug connection X4/41 Plug connection for switch for front heated
C Heated windscreen, front windscreen
A12 Central print (Würth or Berifors)
D Heated windscreen, rear A13 Roof print X4/42 Plug connection for switch for rear heated
A14 Engine print (Würth or Berifors) windscreen
B14 Loudspeaker, left X10/11 Plug connection for roof print supply
B15 Loudspeaker, right X10/14 Plug connection for wiring harness for roof
E25 Heated windscreen, front supply
E26 Heated windscreen, rear X14/14 Plug connection for roof supply [14]
F45 Fuse, supply for roof, ICU potential 15/1 X14/15 Plug connection for central print - wiring
harness for roof supply [15]
F76 Fuse, heated windscreen, rear
X16/5 Screw connection for roof print ground point
F77 Fuse, heated windscreen, front
F93 Fuse, supply for clock, ADIC, radio, potential 30 X18/1 Plug connection for instruments wiring harness
- central print [1]
K5/29 Relay supply for potential, potential 15/1
X20/1 Plug connection for engine wiring harness
K6/7 Relay for rear heated windscreen
(Würth)
K6/8 Relay for front heated windscreen
X23/1 Plug connection for instruments wiring harness
Ground points S2/16/1 Switch for rear heated windscreen [HZS HI] - engine wiring harness
S2/16/2 Switch for front heated windscreen [HZS VO]
7 Roof, front left W6 Antenna
11 Engine device carrier X0/3/9 Weld point for instruments wiring harness,
potential 30
X0/28/1 Weld point for roof wiring harness, potential 30,
memory
X0/28/13 Weld point for roof wiring harness, potential 31
X0/28/3 Weld point for roof wiring harness, potential 58
X0/28/4 Weld point for roof wiring harness, potential 30
X0/39/1 Welded point for additional line, rear heated
windscreen
X1/24 Screw connection for potential 30, roof print,
heated windscreens
X2/90 Plug connection for roof print, front heated
windscreen [90]

Edition 12-2005
4010-43
 Sheet 23 4010-44

Sva 6-51402 EN
SS05N023

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A# Air conditioning A13 Roof print X20/1 Plug connection for engine wiring harness

Sva 6-51402 EN
A14 Engine print (Würth or Berifors) (Würth)
A20 Air conditioning - control X23/1 Plug connection for instruments wiring harness
# Variant on sheet 24 - engine wiring harness
A22 Blower - control
F65 Fuse, air conditioning control Y13 Magnetic coupling for air conditioning
F66 Fuse, blower / air conditioning compressor
F74 Fuse, reserve, potential 30
F90 Fuse, air conditioning compressor, pressure
switch
F103 Fuse, air conditioning, pressure switch
K5/32 Relay supply, D+ air conditioning
K5/36 Reserve
M12 Engine blower, air conditioning
R9 Temperature sensor, air conditioning
R10 Potentiometer for air conditioning - temperature
R11 Potentiometer for air conditioning - roof blower
S30 Pressure switch, air conditioning
Ground points W2 Line for temperature sensor, sheathed
X0/4/4 Weld point for engine wiring harness,
potential 31
X2/9 Plug connection for roof print supply for
blower
X2/14 Plug connection for air conditioning
X2/20 Plug connection for air conditioning blower
motor
X4/16 Plug connection for reserve
X4/44 Plug connection for supply for air conditioning
control
X4/73 Plug connection for temperature sensor
X4/74 Plug connection for blower potentiometer
X4/75 Plug connection for air conditioning control
potentiometer
X10/11 Plug connection for roof print supply
X10/14 Plug connection for wiring harness for roof
supply

Edition 12-2005
4010-45
 Sheet 24 4010-46

Sva 6-51402 EN
SS05N024

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A Supply, potential 15/1 seat, A12 Central print (Würth or Berifors)

Sva 6-51402 EN
trailer brake A13 Roof print
B Air cushion seat F65 Fuse, air conditioning control
F66 Fuse, blower / air conditioning
C# Blower (roof)
K5/32 Relay supply, D+ air conditioning
M7 Motor for pneumatic seat
# Variant on sheet 23 M10 Motor for blower, roof
S50/2 Blower switch 1-2-3, roof
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/7/17 Weld point for wiring harness, cab, right,
handbrake
X2/9 Plug connection for roof print supply for blower
X4/12 Plug connection for radar sensor
X4/61 Plug connection for Grammer seat
X24/2 Plug connection for wiring harness, cab, right

Ground points

Edition 12-2005
4010-47
 Sheet 25 4010-48

Sva 6-51402 EN
SS05N025

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A Horn A12 Central print (Würth or Berifors) X10/14 Plug connection for wiring harness for roof

Sva 6-51402 EN
A13 Roof print supply
B Steering column switch
F26 Fuse, parallel wiper, horn, interval relay, X14/8 Plug connection for instruments wiring harness
C Parallel wipers, front potential 15/2 - steering column [8]
D Windscreen washing system, F63 Fuse, rear wiper X14/15 Plug connection for central print - wiring
front F64 Front wiper for hinged windscreen harness for roof supply [15]
E Windscreen washing system, H1 Signal horn X18/1 Plug connection for instruments wiring harness
rear K3 Interval relay - central print [1]
M2/1 Motor for parallel wipers, front X23/1 Plug connection for instruments wiring harness
F Angled wiper, front
M2/2 Motor for angled wiper, front - engine wiring harness
G Angled wiper, rear X24/1 Plug connection for instruments wiring harness
M4/2 Wiper motor, rear
M5 Motor for windscreen washing system, rear - central print [1]
M6 Motor for windscreen washing system, front
S2/30 Switch for wiper/washing system, rear [Wi.hi]
S4/3 Steering column switch for wiper/washing
system
X0/3/ Weld point for instruments wiring harness,
potential 31
Ground points
X0/5/1 Weld point for engine hood wiring harness,
potential 31
X0/6/1 Weld point for wiring harness, cab, left,
potential 31
X0/28/20 Weld point for roof wiring harness, potential 53
X3/28 Plug connection for work lamp, engine hood
and horn
X4/1 Plug connection for wiper motor, hinged
screen, front [Wi-VO]
X4/17 Plug connection for roof print, wiper motor,
front [17]
X4/65 Plug connection for roof print, wiper motor,
rear [65]
X5/55 Plug connection for parallel wiper, front
X6/10 Plug connection for left cab wiring harness -
instruments wiring harness [10]
X6/23 Plug connection for rear wiper motor
X10/11 Plug connection for roof print supply

Edition 12-2005
4010-49
 Sheet 26 4010-50

Sva 6-51402 EN
SS05N026

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A Power socket, front A12 Central print (Würth or Berifors) X0/6/5 Weld point for wiring harness, cab, left,

Sva 6-51402 EN
A13 Roof print potential R
B Socket, front
A16 EDC print X0/7/10 Weld point for wiring harness, cab, right, radar
C Socket, rear (trailer) A55 EDC box sensor
D Power socket 1, rear A60 ECCU2 X0/25/2 Weld point for wiring harness, control panel,
B16 Radar sensor right, potential 58
E Power socket 2, rear X0/7/5 Weld point for wiring harness, cab, right,
(preparation) CN2/E ECCU2 plug connection
CN3b ECCU2 plug connection potential 31
F Power socket F2 Fuse, power socket for cab, potential 30 X1/6/1 Screw connection for 2nd power socket 40 A
G ASR with radar sensor F3 Fuse, 1st power socket for potential 30 X1/6/2 Screw connection for 1st power socket 40 A
F4 Fuse, 2nd power socket for potential 30 X1/31 Screw connection for engine print, power
socket, front, potential 30
F29 Fuse, supply to front and rear power sockets,
standard signal socket, reverse fan, X1/60 Screw connection for power socket, cab 30 A
potential 15/2 X2/4/1 Plug connection for central print,
F31 Fuse, supply for radar sensor, potential 15/2 potential 15/2
F38 Fuse, trailer socket, potential 58L front and X2/4/2 Screw - plug connection for potential 15/2
rear X3/1 Radar sensor plug connection
F39 Fuse, trailer socket, potential 58R front and X4/12 Radar sensor plug connection
rear X5/1 Screw - plug connection, potential 31, central
Ground points print
F52 Fuse, trailer socket for turn signal, right front
and rear X6/12 Plug connection for wiring harness, cab, left -
11 Engine device carrier 7-pin trailer socket, front [7 Pol.Vo]
F53 Fuse, trailer socket for turn signal, left front
and rear X6/21 Plug connection for 7-pin trailer socket, front
F55 Fuse, trailer socket for brake light, front and [7pol.vo]
rear X10/1 Trailer socket, 7-pin, rear
F99 Fuse, front power socket X10/2 Trailer socket, 7-pin, front
S2/73 Slip control switch [ASR] X10/4 Plug connection for EDC print armrest (GSV)
X0/6/1 Weld point for wiring harness, cab, left, X10/8 Plug connection for wiring harness, cab, left -
potential 31 central print [8]
X0/6/2# Weld point for wiring harness, cab, left, X10/9 Plug connection for wiring harness, cab, right
potential 58L - control panel
X0/6/3 Weld point for wiring harness, cab, left, X14/1 1st power socket, 40 A rear
potential L X14/30 Power socket for cab 30 A
X0/6/4 Weld point for wiring harness, cab, left, X15 Power socket, front
potential 58R X24/2 Plug connection for wiring harness, cab, right

Edition 12-2005
4010-51
 Sheet 27 4010-52

Sva 6-51402 EN
If filter heating is fitted, remove line G FILTERHZG and
plug in line B146

Supply for potential 15

Supply for potential 15

Supply for potential 30

Check for sprung front axle
Supply for potential 31

Check for turn signal, trailer I

Check for turn signal, left
Check for turn signal, right
Check for air filter

Check for turn signal, trailer II

Check for high beam

Check for lighting

Check for hydraulic oil filter

free

SS05N027

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A ADIC A1 ARU connector module - CAN module

Sva 6-51402 EN
A12 Central print (Würth or Berifors)
B Filter heating (preparation)
A14 Engine print (Würth or Berifors)
C Supply for ADIC
A65 KEY PADS
CN1 ADIC plug connection
# Variant on sheet 28 CN3 ADIC plug connection
F6 Fuse, ADIC, keypads, potential 15/1
S3 Test switch for air filter
S23 Test switch for charge pressure 1bar
X0/3/1 Weld point for instruments wiring harness,
potential 58L
X0/3/10 Weld point for instruments wiring harness, turn
signal on right
X0/3/11 Weld point for instruments wiring harness, turn
signal on left
X0/3/22 Weld point for instruments wiring harness,
potential 15/1
X0/3/5 Weld point for instruments wiring harness,
Ground points potential 31
16 Starter X0/3/9 Weld point for instruments wiring harness,
potential 30
X0/4/4 Weld point for engine wiring harness, potential 31
X0/7/17 Weld point for wiring harness, cab, right,
handbrake
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X4/63 Keypads plug connection
X6/6 Plug connection for instruments wiring harness
X18/1 Plug connection for instruments wiring harness
- central print [1]
X23/1 Plug connection for instruments wiring harness
- engine wiring harness
X24/1 Plug connection for instruments wiring harness
- central print [1]
X24/3 Plug connection for instruments wiring harness
- cab wiring harness on right [3]

Edition 12-2005
4010-53
 Sheet 28 4010-54

Sva 6-51402 EN
If filter heating is fitted, remove line G FILTERHZG and
plug in line B146

Check for sprung

front axle

Supply for potential 30

Check for filter heating
Supply for potential 15
Supply for potential 31

Check for turn signal, left

Check for turn signal, trailer I

Check for turn signal, trailer II
Check for turn signal, right
Check for air filter

Check for high beam

Check for lighting

Check for hydraulic oil filter

free

SS05N028

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A ADIC A1 ARU connector module - CAN module

Sva 6-51402 EN
A12 Central print (Würth or Berifors)
B Filter heating (preparation)
A14 Engine print (Würth or Berifors)
C# Supply for ADIC, ISO BUS
A65 KEY PADS
CN1 ADIC plug connection
# Variant on sheet 27 CN3 ADIC plug connection
F6 Fuse, ADIC, keypads, potential 15/1
S3 Test switch for air filter
S23 Test switch for charge pressure 1bar
X0/3/1 Weld point for instruments wiring harness,
potential 58L
X0/3/10 Weld point for instruments wiring harness, turn
signal on right
X0/3/11 Weld point for instruments wiring harness, turn
signal on left
X0/3/22 Weld point for instruments wiring harness,
potential 15/1
X0/3/ Weld point for instruments wiring harness,
Ground points potential 31
16 Starter X0/3/9 Weld point for instruments wiring harness,
potential 30
X0/4/4 Weld point for engine wiring harness, potential 31
X0/7/17 Weld point for wiring harness, cab, right,
handbrake
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X4/63 Keypads plug connection
X6/6 Plug connection for instruments wiring harness
X18/1 Plug connection for instruments wiring harness
- central print [1]
X23/1 Plug connection for instruments wiring harness
- engine wiring harness
X24/1 Plug connection for instruments wiring harness
- central print [1]
X24/3 Plug connection for instruments wiring harness
- cab wiring harness on right [3]

Edition 12-2005
4010-55
 Sheet 29 4010-56

Sva 6-51402 EN
Ground
RS 232 out

Check for tank content

Check for pneumatic air, trailer
RS 232 in

Check for Italy trailer brake

Check for coolant level

Transmission speed
signal
PTO shaft speed
Check for alternator D+
Check for brake fluid level

Radar screen
50% signal, rear power lift
Ground
SS05N029

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A Socket, standard signal A1 ARU connector module - CAN module

Sva 6-51402 EN
A12 Central print (Würth or Berifors)
B ADIC
B2/1 Sensor for tank content, left
C Socket, diagnosis ADIC
B3 Sensor for compressed air
CN1 ADIC plug connection
CN2 ADIC plug connection
CN3 ADIC plug connection
S13 Test switch for brake fluid
S22 Test switch for coolant level
X0/3/12 Weld point for instruments wiring harness,
handbrake check
X0/3/2 Weld point for instruments wiring harness,
potential 15/1
X0/3/3 Weld point for instruments wiring harness,
potential 31
X0/4/4 Weld point for engine wiring harness,
potential 31
X4/62 Plug connection for diagnosis, ADIC
Ground points
X6/6 Plug connection for instruments wiring harness
X6/8 Plug connection for standard signal
socket [NORMS]
X6/10 Plug connection for left cab wiring harness -
instruments wiring harness [10]
X6/11 Plug connection for standard signal socket,
instruments wiring harness [NORMS]
X23/1 Plug connection for instruments wiring harness
- engine wiring harness
X24/1 Plug connection for instruments wiring harness
- central print [1]
X24/3 Plug connection for instruments wiring harness
- cab wiring harness on right [3]
X29 Standard signal socket

Edition 12-2005
4010-57
 Sheet 30 4010-58

Sva 6-51402 EN
SS05N030

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A Speed sensors, PTO, front and A12 Central print (Würth or Berifors)

Sva 6-51402 EN
rear A60 ECCU2
B Switch for reducing speed B7 Rear PTO shaft speed sensor
B8 Front PTO shaft speed sensor
C Switch for HTS
CN2/E ECCU2 plug connection
CN3a ECCU2 plug connection
CN3b ECCU2 plug connection
F32 Fuse, supply for PTO sensors, potential 15/2
S2/15/6 HTS switch [HTS]
S2/15/7 Speed reduction switch
[DREHZAHLABSENKUNG]
X0/4/1 Weld point for engine wiring harness,
potential 31
X0/7/5 Weld point for wiring harness, cab, right,
potential 15
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/25/2 Weld point for wiring harness, control panel,
Ground points right, potential 58
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/25/5 Weld point for wiring harness, control panel,
right GSV1
X3/21 Plug connection for front PTO shaft speed
sensor [PTO]
X23/2 Plug connection for wiring harness, cab, right
- engine wiring harness
X24/2 Plug connection for wiring harness, cab, right
X24/5 Plug connection for wiring harness, cab, right
- control panel

Edition 12-2005
4010-59
 Sheet 31 4010-60

Sva 6-51402 EN
SS05N031

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A Supply, control panel, right A12 Central print (Würth or Berifors)

Sva 6-51402 EN
A16 EDC print
B# Socket, mobile phone, left
E11 Cigarette lighter, right [E11]
C Cigarette lighter with socket on
E11/1 Mobile phone socket, left
right, 2-pin
F13 Fuse, cigarette lighter, 2-pin socket,
D Reserve, EDC print diagnosis socket, EDC print, potential 30
X0/7/17 Weld point for wiring harness, cab, right,
# Variant on sheet 32 handbrake
X0/7/18 Weld point for wiring harness, cab, right 58R
X0/7/23 Weld point for wiring harness, cab, right,
potential 30
X2/1 Socket, 2-pin 30/31 [2/1]
X2/4/1 Plug connection for central print, potential 15/2
X2/6 Plug connection for lighting, potentiometer
EDC
X6/13 Plug connection for cigarette lighter and
socket, 2-pin
X6/15 Plug connection for mobile phone socket, left
Ground points X14/4 Plug connection for EDC print - control unit
X24/2 Plug connection for wiring harness, cab, right

Edition 12-2005
4010-61
 Sheet 32 4010-62

Sva 6-51402 EN
SS05N032

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections
A Supply, control panel, right
Sva 6-51402 EN
B# Socket, mobile phone, left for
reverse travel equipment
D Cigarette lighter with socket on
right, 2-pin
E Reserve, EDC print
# Variant on sheet 31
Ground points
Edition 12-2005
Electrical equipment
A12 Central print (Würth or Berifors)
A16 EDC print
E11 Cigarette lighter, right [E11]
E11/1 Mobile phone socket, left
F13 Fuse, cigarette lighter, 2-pin socket, diagnosis
socket, EDC print, potential 30
X0/7/17 Weld point for wiring harness, cab, right,
handbrake
X0/7/18 Weld point for wiring harness, cab, right 58R
X0/7/23 Weld point for wiring harness, cab, right,
potential 30
X0/27/15 Weld point for reverse travel equipment wiring
harness, potential 58
X0/27/7 Weld point for reverse travel equipment wiring
harness, potential 31
X0/28/8 Weld point for roof wiring harness, all-round
lights
X2/1 Socket, 2-pin 30/31 [2/1]
X2/4/1 Plug connection for central print, potential 15/2
X2/6 Plug connection for lighting, potentiometer EDC
X6/13 Plug connection for cigarette lighter and socket,
2-pin
X6/15 Plug connection for mobile phone socket, left
X14/4 Plug connection for EDC print - control panel
X24/2 Plug connection for wiring harness, cab, right
4010-63
 Sheet 33 4010-64

Sva 6-51402 EN
SS05N033

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A# Supply, EDC box A12 Central print (Würth or Berifors)

Sva 6-51402 EN
A14 Engine print (Würth or Berifors)
B# EDC without raise/lower
A55 EDC box
C Power sensors
B9/1 Rotary angle sensor EDC [LAGES]
D Angle of rotation sensor, power B10/1 Power sensor, left
lift, rear B10/2 Power sensor, right
E Solenoid valves, raising, F49 Fuse, supply for potential 15/1 EDC box
lowering F91 Fuse, supply for EDC, potential 30
X0/7/11 Weld point for wiring harness, cab, right, EDC
GND
# Variant on sheet 34
X0/7/12 Weld point for wiring harness, cab, right,
EDC 9.5V
X0/7/20 Weld point for wiring harness, cab, right,
LOWER valve
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X2/12 Raise/lower plug connection
X20/1 Plug connection for engine wiring harness
Ground points (Würth)
X23/2 Plug connection for wiring harness, cab, right -
engine wiring harness
X24/2 Plug connection for wiring harness, cab, right
X55 Plug connection for EDC box
Y6 Solenoid valve, EDC, RAISE, grey [HEBEN]
Y7 Solenoid valve, EDC, LOWER, black
[SENKEN]

Edition 12-2005
4010-65
 Sheet 34 4010-66

Sva 6-51402 EN
SS05N034

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A# Supply, EDC box A12 Central print (Würth or Berifors)

Sva 6-51402 EN
A14 Engine print (Würth or Berifors)
B# EDC with raise/lower
A55 EDC box
C Power sensors
B9/1 Rotary angle sensor EDC [LAGES]
D Angle of rotation sensor, power B10/1 Power sensor, left
lift, rear B10/2 Power sensor, right
E Solenoid valves, raising, F49 Fuse, supply for potential 15/1 EDC box
lowering F91 Fuse, supply for EDC, potential 30
S28 Raise/lower changeover switch
X0/7/11 Weld point for wiring harness, cab, right, EDC
# Variant on sheet 33
GND
X0/7/12 Weld point for wiring harness, cab, right,
EDC 9.5V
X0/7/20 Weld point for wiring harness, cab, right,
LOWER valve
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X2/12 Raise/lower plug connection
Ground points
X20/1 Plug connection for engine wiring harness
(Würth)
X23/2 Plug connection for wiring harness, cab, right -
engine wiring harness
X24/2 Plug connection for wiring harness, cab, right
X55 Plug connection for EDC box
Y6 Solenoid valve, EDC, RAISE, grey [HEBEN]
Y7 Solenoid valve, EDC, LOWER, black
[SENKEN]

Edition 12-2005
4010-67
 Sheet 35 4010-68

Sva 6-51402 EN
GSV4
EDC stop
Transport

lift RAISE
Transport/

lift LOWER
Controlling/

Potential 31
Potential 58

Front loader
Potential 15/1
Potential 15/1

Rapid retraction

Rapid retraction
Supply for EDC stop

External button, front power

External button, front power

SS05N035

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A Control signal A12 Central print (Würth or Berifors) X0/25/5 Weld point for wiring harness, control panel,

Sva 6-51402 EN
A16 EDC print right GSV1
B Power lift, front, raise/lower
A55 EDC box X3/13 Plug connection for sensor B23
C Armrest X10/4 Plug connection for EDC print armrest (GSV)
A60 ECCU2
CN3a ECCU2 plug connection X10/9 Plug connection for wiring harness, cab, right -
F19 Fuse, supply for ARU, EDC potential 15/1 control panel
F20 Fuse, supply for ARU, EDC potential 15/1 X18/4 Plug connection for wiring harness, cab, right
R3 2 kOhm resistance - armrest
R4 2 kOhm resistance X23/2 Plug connection for wiring harness, cab, right -
R5 2 kOhm resistance engine wiring harness
R6 2 kOhm resistance X24/2 Plug connection for wiring harness, cab, right
R7 2 kOhm resistance X24/5 Plug connection for wiring harness, cab, right -
control panel
R8 Potentiometer, accelerator pedal
R9 2 kOhm resistance X55 Plug connection for EDC box
Y60 Front loader solenoid valve
S2/7/3 Hydraulic master switch [MASTER]
S18/1 External push button AUX BLUE, pressure in
- [ATS]
Ground points S18/2 External push button AUX BLUE, pressure in
+[ATH]
X0/7/11 Weld point for wiring harness, cab, right, EDC
GND
X0/7/17 Weld point for wiring harness, cab, right,
handbrake
X0/7/18 Weld point for wiring harness, cab, right 58R
X0/7/26 Weld point for wiring harness, cab, right,
transport/control signal
X0/7/9 Weld point for wiring harness, cab, right GSV4
X0/25/1 Weld point for wiring harness, control panel,
right, potential 58
X0/25/2 Weld point for wiring harness, control panel,
right, potential 58
X0/25/3 Weld point for wiring harness, control panel,
right, potential 31
X0/7/5 Weld point for wiring harness, cab, right,
potential 31

Edition 12-2005
4010-69
 Sheet 36 4010-70

Sva 6-51402 EN
SS05N036

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A Speed signal A4 FMGR

Sva 6-51402 EN
A4/2 FMGR plug connection - dark grey [2]
B Button, raise/lower EDC
A55 EDC box
C External button, EDC
S2/15/5 Raise / lower pushbutton [INNEN]
S14/1 External pushbutton, LOWER, left [SENKEN]
S14/2 External pushbutton, LOWER, right
[SENKEN]
S15/1 External pushbutton, RAISE, left [HEBEN]
S15/2 External pushbutton, RAISE, right [HEBEN]
X0/7/10 Weld point for wiring harness, cab, right, radar
sensor
X0/7/16 Weld point for wiring harness, cab, right,
EDC 9.5V
X0/7/21 Weld point for wiring harness, cab, right, RAISE
pushbutton
X0/7/25 Weld point for wiring harness, cab, right,
LOWER
X0/7/4 Weld point for wiring harness, cab, right, supply
Ground points for external pushbutton on right
X0/7/6 Weld point for wiring harness, cab, right, supply
for external pushbutton on left
X0/25/1 Weld point for wiring harness, control panel,
right, potential 58
X0/25/3 Weld point for wiring harness, control panel,
right, potential 31
X24/5 Plug connection for wiring harness, cab, right -
control panel
X55 Plug connection for EDC box

Edition 12-2005
4010-71
 Sheet 37 4010-72

Sva 6-51402 EN
transport
Ground during
SS05N037

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A EDC signal 50% A16 EDC print X3/18 Plug connection for EDC mixing

Sva 6-51402 EN
A55 EDC box potentiometer
B Indicator lights, EDC
A60 ECCU2 X3/19 Plug connection for slip control potentiometer
C Potentiometer, EDC X4/2 Plug connection for LED for diagnosis, LED
CN3b ECCU2 plug connection
D1 Diode for slip
E41 EDC lighting X4/3 Plug connection for LED for raise, LED for
E42 EDC lighting lower
E43 EDC lighting X5/6 Plug connection for setpoint potentiometer
H2/1 LED for diagnosis X10/4 Plug connection for EDC print armrest (GSV)
H2/2 LED for slip X14/4 Plug connection for EDC print - control unit
H2/3 LED for raise
H2/4 LED for lower
R1 2 kOhm resistance
R2 2 kOhm resistance
R6 2 kOhm resistance
R6/1 Setpoint potentiometer
R6/2 Lift limitation potentiometer
Ground points R6/3 Mixing potentiometer
R6/4 Lowering speed potentiometer
R6/5 Slip control potentiometer
R12 0 kOhm resistance
R13 0 kOhm resistance
R14 6.2 kOhm resistance
R19 2 kOhm resistance
X0/7/20 Weld point for wiring harness, cab, right,
LOWER valve
X0/25/3 Weld point for wiring harness, control panel,
right, potential 31
X2/6 Plug connection for lighting, potentiometer
EDC
X3/16 Plug connection for lowering speed
potentiometer
X3/17 Plug connection for lift limitation
potentiometer

Edition 12-2005
4010-73
 Sheet 38 4010-74

Sva 6-51402 EN
0.8V to 4.4V
Signal
Handbrake
Signal
Seat switch

3V
0V to 5.8V

1.1V to 4V
4.4V to 0.8V
Ground
5.8 V
Ground
5.8 V
Signal
Engine back
pressure brake

Ground
5.6V
GSV3

Potential 30
Signal 80%

Potential 31
Potential 15/1
signal
Accelerator pedal
SS05N038

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A Supply, FMGR A2 EEM2 control unit X24/3 Plug connection for instruments wiring harness

Sva 6-51402 EN
A4 FMGR - cab wiring harness on right [3]
B# Clutch switch 80%
A4/1 FMGR plug connection - white [1] X24/5 Plug connection for wiring harness, cab, right -
C# Angle of rotation sensor, coupling control panel
A4/2 FMGR plug connection - dark grey [2]
D# Potentiometer, accelerator pedal A4/3 FMGR plug connection - blue [3] X70 Plug connection for engine control unit EEM2
E# Parking interlock switch A4/4 FMGR plug connection - grey [4]
F# Limit load potentiometer A12 Central print (Würth or Berifors)
B17 Angle of rotation sensor, coupling
G Switch for engine back pressure
F14 Fuse, FMGR, potential 30
brake
F51 Fuse, supply for potential 15/1 FMGR
H# Switch for handbrake, seat switch R8 Potentiometer, accelerator pedal
R23 Limit load potentiometer
# Variants on sheets 39, 40 S2/61 Parking interlock switch [PARKBREMSE]
S8 Seat switch
S20 Engine back pressure brake switch
S21 Switch for handbrake
S46 Coupling switch 80%
Ground points X0/3/1 Weld point for instruments wiring harness,
potential 58L
X0/3/3 Weld point for instruments wiring harness,
potential 31
X0/3/6 Weld point for instruments wiring harness,
potential GSV2
X0/7/2 Weld point for wiring harness, cab, right,
accelerator pedal
X0/7/24 Weld point for wiring harness, cab, right GSV3
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X3/23 Plug connection for load limit potentiometer
X4/25 Plug connection for handbrake switch [25]
X4/61 Plug connection for Grammer seat
X4/70 Plug connection for accelerator pedal [70]
X23/2 Plug connection for wiring harness, cab, right -
engine wiring harness
X24/2 Plug connection for wiring harness, cab, right

Edition 12-2005
4010-75
 Sheet 39 4010-76

Sva 6-51402 EN
Potential 31
Ground
5.6V
Ground

Potential 30
Signal 80%
1.1V to 4V

Potential 15/1
0.8V to 4.4V
4.4V to 0.8V
5.8 V

Accelerator
pedal signal

SS05N039

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A# Supply, FMGR A2 EEM2 control unit X0/27/7 Weld point for reverse travel equipment wiring

Sva 6-51402 EN
A4 FMGR harness, potential 31
B# Clutch switch 80% for reverse
A4/1 FMGR plug connection - white [1] X4/70 Plug connection for accelerator pedal [70]
travel equipment
A4/3 FMGR plug connection - blue[3] X4/70/1 Plug connection for accelerator pedal
C# Angle of rotation sensor, [FAHRPEDAL]
A4/4 FMGR plug connection - grey [4]
coupling with reverse travel
A12 Central print (Würth or Berifors) X23/2 Plug connection for wiring harness, cab, right -
equipment
B17 Angle of rotation sensor, clutch engine wiring harness
D# Potentiometer, accelerator pedal B17/1 Angle of rotation sensor, clutch [DW-KUPPL] X24/2 Plug connection for wiring harness, cab, right
for reverse travel equipment X24/3 Plug connection for instruments wiring harness
F14 Fuse, FMGR, potential 30
F51 Fuse, supply for potential 15/1 FMGR - cab wiring harness on right [3]
# Variants on sheets 38, 40 K5/60 Relay for coupling [KUPPLUNG] X70 Plug connection for engine control unit EEM2
K5/61 Relay for front accelerator pedal
[FAHRPEDAL1]
K5/62 Relay for rear accelerator pedal
[FAHRPEDAL1]
R8 Potentiometer, accelerator pedal
R8/1 Potentiometer, accelerator pedal, reverse travel
equipment
Ground points
S46 Coupling switch 80%
S46/1 Coupling switch 80% [KUPPL]
X0/3/6 Weld point for instruments wiring harness,
potential GSV2
X0/7/2 Weld point for wiring harness, cab, right,
accelerator pedal
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/27/1 Weld point for seat wiring harness, reverse
travel equipment
X0/27/10 Weld point for reverse travel equipment wiring
harness, accelerator pedal 2
X0/27/11 Weld point for reverse travel equipment wiring
harness, accelerator pedal 1
X0/27/13 Weld point for reverse travel equipment wiring
harness, coupling
X0/27/14 Weld point for reverse travel equipment wiring
harness, coupling

Edition 12-2005
4010-77
 Sheet 40 4010-78

Sva 6-51402 EN
Signal for
reverse travel
equipment
active

3V
5.8 V
Signal
Handbrake
Signal
Seat switch

Ground
0V to 5.8V
Signal
Engine back
pressure brake
GSV3
SS05N040

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A# Parking interlock switch A4 FMGR X0/27/9 Weld point for reverse travel equipment wiring

Sva 6-51402 EN
A4/1 FMGR plug connection - white [1] harness, GSV2
B# Potentiometer, limit load for
A4/2 FMGR plug connection - dark grey [2] X4/25 Plug connection for handbrake switch [25]
reverse travel equipment
A4/4 FMGR plug connection - grey [4] X4/25/1 Plug connection for switch for handbrake
C# Switch for engine back pressure [HANDBREMSE]
A70 Seat switch
brake, handbrake for reverse
H1/1 Signal horn for reverse travel equipment X6/23 Plug connection for rear wiper motor
travel equipment
R23 Limit load potentiometer X6/27 Plug connection for seat switch ARU -
D# Seat switch for reverse travel S2/61 Parking interlock switch [PARKBREMSE] console for reverse travel equipment
equipment X6/58 Plug connection for seat switch [SITZ RF]
S2/61/1 Parking interlock switch [PARK]
E# Horn for reverse travel S2/74 Reverse fan pushbutton X24/3 Plug connection for instruments wiring harness
equipment S8 Seat switch - cab wiring harness on right [3]
S8/1 Reversible seat switch X24/5 Plug connection for wiring harness, cab, right -
control panel
# Variants on sheets 38, 39 S8/2 Reversible seat switch
S20 Engine back pressure brake switch
S21 Switch for handbrake
X0/3/1 Weld point for instruments wiring harness,
potential 58L
Ground points X0/3/3 Weld point for instruments wiring harness,
potential 31
X0/3/6 Weld point for instruments wiring harness,
potential GSV2
X0/7/24 Weld point for wiring harness, cab, right GSV3
X0/27/1 Weld point for seat wiring harness, reverse
travel equipment
X0/27/15 Weld point for reverse travel equipment wiring
harness, potential 58
X0/27/4 Weld point for reverse travel equipment wiring
harness, parking interlock
X0/27/9 Weld point for reverse travel equipment wiring
harness, GSV2
X0/27/7 Weld point for reverse travel equipment wiring
harness, potential 31
X0/27/8 Weld point for reverse travel equipment wiring
harness, potential 15/2

Edition 12-2005
4010-79
 Sheet 41 4010-80

Sva 6-51402 EN
4WD
Management
Brake oil
cooling valve 2

GSV1
Brake oil
cooling valve 1

Manual mode

0-14 km/h
0-25 km/h
All-wheel drive ON
Differential lock ON
Differential lock management
Differential lock solenoid valve

SS05N041

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A# Switch for speed ranges, A4 FMGR

Sva 6-51402 EN
manual mode A4/1 FMGR plug connection - white [1]
B# Switch for differential lock, all- A4/3 FMGR plug connection - blue[3]
wheel drive management A16 EDC print
A60 ECCU2
C# Solenoid valves, brake oil
cooling CN3b ECCU2 plug connection
S2/56 Switch for differential lock management
[DIFF HI]
# Variant on sheet 42 S2/58/1 Switch for speed ranges [RANGE]
S2/58/2 Switch for manual mode [MAN.MOD]
S2/59 Switch for all-wheel drive management
[4WD]
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/25/2 Weld point for wiring harness, control panel,
right, potential 58
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
Ground points X0/25/5 Weld point for wiring harness, control panel,
right GSV1
X0/25/7 Weld point for wiring harness, control panel,
right GSV1
X10/4 Plug connection for EDC print armrest (GSV)
X14/4 Plug connection for EDC print - control unit
X24/5 Plug connection for wiring harness, cab, right -
control panel
Y10 Differential lock solenoid valve [DIFF]
Y11 Solenoid valve for brake oil cooling 1
Y12 Solenoid valve for brake oil cooling 2

Edition 12-2005
4010-81
 Sheet 42 4010-82

Sva 6-51402 EN
All-wheel drive
ON

4WD
Management
Brake oil
cooling valve 2

GSV1
Brake oil
cooling valve 1

Manual mode

0-14 km/h
0-25 km/h
Differential lock ON
Differential lock management
Differential lock solenoid valve

SS05N042

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A# Switch for speed ranges, A4 FMGR

Sva 6-51402 EN
manual mode for reverse travel A4/1 FMGR plug connection - white [1]
equipment A4/3 FMGR plug connection - blue [3]
B# Switch for differential lock, all- A16 EDC print
wheel drive management for A60 ECCU2
reverse travel equipment CN3b ECCU2 plug connection
C# Solenoid valves, brake oil S2/56 Switch for differential lock management
cooling [DIFF HI]
S2/58/1 Switch for speed ranges [RANGE]
S2/58/2 Switch for manual mode [MAN.MOD]
# Variant on sheet 41 S2/59 Switch for all-wheel drive management
[4WD]
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/25/2 Weld point for wiring harness, control panel,
right, potential 58
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
Ground points X0/25/5 Weld point for wiring harness, control panel,
right GSV1
X0/25/7 Weld point for wiring harness, control panel,
right GSV1
X10/4 Plug connection for EDC print armrest (GSV)
X14/4 Plug connection for EDC print - control panel
X24/5 Plug connection for wiring harness, cab, right -
control panel
Y10 Differential lock solenoid valve [DIFF]
Y11 Solenoid valve for brake oil cooling 1
Y12 Solenoid valve for brake oil cooling 2

Edition 12-2005
4010-83
 Sheet 43 4010-84

Sva 6-51402 EN
Load ground for
reverse gear
with max.
200mA

Forwards
Neutral

Reverse
Dead man
Plug X4/59b in here in
an emergency

SS05N043

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A ICU performance monitor A4 FMGR

Sva 6-51402 EN
A4/2 FMGR plug connection - dark grey [2]
B Gearbox electronics
A12 Central print (Würth or Berifors)
C LIMP HOME plug connection
A13 Roof print
D# Shuttle lever A21 SGR transmission controller
A23 Linde electronics
# Variant on sheet 44 A24 Hydrostat
F9 Fuse, SGR, potential 30
F18 Fuse, SGR, potential 15/1
P8 ICU
S4/4 Shuttle lever
X0/3/6 Weld point for instruments wiring harness,
potential GSV2
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/28/1 Weld point for roof wiring harness, potential 30,
memory
X0/28/12 Weld point for roof wiring harness, potential 31
Ground points
X0/28/3 Weld point for roof wiring harness, potential 58
X4/59/a Plug connection for LIMP HOME [A]
X4/59/b Plug connection for LIMP HOME [A]
X4/59/c Plug connection for LIMP HOME [B]
X6/1 Plug connection for Linde electronics
X6/3 Plug connection for instruments wiring
harness - steering column [3]
X6/9 Plug connection for Linde electronics -
hydrostat A24
X10/12 Plug connection for roof wiring harness
X16/21 SGR plug connection
X24/2 Plug connection for wiring harness, cab, right
X24/3 Plug connection for instruments wiring harness
- cab wiring harness on right [3]

Edition 12-2005
4010-85
 Sheet 44 4010-86

Sva 6-51402 EN
Reverse
Forwards
Neutral

Dead man
Load ground for
reverse gear
with max.
200mA

Plug X4/59b in here in

an emergency

SS05N044

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A ICU performance monitor A4 FMGR X4/59/c Plug connection for LIMP HOME [B]

Sva 6-51402 EN
A4/2 FMGR plug connection - dark grey [2] X6/1 Plug connection for Linde electronics
B Gearbox electronics
A12 Central print (Würth or Berifors) X6/3 Plug connection for instruments wiring harness
C LIMP HOME plug connection - steering column [3]
A13 Roof print
D# Shuttle lever A21 SGR transmission controller X6/9 Plug connection for Linde electronics -
E Display for reverse travel A23 Linde electronics hydrostat A24
equipment A24 Hydrostat X10/12 Plug connection for roof wiring harness
F9 Fuse, SGR, potential 30 X16/21 SGR plug connection
F18 Fuse, SGR, potential 15/1 X24/2 Plug connection for wiring harness, cab, right
# Variant on sheet 43 X24/3 Plug connection for instruments wiring harness
P6 Display for reverse travel equipment
P8 ICU - cab wiring harness on right [3]
S4/4 Shuttle lever
S4/4/1 Forwards - reverse switch [V/R]
X0/3/6 Weld point for instruments wiring harness,
potential GSV2
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
Ground points X0/27/15 Weld point for reverse travel equipment wiring
harness, potential 58
X0/27/2 Weld point for reverse travel equipment wiring
harness “V”
X0/27/3 Weld point for reverse travel equipment wiring
harness “R”
X0/27/5 Weld point for reverse travel equipment wiring
harness, setting off
X0/27/7 Weld point for reverse travel equipment wiring
harness, potential 31
X0/27/8 Weld point for reverse travel equipment wiring
harness, potential 15/2
X0/27/9 Weld point for reverse travel equipment wiring
harness, GSV2
X0/28/12 Weld point for roof wiring harness, potential 31
X0/28/3 Weld point for roof wiring harness, potential 58
X0/28/4 Weld point for roof wiring harness, potential 30
X4/59/a Plug connection for LIMP HOME [A]
X4/59/b Plug connection for LIMP HOME [A]

Edition 12-2005
4010-87
 Sheet 45 4010-88

Sva 6-51402 EN
Ground
Ground
Ground
GND opens at a
difference in
pressure of
> 5 bar

Ground
Ground

Ground
4V
Ground
Ground
4V
4V
10V
10V

4V
4V
Ground
PTC 1 kOhm to
4.4 kOhm

4V
4V
10 to 6000Hz
10 to 6000Hz
0.2V to 3.1V
5V
Ground

10 to 6000Hz
10 to 6000Hz
0.2V to 1.2V
5V

10 to 6000Hz

SS05N045

Line colours and/or coding according to standard 05449

Code letter Colour
A red
B beige
C white
D yellow
E grey
F green
G violet
Type of use
Potential 30 (continuous current) H orange VDC stabilised by electric box
-- control line (at ground end) K light blue D+
+ control line (at positive end) L brown Ground above a box
Potential 15 Si (safety) M Ground strip
Potential 58 (lighting) N pink Electric signals
Signal line P colourless Reserve
Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A Solenoid valves, cartridge A21 SGR transmission controller

Sva 6-51402 EN
B24 Speed sensor, cartridge input
B Speed sensors, cartridge
B25 Speed sensor, planetary carrier 3/4
C Sensors, cartridge switch
B26 Speed sensor, cartridge output
B26 Speed sensor, cartridge output
B32 Speed sensor, temperature sensor,
transmission oil
B35 Speed sensor, planetary carrier 1/2
B47 Pressure sensor, transmission system
pressure
B51 Pressure sensor, transmission lubrication
pressure
S49/1 Pressure filter switch 5bar
X5 Plug connection for pressure filter
X17 Plug connection for parking interlock ground
Y41 Solenoid valve, coupling 1
Y42 Solenoid valve, coupling 2
Y43 Solenoid valve, coupling 3
Ground points
Y44 Solenoid valve, coupling 4
Y45 Solenoid valve, coupling, forward
Y46 Solenoid valve, coupling, reverse
Y57 Solenoid valve, parking interlock On
Y58 Solenoid valve, parking interlock Off
Y59 All-wheel solenoid valve

Edition 12-2005
4010-89
 Sheet 46 4010-90

Sva 6-51402 EN
12V for
PTO shaft
at front active

12V for
PTO shaft
at rear active

SS05N046

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A Rear PTO shaft A60 ECCU2

Sva 6-51402 EN
CN2/E ECCU2 plug connection
B Front PTO shaft
CN3a ECCU2 plug connection
CN3b ECCU2 plug connection
S2/70/1 Switch for front PTO shaft [PTO VO]
S2/70/2 Switch for rear PTO shaft [PTO HI]
S2/71 Switch for rear PTO shaft management
[PTO M]
S17/1 External pushbutton, PTO shaft, rear left
S17/2 External pushbutton, PTO shaft, rear right
X0/7/9 Weld point for wiring harness, cab, right GSV4
X0/25/1 Weld point for wiring harness, control panel,
right, potential 58
X0/25/3 Weld point for wiring harness, control panel,
right, potential 31
X0/25/5 Weld point for wiring harness, control panel,
right GSV1
X24/5 Plug connection for wiring harness, cab, right -
Ground points control panel
Y4 Solenoid valve for front PTO shaft [PTO VO]
Y5 Solenoid valve for rear PTO shaft [PTO]

Edition 12-2005
4010-91
 Sheet 47 4010-92

Sva 6-51402 EN
Potential 15/2

12V
during
locked

DOWN
Ground
Ground
Potential 30

v<14 km/h

12V during
12V during
12 V during

management

12V during UP
Check for
front axle 12V during
ACTIVE 12V during UP UP / DOWN

12V during
UP / DOWN

12 V
Signal flow

12 V
Signal flow
Ground

Ground
BLUE BLACK GREEN

SS05N047

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A Spring-mounted front axle A12 Central print (Würth or Berifors) X2/45 Plug connection for wiring harness, cab, right

Sva 6-51402 EN
A60 ECCU2 - sprung front axle [45]
B Supply, ECCU2
A61 Electronics, front axle with independent X2/46 Plug connection for potential 58/31, sprung
suspension front axle [GE.VA]
# Variant on sheet 48 B33/1 Angle of rotation sensor X4/45 Plug connection for sprung front axle [45]
B33/2 Angle of rotation sensor X12/20 Plug connection for control block, sprung
CN1a ECCU2 plug connection front axle [VA]
CN2/E ECCU2 plug connection X24/2 Plug connection for wiring harness, cab, right
CN3a ECCU2 plug connection Y14 Solenoid valve for sprung front axle, pilot valve
CN3b ECCU2 plug connection Y15 Solenoid valve for sprung front axle, left
F10 Fuse, supply, ECCU2, potential 30 Y16 Solenoid valve for sprung front axle, right
F27 Fuse, sprung front axle, potential 30
F28 Fuse, sprung front axle, potential 15/2
F50 Fuse, supply for potential 15/1 ECCU2
S2/15/1 Switch for sprung front axle UP/DOWN
[VA auf/ab]
S2/15/2 Switch for sprung front axle IN/OUT [VA ein]
Ground points X0/3/1 Weld point for instruments wiring harness,
potential 58L
X0/3/5 Weld point for instruments wiring harness,
potential 31
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/7/8 Weld point for wiring harness, cab, right,
potential 15/1
X0/7/9 Weld point for wiring harness, cab, right GSV4
X0/8/1 Weld point for additional line, independent
suspension, sprung front axle, potential 58
X0/8/2 Weld point for additional line, independent
suspension, sprung front axle, potential 31
X0/8/3 Weld point for additional line, independent
suspension, sprung front axle, potential 15/2
X2/7 Plug connection for OP.CHG

Edition 12-2005
4010-93
 Sheet 48 4010-94

Sva 6-51402 EN
Potential 15/2

12V
during
locked

DOWN
Ground
Ground
Potential 30

12V during
12V during
v< 14 km/h
12 V during

management

12V during UP
Check for 12V during
front axle UP / DOWN
ACTIVE 12V during UP

12 V
Signal flow

12 V
Signal flow
Ground
Ground
12V during UP / DOWN
BLUE BLACK GREEN

SS05N048

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A Spring-mounted front axle A12 Central print (Würth or Berifors) X2/87 Plug connection for cab wiring harness on right

Sva 6-51402 EN
A60 ECCU2 - instruments wiring harness ISO-BUS
B Supply, ECCU2 for ISO BUS
A61 Electronics, sprung front axle X4/45 Plug connection for sprung front axle [45]
B33/1 Angle of rotation sensor X4/85/a Plug connection for cab wiring harness, right
# Variant on sheet 47 B33/2 Angle of rotation sensor - ISO BUS preparation
CN1a ECCU2 plug connection X4/85/b Plug connection for cab wiring harness, right
CN2/E ECCU2 plug connection - ISO BUS preparation
CN3a ECCU2 plug connection X12/20 Plug connection for control block, sprung front
CN3b ECCU2 plug connection axle [VA]
F10 Fuse, supply, ECCU2, potential 30 X24/2 Plug connection for wiring harness, cab, right
F27 Fuse, sprung front axle, potential 30 Y14 Solenoid valve for sprung front axle, UP/DOWN
F28 Fuse, sprung front axle, potential 15/2 Y15 Solenoid valve for sprung front axle, left
F50 Fuse, supply for potential 15/1 ECCU2 Y16 Solenoid valve for sprung front axle, right
S2/15/1 Switch for sprung front axle UP/DOWN
[VA auf/ab]
S2/15/2 Switch for sprung front axle IN/OUT [VA ein]
X0/3/1 Weld point for instruments wiring harness,
Ground points potential 58L
X0/3/5 Weld point for instruments wiring harness,
potential 31
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/7/8 Weld point for wiring harness, cab, right,
potential 15/1
X0/7/9 Weld point for wiring harness, cab, right GSV4
X0/8/1 Weld point for additional line, independent
suspension, sprung front axle, potential 58
X0/8/2 Weld point for additional line, independent
suspension, sprung front axle, potential 31
X0/8/3 Weld point for additional line, independent
suspension, sprung front axle, potential 15/2
X2/7 Plug connection for OP.CHG
X2/45 Plug connection for wiring harness, cab, right -
sprung front axle [45]
X2/46 Plug connection for potential 58/31, sprung
front axle [GE.VA]

Edition 12-2005
4010-95
 Sheet 49 4010-96

Sva 6-51402 EN
SS05N049

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A Power lift, front, management A60 ECCU2

Sva 6-51402 EN
B Angle of rotation sensor, power
lift, front
C External button, AUX, front
D External button, power lift, front
Ground points
B19 Angle of rotation sensor [LAGESENSOR VO]
CN1a ECCU2 plug connection
CN3a ECCU2 plug connection
CN3b ECCU2 plug connection
S14/3 External button, power lift, front LOWER
[Senken]
S15/3 External button, power lift, front RAISE
[Heben]
S19/1 External button, AUX BROWN (to
DBD...YELLOW) pressure in - [Lower]
S19/2 External button, AUX BROWN (to
DBD...YELLOW) pressure in + [Raise]
S28/1 Pushbutton, front power lift management
X0/4/3 Weld point for engine wiring harness GSV4
X0/7/9 Weld point for wiring harness, cab, right GSV4
X0/23/1 Weld point for additional line, external
pushbutton for front power lift GSV4
X3/22 Plug connection for angle of rotation sensor,
front power lift [LAGE]
X4/69 Plug connection for external button for front
power lift [FHW]
X4/72 Plug connection for external pushbutton,
front AUX brown [EHS]
X18/4 Plug connection for cab wiring harness, right -
armrest
X23/2 Plug connection for wiring harness, cab, right -
engine wiring harness

Edition 12-2005
4010-97
 Sheet 50 4010-98

Sva 6-51402 EN
SS05N050

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A CAN BUS A1 ADIC

Sva 6-51402 EN
A2 EEM2 control unit
A65 KEY PADS
CN3 ADIC plug connection
P8 ICU
P8/1 Plug connection for ICU CAN [DISP]
P8/2 Plug connection for ICU CAN
X0/3/13 Weld point for instruments wiring harness,
potential 15 CAN BUS
X0/3/14 Weld point for instruments wiring harness,
potential GND CAN BUS
X0/3/15 Weld point for instruments wiring harness,
CAN H
X0/3/16 Weld point for instruments wiring harness,
CAN L
X0/3/17 Weld point for instruments wiring harness,
potential 15 CAN BUS
X0/3/18 Weld point for instruments wiring harness,
Ground points potential GND CAN BUS
X0/3/19 Weld point for instruments wiring harness,
CAN H
X0/3/20 Weld point for instruments wiring harness,
CAN L
X4/63 Keypads plug connection
X10/14 Plug connection for instruments wiring harness
- supply for roof wiring harness
X14/14 Plug connection for instruments wiring harness
- supply for roof [14]
X23/1 Plug connection for instruments wiring harness
- engine wiring harness
X70 Plug connection for engine control unit EEM2

Edition 12-2005
4010-99
 Sheet 51 4010-100

Sva 6-51402 EN
SS05N051

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A CAN BUS A1 ARU connector module - CAN module X24/3 Plug connection for instruments wiring harness

Sva 6-51402 EN
A4 FMGR - cab wiring harness on right [3]
A4/4 FMGR plug connection (grey) [4]
A21 SGR transmission controller
A60 ECCU2
CN1a ECCU2 plug connection
CN3 ADIC plug connection
S31 CAN SGR/FMGR changeover switch
X0/7/17 Weld point for wiring harness, cab, right,
handbrake
X0/7/23 Weld point for wiring harness, cab, right,
potential 31
X0/7/35 Weld point for wiring harness, cab, right,
potential 15 CAN BUS
X0/7/36 Weld point for wiring harness, cab, right,
CAN H
X0/7/37 Weld point for wiring harness, cab, right, CAN L
X0/7/38 Weld point for wiring harness, cab, right,
Ground points potential 31 CAN BUS
X0/7/43 Weld point for wiring harness, cab, right,
potential 15 CAN BUS
X0/7/44 Weld point for wiring harness, cab, right,
CAN H
X0/7/45 Weld point for wiring harness, cab, right, CAN L
X0/7/46 Weld point for wiring harness, cab, right,
potential 31 CAN BUS
X0/7/51 Weld point for wiring harness, cab, right,
potential 15 CAN BUS
X0/7/52 Weld point for wiring harness, cab, right,
CAN H
X0/7/53 Weld point for wiring harness, cab, right, CAN L
X0/7/54 Weld point for wiring harness, cab, right,
potential 31 CAN BUS
X9/17 Socket for diagnosis service tool
[DIAGNOSE]
X16/21 SGR plug connection

Edition 12-2005
4010-101
 Sheet 52 4010-102

Sva 6-51402 EN
up to DBD094270

up to DBD094270

as of DBD094271

SS05N052

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A CAN BUS A4 FMGR X5/1 Screw - plug connection, potential 31, central

Sva 6-51402 EN
A4/3 FMGR plug connection (blue) [3] print
A12 Central print (Würth or Berifors) X18/4 Plug connection for cab wiring harness, right -
A27 CAN module (to DBD094270) armrest
A28 Connector module (to DBD094270) X24/2 Plug connection for wiring harness, cab, right
A30 Print ARU (ab DBD094271) X55 Plug connection for EDC box
A55 EDC box
F16 Fuse, supply for CAN, FMGR, ARU, AUX,
diagnosis changeover switch, ICU
potential 15/2
F47 Fuse, supply for AUX potential 15/1
X0/7/27 Weld point for wiring harness, cab, right,
potential 30 CAN BUS
X0/7/28 Weld point for wiring harness, cab, right,
CAN H
X0/7/29 Weld point for wiring harness, cab, right, CAN L
X0/7/30 Weld point for wiring harness, cab, right,
potential 31 CAN BUS
Ground points X0/7/31 Weld point for wiring harness, cab, right,
potential 30 CAN BUS
X0/7/32 Weld point for wiring harness, cab, right,
CAN H
X0/7/33 Weld point for wiring harness, cab, right, CAN L
X0/7/34 Weld point for wiring harness, cab, right,
potential 31 CAN BUS
X0/7/39 Weld point for wiring harness, cab, right,
potential 15 CAN BUS
X0/7/40 Weld point for wiring harness, cab, right,
CAN H
X0/7/41 Weld point for wiring harness, cab, right, CAN L
X0/7/42 Weld point for wiring harness, cab, right,
potential 31 CAN BUS

Edition 12-2005
4010-103
 Sheet 53 4010-104

Sva 6-51402 EN
SS05N053

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A AUX valves A60 ECCU2 X4/93 Plug connection for AUX 4

Sva 6-51402 EN
CN3b ECCU2 plug connection X4/94 Plug connection for AUX 5
B Heating valve for hydraulic oil
X0/7/5 Weld point for wiring harness, cab, right, Y8 Heating valve
potential 31
X0/9/10 Weld point for wiring harness, AUX potential 15
CAN BUS
X0/9/11 Weld point for wiring harness, AUX potential 31
CAN BUS
X0/9/12 Weld point for wiring harness, AUX CAN H
X0/9/13 Weld point for wiring harness, AUX CAN L
X0/9/20 Weld point for wiring harness, AUX potential 15
CAN BUS
X0/9/21 Weld point for wiring harness, AUX potential 31
CAN BUS
X0/9/22 Weld point for wiring harness, AUX CAN H
X0/9/23 Weld point for wiring harness, AUX CAN L
X0/9/30 Weld point for wiring harness, AUX potential 15
CAN BUS
Ground points X0/9/31 Weld point for wiring harness, AUX potential 31
CAN BUS
X0/9/32 Weld point for wiring harness, AUX CAN H
X0/9/33 Weld point for wiring harness, AUX CAN L
X0/9/40 Weld point for wiring harness, AUX potential 15
CAN BUS
X0/9/41 Weld point for wiring harness, AUX potential 31
CAN BUS
X0/9/42 Weld point for wiring harness, AUX CAN H
X0/9/43 Weld point for wiring harness, AUX CAN L
X0/9/50 Weld point for wiring harness, AUX CAN H
X0/9/51 Weld point for wiring harness, AUX CAN L
X3/10 Plug connection for terminal resistance
X4/83 Plug connection for remote control
valves [EHS]
X4/90 Plug connection for AUX 1
X4/91 Plug connection for AUX 2
X4/92 Plug connection for AUX 3

Edition 12-2005
4010-105
 Sheet 54 4010-106

Sva 6-51402 EN
up to DBD094270
as of DBD094271
up to DBD094270

Supply for EDC stop

Lighting, potential 58
External button, power lift, front, raise
Transport
EDC stop
Potential 31
Potential 15
GSV
Front loader solenoid valve
Controlling
Output for EDC stop

External button, power lift, front, lower

Rapid retraction
Interface, wiring harness, cab, right

SS05N054

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A Interface, wiring harness, cab, A27 CAN module (to DBD094270)

Sva 6-51402 EN
right A28 Connector module (to DBD094270)
B Armrest, electronics A30 Print ARU (ab DBD094271)
C1 Condenser
C2 Condenser
C3 Condenser
C4 Condenser
L1 Disturbance protection
L2 Disturbance protection
V1/1 Diode
V1/2 Z diode
V1/3 Protective diode CAN H
V1/4 Protective diode CAN L
X18/4 Plug connection for cab wiring harness, right -
armrest
X28/1 Plug connection for ARU - wiring harness,
cab, right,
Ground points X28/7 Plug connection for ARU CAN - BUS
YA1 Plug connection for ARU connector module -
CAN module (to DBD094270)
YB1 Plug connection for ARU CAN module -
connector module (to DBD094270)

Edition 12-2005
4010-107
 Sheet 55 4010-108

Sva 6-51402 EN
up to DBD094270

as of DBD094271
up to DBD094270

SS05N055

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A Joystick with button A27 CAN module (to DBD094270)

Sva 6-51402 EN
A28 Connector module (to DBD094270)
B Control handle for AUX
A29 Joystick
C Manual accelerator slider
A30 Print ARU (from DBD094271)
D Armrest, electronics B28 Manual accelerator slider
B30 Longitudinal joystick
B31 Transverse joystick
B52 Control lever
S35 Joystick button
X28/3 Plug connection for ARU - manual
accelerator slider
X28/4 Plug connection for ARU - AUX control lever
X28/5 Plug connection for ARU - AUX joystick
YA1 Plug connection for ARU connector module -
CAN module (to DBD094270)
YB1 Plug connection for ARU CAN module -
connector module (to DBD094270)
Ground points

Edition 12-2005
4010-109
 Sheet 56 4010-110

Sva 6-51402 EN
up to DBD094270

as of DBD094271
up to DBD094270

SS05N056

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A# Button, AUX 5 A27 CAN module (to DBD094270)

Sva 6-51402 EN
A28 Connector module (to DBD094270)
B Reserve
A30 Print ARU (from DBD094271)
C Button, rapid retraction
E28/1 Lighting ARU
D Button, EDC - stop and lighting R12 0 Ohm resistance
E Armrest, electronics R13 0 Ohm resistance
R14 6.2 kOhm resistance
R15 1.2 kOhm resistance
R16 6.2 kOhm resistance
R17 2 kOhm resistance
S2/72 Rapid retraction button
S33 EDC stop button
S34 Button for 5th AUX
X28/2 Plug connection for ARU - rapid retraction
button
X28/6 Plug connection for ARU - AUX button
X28/8 Plug connection for ARU reserve
Ground points X28/9 Plug connection for ARU - lighting, switch for
front power lift management
X28/13 Plug connection for ARU lighting
X28/14 Plug connection for ARU, button for EDC
stop
YA1 Plug connection for ARU connector module -
CAN module (to DBD094270)
YB1 Plug connection for ARU CAN module -
connector module (to DBD094270)

Edition 12-2005
4010-111
 Sheet 57 4010-112

Sva 6-51402 EN
up to DBD094270

as of DBD094271
up to DBD094270

SS05N057

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A Potentiometer, AUX remote A27 CAN module (to DBD094270)

Sva 6-51402 EN
control valves A28 Connector module (to DBD094270)
B Armrest, electronics A30 Print ARU (from DBD094271)
R20/1 Potentiometer for 1st AUX
R20/2 Potentiometer for 2nd AUX
R20/3 Potentiometer for 3rd AUX
R20/4 Potentiometer for 4th AUX
R20/5 Potentiometer for 5th AUX
R28/1 470 Ohm resistance
R28/2 560 Ohm resistance
R28/3 470 Ohm resistance
R28/4 560 Ohm resistance
R28/5 470 Ohm resistance
R28/6 560 Ohm resistance
R28/7 470 Ohm resistance
R28/8 560 Ohm resistance
R28/9 470 Ohm resistance
Ground points R28/10 560 Ohm resistance
X28/12 Plug connection for ARU - potentiometer for
AUX 5
X28/15 Plug connection for ARU - potentiometer for
AUX 3 and AUX 4
X28/16 Plug connection for ARU - potentiometer for
AUX 1 and AUX 2
YA1 Plug connection for ARU connector module -
CAN module (to DBD094270)
YB1 Plug connection for ARU CAN module -
connector module (to DBD094270)

Edition 12-2005
4010-113
 Sheet 58 4010-114

Sva 6-51402 EN
up to
DBD094270

as of
DBD094271
up to DBD094270

SS05N058

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A Multicontroller II A27 CAN module (to DBD094270)

Sva 6-51402 EN
A28 Connector module (to DBD094270)
B Armrest, electronics
A30 Print ARU (from DBD094271)
A31 Multicontroller II
S60/1 F/R button
S60/2 Cruise control button
S60/3 Speed button +
S60/4 Speed button -
S60/5 HTS button
S60/6 AUX blue button
S60/7 EDC Transport/control button
S60/8 Shift button (floating switch)
X4 Plug connection for ARU multicontroller II - print
X21 Plug connection for multicontroller II - print
X28/11 Plug connection for ARU - multicontroller II
X28/19 Plug connection for ARU - shift button
YA1 Plug connection for ARU connector module -
Ground points CAN module (to DBD094270)
YB1 Plug connection for ARU CAN module -
connector module (to DBD094270)

Edition 12-2005
4010-115
 Sheet 59 4010-116

Sva 6-51402 EN
SS05N059

Line colours and/or coding according to standard 05449

Code letter Colour Type of use
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 12-2005
 Designation of sections Electrical equipment

A ISO-BUS A12 Central print (Würth or Berifors) X0/32/3 Weld point for wiring harness, ISO-BUS

Sva 6-51402 EN
A60 ECCU2 potential 30
CN1a ECCU2 plug connection X0/32/4 Weld point for wiring harness, ISO-BUS
CN3b ECCU2 plug connection potential 15/1
CN4 Plug connection for ISO-BUS X0/32/5 Weld point for wiring harness, ISO-BUS
F50 Fuse, supply, ECCU2, potential 15/1 potential 15/1
F80 Fuse, potential 30 ISO-BUS X0/32/6 Weld point for wiring harness, ISO-BUS
F81 Fuse, potential 30 ISO-BUS potential 30
F82 Fuse, potential 30 ISO-BUS X0/32/7 Weld point for wiring harness, ISO-BUS
CAN 31
K5/80 Relay for potential 15 ISO-BUS
K5/81 Relay for ECU Power ISO-BUS X0/32/8 Weld point for wiring harness, ISO-BUS CAN L
X0/32/9 Weld point for wiring harness, ISO-BUS CAN H
K5/82 Relay for power socket ISO-BUS
X1/80 Plug connection for potential 30 ISO-BUS
P9 Virtual terminal
V8/1 Diode group, ISO-BUS X2/86 Plug connection for socket LBS ISO-BUS
X3/85 Plug connection for terminal resistance ISO-
X0/7/8 Weld point for wiring harness, cab, right,
BUS
potential 15
X4/85/a Plug connection for cab wiring harness, right -
X0/32/1 Weld point for wiring harness, ISO-BUS
ISO BUS preparation
Ground points potential 31
X0/32/10 Weld point for wiring harness, ISO-BUS X4/85/b Plug connection for cab wiring harness, right -
CAN 15 ISO BUS preparation
16 Starter
X4/86 Plug connection for socket LBS ISO-BUS
X0/32/11 Weld point for wiring harness, ISO-BUS
CAN GND X9/17 Socket for diagnosis service tool [DIAGNOSE]
X0/32/12 Weld point for wiring harness, ISO-BUS CAN L X9/20 Socket for ISO-BUS
X0/32/13 Weld point for wiring harness, ISO-BUS CAN H X12/8 Plug connection for virtual terminal ISO-BUS
X0/32/14 Weld point for wiring harness, ISO-BUS X24/2 Plug connection for wiring harness, cab, right
CAN 15 X85 Socket for LBS, ISO-BUS
X0/32/15 Weld point for wiring harness, ISO-BUS
CAN 31
X0/32/16 Weld point for wiring harness, ISO-BUS CAN L
X0/32/17 Weld point for wiring harness, ISO-BUS CAN H
X0/32/18 Weld point for wiring harness, ISO-BUS
CAN 15
X0/32/19 Weld point for wiring harness, ISO-BUS
potential 30
X0/32/2 Weld point for wiring harness, ISO-BUS
potential 30

Edition 12-2005
4010-117
 $
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CNH Österreich GmbH Sva 6-93360 EN © 2006 CNH Österreich GmbH

Technical documentation January 2006
A - 4300 St. Valentin, Steyrer Strasse 32
 4010A-3

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$ (
Additional marker light, front left .......................... 25 EDC signal 50% ..................................................71
Additional marker light, front right ....................... 25 EDC with raise/lower ...........................................65
Additional marker light, rear left .......................... 25 EDC without raise/lower ......................................63
Additional marker light, rear right ........................ 25 EEM3 box supply ................................................13
ADIC ........................................................ 51, 53, 55 EEM3 box with sensors and injectors .................15
Air conditioning .................................................... 43 Electrical mirror adjustment .....................35, 37, 39
Air cushion seat ................................................... 45 External button, AUX, front .................................95
All-round light carrier 45 ...................................... 37 External button, power lift, front ..........................95
All-round lights (can be plugged in) ..................... 35 )
All-round lights (magnetic) .................................. 39 Filter heating (preparation) ............................51, 53
Angle of rotation sensor, coupling ....................... 73 Front power lift, Raise / Lower ............................67
Angle of rotation sensor, coupling with Front PTO ...........................................................89
reverse travel equipment ..................................... 75 Fuel delivery pump ............................................7, 9
Angle of rotation sensor, power lift, front ............. 95 *
Angle of rotation sensor, power lift, rear ....... 63, 65 Gearbox electronics ......................................83, 85
Angled wiper, front .............................................. 47 +
Angled wiper, rear ............................................... 47 Headlight .............................................................27
Armrest ................................................................ 67 Heated windscreen, front ....................................41
Armrest, electronics .......... 105, 107, 109, 111, 113 Heated windscreen, rear .....................................41
ASR with radar sensor ........................................ 49 Heating ................................................................21
AUX valves ........................................................ 103 Heating flange ...................................................7, 9
AUX5 button ...................................................... 109 Heating flange, fuel delivery pump ......................11
Auxiliary headlight and 4 work lamps .................. 27 Heating valve for hydraulic oil ...........................103
% Horn ....................................................................47
BB light, left ......................................................... 23 Horn for reverse travel equipment .......................77
BB light, left and right .......................................... 25 ,
BB light, right ....................................................... 23 ICU performance monitor ..............................83, 85
Blower (roof) ........................................................ 45 Indicator lights, EDC ...........................................71
Bosch and Magneton generator ............................ 9 Interface, wiring harness, cab, right ..................105
Bosch generator .............................................. 7, 11 Interior light .........................................................33
Brake light ........................................................... 17 ISO-BUS ........................................................... 115
Brake light for reverse travel equipment ............. 19 Italy brake ............................................................21
Button, EDC - stop and lighting ......................... 109 -
Button, rapid retraction ...................................... 109 Joystick with button ...........................................107
& /
CAN BUS .............................................. 97, 99, 101 Licence plate lights, roof .....................................33
Cigarette lighter with socket on right, 2-pin ... 59, 61 Limit load potentiometer ......................................73
Clutch switch 80% ............................................... 73 LIMP HOME plug connection ........................83, 85
Clutch switch 80% for Low beam, high beam .........................................27
reverse travel equipment ..................................... 75 0
Control handle for AUX ..................................... 107 Manual accelerator slider ..................................107
' Mirror heating ..........................................35, 37, 39
D supply+ ............................................................ 13 Multicontroller II .................................................113
Display for reverse travel equipment ................... 85
Door contact switch ............................................. 33
Doorway lights ..................................................... 33

Sva 6-93360 EN Edition 01-2006

4010A-4
3 Supply for ADIC ...................................................51
Parallel wipers, front ............................................47 Supply for ADIC, ISO BUS ..................................53
Parking interlock switch .................................73, 77 Supply for potential 15 .....................................9, 11
Potentiometer, accelerator pedal ........................73 Supply, control panel, right ............................59, 61
Potentiometer, accelerator pedal for Supply, ECCU2 ...................................................91
reverse travel equipment .....................................75
Supply, ECCU2 for ISO BUS ..............................93
Potentiometer, AUX remote control valves .......111
Supply, EDC box ...........................................63, 65
Potentiometer, EDC ............................................71
Supply, FMGR ...............................................73, 75
Potentiometer, limit load for
Supply, roof .........................................................41
reverse travel equipment .....................................77
Switch for differential lock, all-wheel drive
Power lift, front, management .............................95
management .......................................................79
Power sensors ...............................................63, 65
Switch for differential lock, all-wheel drive
Power socket .......................................................49 management for reverse travel equipment ..........81
Power socket 1, rear ...........................................49 Switch for engine back pressure brake ...............73
Power socket 2, rear (preparation) ......................49 Switch for engine back pressure brake,
Power socket, front ..............................................49 handbrake for reverse travel equipment ..............77
Power supply and starter ...................................7, 9 Switch for handbrake, seat switch .......................73
Power supply for main electrical battery switch ...11 Switch for HTS ....................................................57
Power supply, potential 15, cab GND ...................7 Switch for hydraulic master .................................67
Preparation for buzzer, reverse gear ...................83 Switch for reducing speed ...................................57
5 Switch for speed ranges, manual mode ..............79
Radio preparation ................................................41 Switch for speed ranges, manual mode for
reverse travel equipment .....................................81
Raise / Lower button EDC ...................................69
:
Rear PTO shaft ...................................................89
Warning light system ...........................................25
Reserve central print .....................................17, 19
Warning light system with ISO-BUS ....................23
Reserve for engine print ......................................33
Windscreen washing system, front ......................47
Reserve, EDC print .......................................59, 61
Windscreen washing system, rear ......................47
Reverse fan ...................................................17, 19
Work lamp at rear inside .....................................29
6
Work lamp at rear outside ...................................29
SBB light, left .................................................23, 25
Work lamp, at front, 6 ..........................................29
SBB light, right ...............................................23, 25
Work lamp, BB light .............................................29
Seat switch for reverse travel equipment ............77
Work lamp, engine hood .....................................33
Sensors, cartridge switch ....................................87
Work lamp, fender ...............................................27
Shuttle lever ..................................................83, 85
Work lamp, rear, XENON ....................................31
Socket, front ........................................................49
Socket, mobile phone, left ...................................59
Socket, mobile phone, left for
reverse travel equipment .....................................61
Socket, rear (trailer) .............................................49
Socket, standard signal .......................................55
Solenoid valves, brake oil cooling .................79, 81
Solenoid valves, cartridge ...................................87
Solenoid valves, raising, lowering .................63, 65
Speed sensors, cartridge ....................................87
Speed sensors, PTO, front and rear ...................57
Speed signal ........................................................69
Spot light .................................................35, 37, 39
Spring-mounted front axle .............................91, 93
Starter ..................................................................11
Steering column switch .......................................47
Sva 6-93360 EN Edition 01-2006
 4010A-5

$EEUHYLDWLRQV
ADIC ................................................................................................................................. Analogue/ digital instrument
ARU .................................................................................................................................................................. Armrest
AUX .............................................................................................................................................Remote control valve
BB light ...........................................................................................................................Turn signal / side marker light
DMM ..................................................................................................................................................Digital multimeter
ECCU2 ........................................................................................................................................... Central control unit
EDC ....................................................................................................................................Electronic power lift control
EEM3 ..............................................................................................................................................Engine control unit
FMGR ............................................................................................................... Vehicle/engine/transmission controller
GSV .........................................................................................................................................................Cyclic supply
HTS ..................................................................................................Field end management (headland management)
ICU .............................................................................................................................................. Performance monitor
ID module ................................................................................................. Identification module for engine electronics
KEY PADS ............................................................................................ Function keys for analogue/digital instrument
NTC ...........................................................................................................................Negative temperature coefficient
PCB .........................................................................................Printed circuit board (relay circuit, terminal resistance)
PTC ............................................................................................................................ Positive temperature coefficient
SBB light .......................................................................................................... tail light, turn signal / side marker light
SGR .........................................................................................................................................Transmission controller

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Sva 6-93360 EN Edition 01-2006

 6KHHW 4010A-6

Sva 6-93360 EN
SS06A001

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A# Power supply and starter A3 EEM3 control unit X1/30/1 Screw connection for engine print,

Sva 6-93360 EN
A12 Central print potential 30
B Heating flange
A14 Engine print X1/30/2 Screw connection for engine print,
C Fuel delivery pump potential 30
E10/1 Heating flange
D Bosch generator F1 Fuse, start switch supply X1/31/1 Screw connection for engine print,
E Power supply, potential 15, cab F200 Main fuse potential 31
GND F208 Fuse, fuel delivery pump X1/50 Screw connection for engine print,
F212 Fuse, ADIC, ICU, radio memory, potential 30 potential 50
F213 Fuse, main electrical battery switch, X2/17 Plug connection for generator D+
# Variants on sheet 2, 3 X2/19 Plug connection for heating flange relay
potential 30
F217 Fuse, power supply, warning light system, X2/BATT Plug connection for engine print - main
potential 30 electrical battery switch
G1 Battery X5/1 Screw-plug connection, potential 31, central
G2/2 Generator, Bosch, 120A print
K5/7/1 Relay, potential 15/1 supply X10/3 Plug connection for engine print - instruments
K5/7/2 Relay, potential 15/2 supply wiring harness
X10/18 Plug connection for instruments wiring
K5/LP Relay, fuel delivery pump
harness - engine wiring harness [INSTR]
*URXQGSRLQWV K8/2 Heating flange relay 300A
X12/1 Plug connection for engine wiring harness -
K8/50 Relay, starter
engine print
1 Battery M1 Starter
X18/1 Plug connection for instruments wiring
11 Engine cable carrier, rear M13 Fuel delivery pump
harness - central print [1]
12 Engine cable carrier, front S1 Start switch
X24/1 Plug connection for instruments wiring
16 Starter X0/3/2 Weld point for instruments wiring harness, harness - central print [1]
potential 15/1 X36/1 Plug connection for EEM3 engine control unit
X0/3/16 Weld point for instruments wiring harness - engine sensors wiring harness
CAN L
X89/1 Plug connection for EEM3 engine control unit
X0/42/1 Weld point for engine wiring harness, - engine wiring harness
potential 31
X0/42/3 Weld point for engine wiring harness,
potential 30 (radio)
X1/5 Plug connection for potential 30, ADIC, ICU,
radio, warning light system
X1/8 Plug connection for central print supply,
potential 30, start switch
X1/11 Plug connection for central print, potential 30

Edition 01-2006
4010A-7
 6KHHW 4010A-8

Sva 6-93360 EN
SS06A002

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A# Power supply and starter A3 EEM3 control unit X1/5 Plug connection for potential 30, ADIC, ICU,

Sva 6-93360 EN
A12 Central print radio, warning light system
B Heating flange
A14 Engine print X1/8 Plug connection for central print supply,
C Fuel delivery pump potential 30, start switch
E10/1 Heating flange
D Bosch and Magneton generator F1 Fuse, start switch supply X1/11 Plug connection for central print, potential 30
E Supply for potential 15 F200 Main fuse X1/30/1 Screw connection for engine print, potential 30
F208 Fuse, fuel delivery pump X1/30/2 Screw connection for engine print, potential 30
F212 Fuse, ADIC, ICU, radio memory, potential 30 X1/31/1 Screw connection for engine print, potential 31
# Variants on sheet 1, 3 X1/50 Screw connection for engine print, potential 50
F213 Fuse, main electrical battery switch,
potential 30 X2/17 Plug connection for generator D+
F217 Fuse, power supply, warning light system, X2/19 Plug connection for heating flange relay
potential 30 X2/BATT Plug connection for engine print - main
G1 Battery electrical battery switch
G2/2 Generator, Bosch, 120A X5/1 Screw-plug connection, potential 31, central
G2/2/2 Generator, 2 Magneton, 95A print
K5/7/1 Relay, potential 15/1 supply X10/3 Plug connection for engine print - instruments
K5/7/2 Relay, potential 15/2 supply wiring harness
K5/42 Relay D+ 2nd generator X10/18 Plug connection for instruments wiring harness
*URXQGSRLQWV - engine wiring harness [INSTR]
K5/LP Relay, fuel delivery pump
K8/2 Heating flange relay 300A X12/1 Plug connection for engine wiring harness -
1 Battery
engine print
11 Engine cable carrier, rear K8/50 Relay, starter
L20/1 Indicator light, 2nd generator X18/1 Plug connection for instruments wiring harness
12 Engine cable carrier, front
- central print [1]
16 Starter L20/2 Indicator light, 2nd generator
X24/1 Plug connection for instruments wiring harness
M1 Starter
- central print [1]
M13 Fuel delivery pump
X36/1 Plug connection for EEM3 engine control unit -
Q1 Main switch engine sensors wiring harness
S1 Start switch
X89/1 Plug connection for EEM3 engine control unit -
X0/3/16 Weld point for instruments wiring harness, engine wiring harness
CAN L
X0/3/2 Weld point for instruments wiring harness,
potential 15/1
X0/42/1 Weld point for engine wiring harness,
potential 31
X0/42/3 Weld point for engine wiring harness,
potential 30 (radio)

Edition 01-2006
4010A-9
 6KHHW 4010A-10

Sva 6-93360 EN
SS06A003

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A# Power supply for main electrical A3 EEM3 control unit X1/11 Plug connection for central print, potential 30

Sva 6-93360 EN
battery switch A12 Central print X1/30/1 Screw connection for engine print, potential 30
B Starter A14 Engine print X1/30/2 Screw connection for engine print, potential 30
E10/1 Heating flange X1/31/1 Screw connection for engine print, potential 31
C Heating flange, fuel delivery
F1 Fuse, start switch supply X1/50 Screw connection for engine print, potential 50
pump
F200 Main fuse X2/17 Plug connection for generator D+
D Bosch generator F208 Fuse, fuel delivery pump X2/19 Plug connection for heating flange relay
E Supply for potential 15 F212 Fuse, ADIC, ICU, radio memory, potential 30 X2/BATT Plug connection for engine print - main
F213 Fuse, main electrical battery switch, electrical battery switch
potential 30 X5/1 Screw-plug connection, potential 31, central
# Variants on sheet 1, 2
F217 Fuse, power supply, warning light system, print
potential 30 X10/3 Plug connection for engine print - instruments
G1 Battery wiring harness
G2/2 Generator, Bosch, 120A X10/18 Plug connection for instruments wiring harness
K4/BATT Time relay, main electrical battery switch - engine wiring harness [INSTR]
K5/7/1 Relay, potential 15/1 supply X12/1 Plug connection for engine wiring harness -
K5/7/2 Relay, potential 15/2 supply engine print
K5/LP Relay, fuel delivery pump X18/1 Plug connection for instruments wiring harness
*URXQGSRLQWV - central print [1]
K8/2 Heating flange relay 300A
K8/50 Relay, starter X24/1 Plug connection for instruments wiring harness
1 Battery
- central print [1]
11 Engine cable carrier, rear M1 Starter
M13 Fuel delivery pump X89/1 Plug connection for EEM3 engine control unit -
12 Engine cable carrier, front
engine wiring harness
16 Starter Q2 Electrical main battery switch
S1 Start switch
X0/3/16 Weld point for instruments wiring harness,
CAN L
X0/3/2 Weld point for instruments wiring harness,
potential 15/1
X0/42/1 Weld point for engine wiring harness,
potential 31
X0/42/3 Weld point for engine wiring harness,
potential 30 (radio)
X1/5 Plug connection for potential 30, ADIC, ICU,
radio, warning light system
X1/8 Plug connection for central print supply,
potential 30, start switch

Edition 01-2006
4010A-11
 6KHHW 4010A-12

Sva 6-93360 EN
Potential 30
Potential 15

Potential 31

SS06A004

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A D supply+ A3 EEM3 control unit

Sva 6-93360 EN
A7 ID module
B EEM3 box supply
A12 Central print
A14 Engine print
A60 ECCU2
B23 ’Water in fuel’ sensor
CN3a ECCU2 plug connection
F21 Fuse, supply for D+ relay, ECCU2, EDC
F30 Fuse, supply for engine print, potential 15/2
F203 Fuse, supply for EEM3, potential 30
F204 Fuse, central lubrication, potential D+
F207 Fuse, supply for EEM3, potential 15
K5/11 Relay, potential D+ supply
K5/43 Relay, D+ cut-off
K5/IGN Relay, engine, potential 15
W1/4 Plug connection for radio start
X0/7/22 Weld point for cab wiring harness, right D+
*URXQGSRLQWV X0/42/1 Weld point for engine wiring harness,
potential 31
2 EEM3 control unit X0/42/2 Weld point for engine wiring harness,
potential 30 (EEM3)
X1/30/EEM Screw connection Motorprint Potential 30
X1/CL Plug connection, central lubrication
X3/12 Plug connection, ’water in fuel’ sensor
X4/4 Plug connection, ID module
X10/3 Plug connection for engine print - instruments
wiring harness
X12/1 Plug connection for engine wiring harness -
engine print
X18/1 Plug connection for instruments wiring harness
- central print [1]
X24/3 Plug connection for instruments wiring harness
- cab wiring harness on right [3]
X89/1 Plug connection for EEM3 engine control unit -
engine wiring harness

Edition 01-2006
4010A-13
 6KHHW 4010A-14

Sva 6-93360 EN
Signal

Supply
Signal
Signal
Ground
Ground

Ground

Ground
Signal

Ground
Ground
Signal
5V
5V
Signal
Signal

5V
Ground

Ground
SS06A005

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU
A red
B beige
C white
D yellow
E grey
F green
G violet

7\SHRIXVH
Potential 30 (continuous current) H orange VDC stabilised by electric box
-- control line (at ground end) K light blue D+
+ control line (at positive end) L brown Ground above a box
Potential 15 Si (safety) M Ground strip
Potential 58 (lighting) N pink Electric signals
Signal line P colourless Reserve
Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A EEM3 box with sensors and A3 EEM3 control unit

Sva 6-93360 EN
injectors B20 Engine speed sensor
B22 Engine temperature sensor
B29 Sensor for charger pressure/charged air
temperature
B36 Fuel temperature sensor
B37 Oil pressure sensor
B38 Rail pressure sensor
B39 Fuel delivery pressure sensor
B40 Camshaft position sensor
X2/21 Plug connection, solenoid valve, high-
pressure pump
X2/22 Plug connection, temperature sensor
EEM3 [22]
X2/28 Plug connection, engine speed sensor
X2/36 Screw connection, fuel temperature sensor
X3/37 Plug connection, oil pressure sensor
*URXQGSRLQWV X3/38 Plug connection, rail pressure sensor
X3/39 Plug connection, fuel delivery pressure
sensor
X3/40 Plug connection, camshaft position sensor
X4/29 Plug connection, charge-air pressure/charge-
air temperature sensor
X16/1 Plug connection, EEM3 engine control unit -
engine injection nozzles wiring harness
X36/1 Plug connection for EEM3 engine control unit
- engine sensors wiring harness
Y20 Solenoid valve, high-pressure pump
Y21 Screw connection, injector, 1st cylinder
Y22 Screw connection, injector, 2nd cylinder
Y23 Screw connection, injector, 3rd cylinder
Y24 Screw connection, injector, 4th cylinder
Y25 Screw connection, injector, 5th cylinder
Y26 Screw connection, injector, 6th cylinder

Edition 01-2006
4010A-15
 6KHHW 4010A-16

Sva 6-93360 EN
signal
switch

Steering

Brake light
Brake light

brake switch

GSV2
SS06A006

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A# Brake light A4 FMGR X24/2 Plug connection for cab wiring harness, right -

Sva 6-93360 EN
A4/2 FMGR plug connection - dark grey [2] central print
B Reserve central print
A12 Central print X24/3 Plug connection for instruments wiring harness
C Reverse fan - cab wiring harness on right [3]
A14 Engine print
A60 ECCU2
# Variant on sheet 7 A62 Reverse fan
CN3a ECCU2 plug connection
CN3b ECCU2 plug connection
F8 Fuse, reserve, potential 30
F15 Fuse, reserve, potential 15/2
F46 Fuse, relay for brake light, Optistop,
potential 15/1
F211 Fuse, supply for reverse fan, potential 30
K5/12 Relay, brake light, Optistop
K5/FAN Relay, reverse fan
S2/74 Reverse fan pushbutton
S5 Brake light switch
*URXQGSRLQWV S25 Steering brake switch
X0/3/1 Weld point for instruments wiring harness,
potential 58L
X0/3/15 Weld point for instruments wiring harness,
CAN H
X0/3/18 Weld point for instruments wiring harness,
potential GND CAN BUS
X0/3/2 Weld point for instruments wiring harness,
potential 15/1
X3/5 Plug connection, reserve
X4/14 Plug connection for brake light, Optistop
X4/66 Plug connection for reverse fan [LU]
X4/64 Plug connection for reverse fan
X6/2 Plug connection for engine print, supply
EDC [2]
X10/8 Plug connection for wiring harness, cab, left -
central print [8]
X18/1 Plug connection for instruments wiring harness
- central print [1]

Edition 01-2006
4010A-17
 6KHHW 4010A-18

Sva 6-93360 EN
signal
switch

Steering

Brake light
Brake light

brake switch

GSV2
SS06A6A007

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A# Brake light for reverse travel A4 FMGR X6/2 Plug connection for engine print, supply

Sva 6-93360 EN
equipment A4/2 FMGR plug connection - dark grey [2] EDC [2]
A12 Central print X10/8 Plug connection for wiring harness, cab, left -
B Reserve central print
A14 Engine print central print [8]
C Reverse fan X18/1 Plug connection for instruments wiring harness
A60 ECCU2
A62 Reverse fan - central print [1]
# Variant on sheet 6 CN3a ECCU2 plug connection X24/2 Plug connection for cab wiring harness, right -
CN3b ECCU2 plug connection central print
F8 Fuse, reserve, potential 30 X24/3 Plug connection for instruments wiring harness
- cab wiring harness on right [3]
F15 Fuse, reserve, potential 15/2
F46 Fuse, relay for brake light, Optistop,
potential 15/1
F211 Fuse, supply for reverse fan, potential 30
K5/12 Relay, brake light, Optistop
K5/FAN Relay, reverse fan
S2/74 Reverse fan pushbutton
S5 Brake light switch
*URXQGSRLQWV S5/1 Switch for brake light, reverse travel equipment
[BREMSL]
S25 Steering brake switch
X0/3/1 Weld point for instruments wiring harness,
potential 58L
X0/3/15 Weld point for instruments wiring harness,
CAN H
X0/3/16 Weld point for instruments wiring harness,
CAN L
X0/3/18 Weld point for instruments wiring harness,
potential GND CAN BUS
X0/27/9 Weld point for reverse travel equipment wiring
harness, GSV2
X0/27/12 Weld point for reverse travel equipment wiring
harness, brake
X3/5 Plug connection, reserve
X4/14 Plug connection for brake light, Optistop
X4/64 Plug connection for reverse fan
X4/66 Plug connection for reverse fan [LU]

Edition 01-2006
4010A-19
 6KHHW 4010A-20

Sva 6-93360 EN
SS06A008

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Italy brake A12 Central print

Sva 6-93360 EN
A14 Engine print
B Heating
F10 Fuse, supply, ECCU2, potential 30
F17 Fuse, heating blower, potential 15/2
F48 Fuse, supply for seat, ’Italy’ trailer brake,
potential 15/1
K5/37 Relay for trailer brake, Italy
K6/HEAT Relay for heating blower
M3 Heating blower motor
S7 Switch for handbrake
S50 Pushbutton for trailer brake valve
S50/1 Blower switch 1-2-3
X0/7/17 Weld point for wiring harness, cab, right,
handbrake
X0/15/1 Weld point for additional line, hydraulic trailer
brake, potential 31
X0/15/2 Weld point for additional line, hydraulic trailer
brake, potential 15/1
*URXQGSRLQWV
X1/26 Plug connection, potential 15/2, 15 A heating
blower
X1/HZG Plug connection, heating GND
X4/25 Plug connection for handbrake switch [25]
X4/50 Plug connection for heating
X4/51 Plug connection for ’Italy’ trailer brake, central
print [ITALB]
X4/52 Plug connection for additional line, Italy trailer
brake [MGV]
X24/2 Plug connection for cab wiring harness, right -
central print
Y50 Solenoid valve, trailer brake

Edition 01-2006
4010A-21
 6KHHW 4010A-22

Sva 6-93360 EN
SS06A009

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Warning light system with ISO- A12 Central print X0/3/4 Weld point for instruments wiring harness, turn

Sva 6-93360 EN
BUS
B SBB light, left
C SBB light, right
D BB light, left
E BB light, right
# Variant on sheet 10
*URXQGSRLQWV
8 Roof, front right
11 Engine cable carrier, rear
A13 Roof print signal, right
E3 Front left side marker light X0/3/5 Weld point for instruments wiring harness,
E4 Rear left side marker light potential 31
X0/3/17 Weld point for instruments wiring harness,
E6 Front right side marker light
E7 Rear right side marker light potential 15 CAN BUS
E12 Brake light, left X0/6/1 Weld point for wiring harness, cab, left,
E13 Brake light, right potential 31
E14 Turn signal, front right X0/7/5 Weld point for wiring harness, cab, right,
potential 31
E15 Turn signal, rear right
X0/7/18 Weld point for wiring harness, cab, right 58R
E16 Turn signal, rear left
E17 Turn signal, front left X0/28/3 Weld point for roof wiring harness, potential 58
X0/28/12 Weld point for roof wiring harness, potential 31
F5 Fuse, supply for turn signal, potential 15/1
X0/28/13 Weld point for roof wiring harness, potential 31
F24 Fuse, parking light, rear left, ADIC, switch
lighting for instrument panel, trailer socket, front X2/87 Plug connection for cab wiring harness on right
and rear, ISO-BUS - instruments wiring harness ISO-BUS
F25 Fuse, parking light, rear right, ARU, switch X6/12L Plug connection for turn signal / side marker
lighting for control panel, mobile phone socket light, front left [BB-L]
F33 Fuse, supply for hazard warning light, X6/12R Plug connection for turn signal / side marker
potential 30 light, front right [BB-R]
X10/8 Plug connection for wiring harness, cab, left -
F60 Fuse, side marker light, front left, licence plate
lights, roof central print [8]
F61 Fuse, side marker light front right, ICU switch X10/11 Plug connection for roof print supply
lighting for roof, spot light, radio and ASW panel X10/12 Plug connection for roof wiring harness
lighting, activation of all work lamps X14/8 Plug connection for instruments wiring harness
K2 Indicator relay - steering column [8]
K5/10 Relay, light, potential 58 X14/14 Plug connection for roof supply [14]
S2/5 Hazard warning switch [WARN] X14/15 Plug connection for central print - wiring
S4/2 Turn signal switch, steering column harness for roof supply [15]
X0/3/1 Weld point for instruments wiring harness, X18/1 Plug connection for instruments wiring harness
potential 58L - central print [1]
X0/3/2 Weld point for instruments wiring harness, X24/1 Plug connection for instruments wiring harness
potential 15/1 - central print [1]
X0/3/3 Weld point for instruments wiring harness, X24/2 Plug connection for cab wiring harness, right -
potential 15/2 central print

Edition 01-2006
4010A-23
 6KHHW 4010A-24

Sva 6-93360 EN
SS06A010

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Warning light system A12 Central print X0/3/3 Weld point for instruments wiring harness,

Sva 6-93360 EN
A13 Roof print potential 15/2
B Additional marker light, rear left
E3 Front left side marker light X0/3/4 Weld point for instruments wiring harness, turn
C SBB light, left E3/1 Additional front left side marker light signal, right
D SBB light, right E4 Rear left side marker light X0/3/5 Weld point for instruments wiring harness,
E6 Front right side marker light potential 31
E Additional marker light, rear right X0/3/17 Weld point for instruments wiring harness,
E6/1 Additional front right side marker light
F Additional marker light, front left E7 Rear right side marker light potential 15 CAN BUS
E12 Brake light, left X0/6/1 Weld point for wiring harness, cab, left,
G BB light, left and right
potential 31
E12/1 Additional rear left side marker light
H Additional marker light, front X0/7/5 Weld point for wiring harness, cab, right,
E13 Brake light, right
right potential 31
E13/1 Additional rear right side marker light
# Variant on sheet 9 X0/7/18 Weld point for wiring harness, cab, right 58R
E14 Turn signal, front right
X0/28/3 Weld point for roof wiring harness, potential 58
E15 Turn signal, rear right
X0/28/12 Weld point for roof wiring harness, potential 31
E16 Turn signal, rear left
X0/28/13 Weld point for roof wiring harness, potential 31
E17 Turn signal, front left
X6/12L Plug connection for turn signal / side marker
F5 Fuse, supply for turn signal, potential 15/1
light, front left [BB-L]
F24 Fuse, parking light, rear left, ADIC, switch
X6/12R Plug connection for turn signal / side marker
lighting for instrument panel, trailer socket, front
*URXQGSRLQWV light, front right [BB-R]
and rear, ISO-BUS
X10/8 Plug connection for wiring harness, cab, left -
F25 Fuse, parking light, rear right, ARU, switch
11 Engine cable carrier, rear central print [8]
lighting for control panel, mobile phone socket
X10/11 Plug connection for roof print supply
F33 Fuse, supply for hazard warning light,
X10/12 Plug connection for roof wiring harness
potential 30
X14/8 Plug connection for instruments wiring harness
F60 Fuse, side marker light, front left, licence plate
lights, roof - steering column [8]
X14/14 Plug connection for roof supply [14]
F61 Fuse, side marker light front right, ICU switch
lighting for roof, spot light, radio and ASW panel X14/15 Plug connection for central print - wiring
lighting, activation of all work lamps harness for roof supply [15]
K2 Indicator relay X18/1 Plug connection for instruments wiring harness
- central print [1]
K5/10 Relay, light, potential 58
X24/1 Plug connection for instruments wiring harness
S2/5 Hazard warning switch [WARN]
- central print [1]
S4/2 Turn signal switch, steering column
X24/2 Plug connection for cab wiring harness, right -
X0/3/1 Weld point for instruments wiring harness,
central print
potential 58L
X0/3/2 Weld point for instruments wiring harness,
potential 15/1

Edition 01-2006
4010A-25
 6KHHW 4010A-26

Sva 6-93360 EN
SS06A011

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Auxiliary headlight and 4 work A12 Central print X0/6/1 Weld point for wiring harness, cab, left,

Sva 6-93360 EN
lamps A13 Roof print potential 31
A64 Work lamp panel X0/7/5 Weld point for wiring harness, cab, right,
B Headlight
E1 Headlight, left potential 31
C Low beam, high beam E2 Headlight, right X2/2 Plug connection for high beam headlight,
D Work lamp, fender E8 Work lamp, fender, left engine bonnet
E9 Work lamp, fender, right X2/3 Plug connection for low beam headlight, engine
E21 Auxiliary headlight, left bonnet
E22 Auxiliary headlight, right X4/40 [X4/ESW] Plug connection for roof print,
auxiliary headlight
E33 Work lamp, roof, front left centre [M]
X5/7 Socket for auxiliary headlight and work lamp,
E34 Work lamp, roof, front right centre [M]
front left
E37 Work lamp, roof, at front, outside left [A]
X5/8 Socket for auxiliary headlight and work lamp,
E38 Work lamp, roof, at front, outside right [A]
front right
F7 Fuse, relay 56a, potential 30
X6/6 Plug connection for instruments wiring harness
F11 Fuse, relay, work lamp, fender, potential 30
X10/8 Plug connection for wiring harness, cab, left -
F12 Fuse, light switch, potential 30 central print [8]
F34 Fuse, headlight, roof, right 56b X10/11 Plug connection for roof print supply
F35 Fuse, headlight, roof, left 56b X14/8 Plug connection for instruments wiring harness
*URXQGSRLQWV F36 Fuse, headlight, engine hood, right 56b - steering column [8]
F37 Fuse, headlight, engine hood, left 56b X14/14 Plug connection for roof supply [14]
7 Roof, front left F40 Fuse, supply for steering column switch, X14/15 Plug connection for central print - wiring
8 Roof, front right potential 15/1 harness for roof supply [15]
11 Engine cable carrier, rear K5/5 Switchover relay for high beam X16/5 Screw connection for roof print ground point
K5/6 Switchover relay for low beam X18/1 Plug connection for instruments wiring harness
K5/9 Relay, work lamp, fender - central print [1]
K5/56a Relay for high beam X24/1 Plug connection for instruments wiring harness
K5/56b Relay for low beam - central print [1]
S2/1 Light switch [LICHT] X24/2 Plug connection for cab wiring harness, right -
S2/17 Switch for auxiliary headlight central print
S4/1 High/low beam steering column switch X24/6 Plug connection for work lamp panel
V3/9 Diode
X0/3/1 Weld point for instruments wiring harness,
potential 58L
X0/3/2 Weld point for instruments wiring harness,
potential 15/1
X0/5/1 Weld point for engine hood wiring harness,
potential 31

Edition 01-2006
4010A-27
 6KHHW 4010A-28

Sva 6-93360 EN
SS06A013

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Work lamp at rear outside A13 Roof print X4/21 Plug connection for work lamp, at rear, outside

Sva 6-93360 EN
A60 ECCU2 right
B Work lamp at rear inside
A64 Work lamp panel X4/22 Plug connection for work lamp, at rear, inside
C# Work lamp, at front, 6 right
CN3a ECCU2 plug connection
D Work lamp, BB light E23/1 Work lamp, roof, at rear, inside left X4/23 Plug connection for work lamp, at rear, outside
E23/2 Work lamp, roof, at rear, outside left left
E24/1 Work lamp, roof, at rear, inside right X4/24 Plug connection for work lamp, at rear, inside
# Variant on sheet 16
E24/2 Work lamp, roof, at rear, outside right left
E33 Work lamp, roof, at front, centre left [M] X4/38 [X4/ASW] Plug connection for roof print, work
lamp at front
E34 Work lamp, roof, at front, centre right [M]
E35 Work lamp, front left, on turn signal/ X5/7 Socket for auxiliary headlight and work lamp,
side marker light front left
X5/8 Socket for auxiliary headlight and work lamp,
E36 Work lamp, front right, on turn signal/side
front right
marker light
X6/12L Plug connection for turn signal / side marker
E37 Work lamp, roof, at front, outside left [A]
light, front left [BB-L]
E38 Work lamp, roof, at front, outside right [A]
X6/12R Plug connection for turn signal / side marker
E44 Work lamp, roof, at front, inside left [I]
light, front right [BB-R]
E45 Work lamp, roof, at front, inside right [I]
*URXQGSRLQWV X10/4 Plug connection for EDC print armrest (GSV)
F67 Fuse, 4 work lamps, at front, outside
X10/12 Plug connection for roof wiring harness
7 Roof, front left F68 Fuse, 4 rear work lamps, ASW panel supply for
X10/13 Plug connection for roof wiring harness
8 Roof, front right potential 30
X14/14 Plug connection for roof supply [14]
F70 Fuse, 2 rear work lamps
X16/4 Screw connection for potential 30, supply for
F101 Fuse, ASW panel supply for 4 work lamps, at
roof print
front, work lamps on BB light
X24/3 Plug connection for instruments wiring harness
F102 Fuse, 4+2 front work lamps
- cab wiring harness on right [3]
K5/30 Relay, 4 work lamps, at rear (outside)
X24/6 Plug connection for work lamp panel
K5/31 Relay, 4 work lamps, at front (outside)
K5/33 Relay, 4+2 work lamps, at front
S2/63/2 Switch, 4+2 work lamps, at front
X0/28/2 Weld point for roof wiring harness, work lamp 2
X0/28/6 Weld point for roof wiring harness, work lamp 2
X0/28/12 Weld point for roof wiring harness, potential 31
X0/28/13 Weld point for roof wiring harness, potential 31
X0/28/14 Weld point for roof wiring harness, potential 31
X0/28/15 Weld point for roof wiring harness, potential 31

Edition 01-2006
4010A-29
 6KHHW 4010A-30

Sva 6-93360 EN
SS06A016

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Work lamp, rear, XENON A13 Roof print

Sva 6-93360 EN
A18 Electronics, xenon work lamp, right
A19 Electronics, xenon work lamp, left
# Variant on sheet 13
A64 Work lamp panel
E27 Work lamp, roof, at rear, XENON, left
E29 Work lamp, roof, at rear, XENON, right
F68 Fuse, 4 rear work lamps, ASW panel supply for
potential 30
F70 Fuse, 2 rear work lamps
K5/30 Relay, 4 work lamps, at rear (outside)
X0/28/2 Weld point for roof wiring harness, work lamp 2
X0/28/14 Weld point for roof wiring harness, potential 31
X0/28/15 Weld point for roof wiring harness, potential 31
X2/26 Plug connection for electronics, xenon input,
right
X2/27 Plug connection for electronics, xenon input,
left
X4/10 Plug connection for electronics, xenon output,
*URXQGSRLQWV
right
X4/11 Plug connection for electronics, xenon output,
left
X4/21 Plug connection for work lamp, at rear, outside
right
X4/22 Plug connection for work lamp, at rear, inside
right
X4/23 Plug connection for work lamp, at rear, outside
left
X4/24 Plug connection for work lamp, at rear, inside
left
X10/12 Plug connection for roof wiring harness
X10/13 Plug connection for roof wiring harness
X16/4 Screw connection for potential 30, supply for
roof print
X24/6 Plug connection for work lamp panel

Edition 01-2006
4010A-31
 6KHHW 4010A-32

Sva 6-93360 EN
SS06A017

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV
A Work lamp, engine hood
Sva 6-93360 EN
B Reserve for engine print
C Licence plate lights, roof
D Door contact switch
E Doorway lights
F Interior light
*URXQGSRLQWV
Edition 01-2006
(OHFWULFDOHTXLSPHQW
A13 Roof print X2/WKL Plug connection for work lamp, engine bonnet,
A14 Engine print reserve
A64 Work lamp panel X3/28 Plug connection for work lamp, engine hood
and horn
E5/3 Licence plate lights, roof, left
E5/4 Licence plate lights, roof, right X4/65L Plug connection for licence plate lights, roof, left
E19 Interior light X4/67 Plug connection for work lamp, front left
E30 Doorway lights, left X6/1 Plug connection for Linde electronics
E61 Work lamp, left X6/12L Plug connection for turn signal / side marker
E62 Work lamp, right light, front left [BB-L]
F201 Fuse for work lamp, engine bonnet X10/3 Plug connection for engine print - instruments
F202 Fuse for work lamp, engine bonnet, reserve wiring harness
F206 Fuse, reserve (potential 15) X10/11 Plug connection for roof print supply
F209 Fuse, reserve (potential 30) X10/13 Plug connection for roof wiring harness
F214 Fuse for fuel filter, heating, potential 15 X10/14 Plug connection for wiring harness for roof
F215 Fuse for ABS supply supply
F218 Fuse for ABS supply, potential 30 X12/1 Plug connection for engine wiring harness -
K4/2/2 Time relay for interior light engine print
K6/WKL Relay for work lamp, engine bonnet X14/14 Plug connection for roof supply [14]
X24/6 Plug connection for work lamp panel
S24/1 Switch for left door contact
S24/2 Switch for right door contact
X0/5/1 Weld point for engine hood wiring harness,
potential 31
X0/28/4 Weld point for roof wiring harness, potential 30
X0/28/5 Weld point for roof wiring harness, supply for
time relay
X0/28/9 Weld point for roof wiring harness, potential 31
X0/28/11 Weld point for roof wiring harness, potential 58
X0/28/12 Weld point for roof wiring harness, potential 31
X0/28/13 Weld point for roof wiring harness, potential 31
X0/28/14 Weld point for roof wiring harness, potential 31
X0/28/15 Weld point for roof wiring harness, potential 31
X1/15/ABS Plug connection for ABS, potential 15
X1/15/FUELPlug connection for filter heating, potential 15
X1/30/ABS Screw connection for ABS, potential 30
4010A-33
 6KHHW 4010A-34

Sva 6-93360 EN
SS06A018

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Mirror heating A5/1 All-round light, left X9/1 Plug connection for switch for mirror adjustment

Sva 6-93360 EN
A5/2 All-round light, right X10/12 Plug connection for roof wiring harness
B Electrical mirror adjustment
A13 Roof print X19/1 Plug connection for all-round light, left
C Spot light A40 Control unit - mirror adjustment X19/2 Plug connection for all-round light, right
D All-round lights (can be plugged A41 Electric mirror heating and adjustment X24/6 Plug connection for work lamp panel
in) A42 Electric mirror heating and adjustment
A64 Work lamp panel
E18/1 Heated mirror, left
# Variants on sheet 19, 20 E18/2 Heated mirror, right
E20 Spot light
F69 Fuse, all-round light, ASW panel supply for
potential 30
F71 Fuse, heated mirror
F72 Fuse, supply for radio, interior light, ASW panel
supply for potential 30
F100 Fuse, electrically adjustable mirror
S2/19 Switch for heated mirror [HEIZSP]
X0/13/1 Weld point for additional line, mirror heating
*URXQGSRLQWV supply
X0/13/2 Weld point for additional line, mirror heating
supply
X0/28/3 Weld point for roof wiring harness, potential 58
X0/28/4 Weld point for roof wiring harness, potential 30
X0/28/8 Weld point for roof wiring harness, all-round
lights
X0/28/12 Weld point for roof wiring harness, potential 31
X0/28/13 Weld point for roof wiring harness, potential 31
X0/28/14 Weld point for roof wiring harness, potential 31
X0/28/15 Weld point for roof wiring harness, potential 31
X3/80 Plug connection for mirror adjustment, roof print
[X3/13]
X4/15 Plug connection for heated mirror, roof print [15]
X4/39 Plug connection for switch for heated mirror,
roof print [39]
X6/23 Plug connection for rear wiper motor
X6/24 Plug connection for electric mirror, right
[SPIEGEL]

Edition 01-2006
4010A-35
 6KHHW 4010A-36

Sva 6-93360 EN
SS06A019

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Mirror heating A5/1 All-round light, left X6/23 Plug connection for rear wiper motor

Sva 6-93360 EN
A5/2 All-round light, right X6/24 Plug connection for electric mirror, right
B Electrical mirror adjustment
A13 Roof print [SPIEGEL]
C Spot light X9/1 Plug connection for switch for mirror adjustment
A40 Control unit - mirror adjustment
D All-round light carrier A41 Electric mirror heating and adjustment X10/12 Plug connection for roof wiring harness
A42 Electric mirror heating and adjustment X19/1 Plug connection for all-round light, left
# Variants on sheet 18, 20 A64 Work lamp panel X19/2 Plug connection for all-round light, right
E18/1 Heated mirror, left X24/6 Plug connection for work lamp panel
E18/2 Heated mirror, right
E20 Spot light
F69 Fuse, all-round light, ASW panel supply for
potential 30
F71 Fuse, heated mirror
F72 Fuse, supply for radio, interior light, ASW panel
supply for potential 30
F100 Fuse, electrically adjustable mirror
S2/19 Switch for heated mirror [HEIZSP]
*URXQGSRLQWV X0/13/1 Weld point for additional line, mirror heating
supply
X0/13/2 Weld point for additional line, mirror heating
supply
X0/28/3 Weld point for roof wiring harness, potential 58
X0/28/4 Weld point for roof wiring harness, potential 30
X0/28/8 Weld point for roof wiring harness, all-round
lights
X0/28/12 Weld point for roof wiring harness, potential 31
X0/28/13 Weld point for roof wiring harness, potential 31
X0/28/14 Weld point for roof wiring harness, potential 31
X0/28/15 Weld point for roof wiring harness, potential 31
X3/80 Plug connection for mirror adjustment, roof print
[X3/13]
X4/15 Plug connection for heated mirror, roof print [15]
X4/39 Plug connection for switch for heated mirror,
roof print [39]

Edition 01-2006
4010A-37
 6KHHW 4010A-38

Sva 6-93360 EN
SS06A020

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Mirror heating A5/1 All-round light, left X4/39 Plug connection for switch for heated mirror,

Sva 6-93360 EN
A5/2 All-round light, right roof print [39]
B Electrical mirror adjustment
A13 Roof print X6/23 Plug connection for rear wiper motor
C Spot light X6/24 Plug connection for electric mirror, right
A40 Control unit - mirror adjustment
D All-round lights (magnetic) A41 Electric mirror heating and adjustment [SPIEGEL]
A42 Electric mirror heating and adjustment X9/1 Plug connection for switch for mirror adjustment
A64 Work lamp panel X10/12 Plug connection for roof wiring harness
# Variants on sheet 18, 19
E18/1 Heated mirror, left X24/6 Plug connection for work lamp panel
E18/2 Heated mirror, right
E20 Spot light
F69 Fuse, all-round light, ASW panel supply for
potential 30
F71 Fuse, heated mirror
F72 Fuse, supply for radio, interior light, ASW panel
supply for potential 30
F100 Fuse, electrically adjustable mirror
S2/19 Switch for heated mirror [HEIZSP]
*URXQGSRLQWV X0/13/1 Weld point for additional line, mirror heating
supply
X0/13/2 Weld point for additional line, mirror heating
supply
X0/28/3 Weld point for roof wiring harness, potential 58
X0/28/4 Weld point for roof wiring harness, potential 30
X0/28/8 Weld point for roof wiring harness, all-round
lights
X0/28/12 Weld point for roof wiring harness, potential 31
X0/28/13 Weld point for roof wiring harness, potential 31
X0/28/14 Weld point for roof wiring harness, potential 31
X0/28/15 Weld point for roof wiring harness, potential 31
X3/80 Plug connection for mirror adjustment, roof print
[X3/13]
X4/15 Plug connection for heated mirror, roof print [15]
X4/33 Socket for all-round light, left, magnetic
X4/34 Socket for all-round light, right, magnetic

Edition 01-2006
4010A-39
 6KHHW 4010A-40

Sva 6-93360 EN
SS06A021

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Radio preparation A6 Radio X4/41 Plug connection for front heated windscreen

Sva 6-93360 EN
A6/A Plug connection for radio switch
B Supply, roof
A6/B Plug connection for loudspeaker X4/42 Plug connection for rear heated windscreen
C Heated windscreen, front switch
A12 Central print
D Heated windscreen, rear A13 Roof print X10/3 Plug connection for engine print - instruments
A14 Engine print wiring harness
B14 Loudspeaker, left X10/11 Plug connection for roof print supply
B15 Loudspeaker, right X10/14 Plug connection for wiring harness for roof
E25 Heated windscreen, front supply
E26 Heated screen, rear X14/14 Plug connection for roof supply [14]
F45 Fuse, supply for roof, ICU potential 15/1 X14/15 Plug connection for central print - wiring
harness for roof supply [15]
F76 Fuse, heated windscreen, rear
X16/5 Screw connection for roof print ground point
F77 Fuse, heated windscreen, front
F212 Fuse, ADIC, ICU, radio memory, potential 30 X18/1 Plug connection for instruments wiring harness
- central print [1]
K5/29 Relay for supply, potential 15/1
K6/7 Relay for rear heated windscreen
K6/8 Relay for front heated windscreen
*URXQGSRLQWV S2/16/1 Switch for rear heated windscreen [HZS HI]
S2/16/2 Switch for front heated windscreen [HZS VO]
7 Roof, front left W6 Antenna
11 Engine cable carrier, rear X0/3/14 Weld point for instruments wiring harness,
potential GND CAN BUS
X0/28/1 Weld point for roof wiring harness, potential 30,
memory
X0/28/3 Weld point for roof wiring harness, potential 58
X0/28/4 Weld point for roof wiring harness, potential 30
X0/28/13 Weld point for roof wiring harness, potential 31
X0/39/1 Welded point for additional line, rear heated
windscreen
X1/24 Screw connection, potential 30, roof print,
heated windscreens
X2/90 Plug connection for roof print, front heated
windscreen [90]
X2/91 Plug connection for roof print, rear heated
windscreen [91]

Edition 01-2006
4010A-41
 6KHHW 4010A-42

Sva 6-93360 EN
SS06A022

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A# Air conditioning A13 Roof print X12/1 Plug connection for engine wiring harness -

Sva 6-93360 EN
A14 Engine print engine print
A20 Air conditioning - control Y13 Magnetic coupling, air conditioning compressor
# Variant on sheet 23
A22 Blower - control
F65 Fuse, air conditioning control
F66 Fuse, blower / air conditioning
F74 Fuse, reserve, potential 30
F103 Fuse, air conditioning, pressure switch
F205 Fuse for air-conditioning compressor
K5/32 Supply, D+ air conditioning
K5/36 Reserve
M12 Engine blower, air conditioning
R9/1 Temperature sensor for air conditioning system
R10 Potentiometer for air conditioning - temperature
R11 Potentiometer for air conditioning - roof blower
S30 Pushbutton for air conditioning system
W2 Line for temperature sensor, sheathed
*URXQGSRLQWV X0/42/1 Weld point for engine wiring harness,
potential 31
X2/9 Plug connection for roof print supply for blower
X2/14 Plug connection for air conditioning system
X2/20 Plug connection for blower motor, air
conditioning
X4/16 Plug connection, reserve
X4/44 Plug connection for air conditioning control
supply
X4/73 Plug connection for temperature sensor
X4/74 Plug connection for blower potentiometer
X4/75 Plug connection for air conditioning control
potentiometer
X10/3 Plug connection for engine print - instruments
wiring harness
X10/11 Plug connection for roof print supply
X10/14 Plug connection for wiring harness for roof
supply

Edition 01-2006
4010A-43
 6KHHW 4010A-44

Sva 6-93360 EN
SS06A023

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Air cushion seat A12 Central print

Sva 6-93360 EN
A13 Roof print
B Blower (roof)
F65 Fuse, air conditioning control
F66 Fuse, blower / air conditioning
# Variant on sheet 22 K5/32 Supply, D+ air conditioning
M7 Motor for pneumatic seat
M10 Motor for blower, roof
S50/2 Blower switch 1-2-3 roof
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/7/17 Weld point for wiring harness, cab, right,
handbrake
X2/9 Plug connection for roof print supply for
blower
X4/44 Plug connection for air conditioning control
supply
X4/61 Plug connection for Grammer seat
X24/2 Plug connection for cab wiring harness, right -
*URXQGSRLQWV central print

Edition 01-2006
4010A-45
 6KHHW 4010A-46

Sva 6-93360 EN
SS06A024

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Horn A12 Central print X10/11 Plug connection for roof print supply

Sva 6-93360 EN
A13 Roof print X10/14 Plug connection for wiring harness for roof
B Steering column switch
F26 Fuse for parallel wiper, horn, interval relay, supply
C Parallel wipers, front potential 15/2 X14/8 Plug connection for instruments wiring harness
D Windscreen washing system, F63 Fuse for rear wiper - steering column [8]
front F64 Front wiper on hinged windscreen X14/15 Plug connection for central print - wiring
E Windscreen washing system, H1 Signal horn harness for roof supply [15]
rear K3 Interval relay X18/1 Plug connection for instruments wiring harness
M2/1 Motor for parallel wipers, front - central print [1]
F Angled wiper, front
M2/2 Motor for angled wiper, front X23/1 Plug connection for instruments wiring harness
G Angled wiper, rear - engine wiring harness
M4/2 Wiper motor, rear
M5 Motor for windscreen washing system, rear X24/1 Plug connection for instruments wiring harness
- central print [1]
M6 Motor for windscreen washing system, front
S2/30 Switch for wiper/washing system, rear [Wi.hi]
S4/3 Steering column switch for wiper/washing
system
X0/3/16 Weld point for instruments wiring harness,
CAN L
*URXQGSRLQWV
X0/5/1 Weld point for engine hood wiring harness,
potential 31
X0/6/1 Weld point for wiring harness, cab, left,
potential 31
X0/28/20 Weld point for roof wiring harness, potential 53
X3/28 Plug connection for work lamp, engine hood
and horn
X4/1 Plug connection for wiper motor, hinged
windscreen, front [Wi-VO]
X4/17 Plug connection for roof print, wiper motor,
front [17]
X4/65 Plug connection for roof print, wiper motor,
rear [65]
X5/55 Plug connection, front parallel wiper
X6/10 Plug connection for left cab wiring harness -
instruments wiring harness [10]
X6/23 Plug connection for rear wiper motor

Edition 01-2006
4010A-47
 6KHHW 4010A-48

Sva 6-93360 EN
SS06A025

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Power socket, front A12 Central print X0/7/10 Weld point for wiring harness, cab, right, radar

Sva 6-93360 EN
A14 Engine print sensor
B Socket, front X0/25/2 Weld point for wiring harness, control panel,
A16 EDC print
C Socket, rear (trailer) A55 EDC box right, potential 58
D Power socket 1, rear A60 ECCU2 X0/7/5 Weld point for wiring harness, cab, right,
B16 Radar sensor potential 31
E Power socket 2, rear CN2/E ECCU2 plug connection X1/6/1 Screw connection for 2nd power socket, 40 A
(preparation) CN3b ECCU2 plug connection X1/6/2 Screw connection for 1st power socket, 40 A
F Power socket F2 Fuse for power socket, cab, potential 30 X1/15/1 Plug connection for power socket, front,
F3 Fuse, 1st power socket for potential 30 potential 15
G ASR with radar sensor X1/30/SOC Screw connection for power socket, front,
F4 Fuse, 2nd power socket for potential 30
potential 30
F29 Fuse, supply to front and rear power sockets,
standard signal socket, reverse fan, X1/31/2 Screw connection for engine print,
potential 15/2 potential 31
F31 Fuse, supply for radar sensor, potential 15/2 X1/60 Screw connection for power socket, cab, 30 A
F38 Fuse, trailer socket, potential 58L front and X2/4/1 Plug connection for central print, potential 15/2
rear X2/4/2 Screw-plug connection, potential 15/2
F39 Fuse, trailer socket, potential 58R X3/1 Plug connection for radar sensor
front and rear X3/2 Radar sensor plug connection
F52 Fuse, trailer socket for turn signal, right front X5/1 Screw - plug connection, potential 31, central
*URXQGSRLQWV print
and rear
F53 Fuse, trailer socket for turn signal, left front X6/12 Plug connection for cab wiring harness, left -
11 Engine cable carrier, rear
and rear 7-pin trailer socket, front [7 Pol.Vo]
12 Engine cable carrier, front X10/1 Trailer socket, 7-pin, rear
F55 Fuse, trailer socket for brake light, front and
rear X10/2 Trailer socket, 7-pin, front
F216 Fuse for power socket, front, potential 15 X10/4 Plug connection for EDC print armrest (GSV)
F221 Fuse for power socket, front, potential 30 X10/8 Plug connection for wiring harness, cab, left -
S2/73 Switch for slip control [ASR] central print [8]
X0/6/1 Weld point for wiring harness, cab, left, X10/9 Plug connection for wiring harness, cab, right -
potential 31 control panel
X0/6/2 Weld point for wiring harness, cab, left, X14/1 Power socket 1, rear, 40 A
potential 58L X14/30 Power socket, cab, 30 A
X0/6/3 Weld point for wiring harness, cab, left, X15 Power socket, front
potential L X24/2 Plug connection for cab wiring harness, right -
X0/6/4 Weld point for wiring harness, cab, left, central print
potential 58R X55 Plug connection for EDC box
X0/6/5 Weld point for wiring harness, cab, left,
potential R

Edition 01-2006
4010A-49
 6KHHW 4010A-50

Sva 6-93360 EN
Supply for potential 15
Supply for potential 15

Supply for potential 30

Check for sprung front axle
Supply for potential 31

Check for turn signal, trailer I

Check for turn signal, left
Check for turn signal, right
Check for air filter

Check for turn signal, trailer II

Check for high beam

Check for lighting

Check for hydraulic oil filter

SS06A026

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A ADIC A1 ADIC

Sva 6-93360 EN
A12 Central print
B Filter heating (preparation)
A65 KEY PADS
C Supply for ADIC CN1 Plug connection for ADIC
CN3 Plug connection for ADIC
# Variant on sheet 27 F6 Fuse for ADIC, KEY PADS, potential 15/1
S3 Test switch for air filter
S23 Test switch for charge pressure 1bar
X0/3/1 Weld point for instruments wiring harness,
potential 58L
X0/3/4 Weld point for instruments wiring harness,
turn signal, right
X0/3/5 Weld point for instruments wiring harness,
potential 31
X0/3/11 Weld point for instruments wiring harness,
turn signal, left
X0/3/14 Weld point for instruments wiring harness,
potential GND CAN BUS
X0/3/16 Weld point for instruments wiring harness
*URXQGSRLQWV CAN L
X0/7/17 Weld point for wiring harness, cab, right,
11 Engine cable carrier, rear handbrake
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/42/1 Weld point for engine wiring harness,
potential 31
X4/63 Plug connection for KEY PADS
X6/6 Plug connection for instruments wiring
harness
X10/18 Plug connection for instruments wiring
harness - engine wiring harness [INSTR]
X18/1 Plug connection for instruments wiring
harness - central print [1]
X24/1 Plug connection for instruments wiring
harness - central print [1]
X24/3 Plug connection for instruments wiring
harness - cab wiring harness on right [3]

Edition 01-2006
4010A-51
 6KHHW 4010A-52

Sva 6-93360 EN
Check for sprung front axle

Supply for potential 30

Check for filter heating
Supply for potential 15
Supply for potential 31

Check for turn signal, left

Check for turn signal, trailer I

Check for turn signal, trailer II
Check for turn signal, right
Check for air filter

Check for high beam

Check for lighting

Check for hydraulic oil filter

SS06A027

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A ADIC A1 ADIC

Sva 6-93360 EN
A12 Central print
B Filter heating (preparation)
A65 KEY PADS
C# Supply for ADIC, ISO BUS
CN1 Plug connection ADIC
CN3 ADIC plug connection
# Variant on sheet 26 F6 Fuse for ADIC, KEY PADS, potential 15/1
S3 Test switch for air filter
S23 Test switch for charge pressure 1bar
X0/3/1 Weld point for instruments wiring harness,
potential 58L
X0/3/5 Weld point for instruments wiring harness,
potential 31
X0/3/9 Weld point for instruments wiring harness,
potential 30
X0/3/10 Weld point for instruments wiring harness, turn
signal on right
X0/3/11 Weld point for instruments wiring harness, turn
signal on left
*URXQGSRLQWV X0/7/5 Weld point for wiring harness, cab, right,
potential 31
11 Engine cable carrier, rear
X0/7/17 Weld point for wiring harness, cab, right,
handbrake
X0/42/1 Weld point wiring harness Motor Potential 31
X4/63 Plug connection KEY PAD´S
X6/6 Plug connection for instruments wiring harness
X10/18 Plug connection for instruments wiring harness
- engine wiring harness [INSTR]
X18/1 Plug connection for instruments wiring harness
- central print [1]
X24/1 Plug connection for instruments wiring harness
- central print [1]
X24/3 Plug connection for instruments wiring harness
- cab wiring harness on right [3]

Edition 01-2006
4010A-53
 6KHHW 4010A-54

Sva 6-93360 EN
Ground
RS 232 out

Check for tank content

Check for pneumatic air, trailer
RS 232 in

Check for Italy trailer brake

Check for alternator D+

Check for coolant level
Check for brake fluid level

Transmission speed
signal
Radar screen
PTO shaft speed
50% signal, rear power lift
Ground

Potential 15
SS06A028

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Socket, standard signal A1 ADIC

Sva 6-93360 EN
A12 Central print
B ADIC
B2/1 Fuel tank level transmitter, left
B3 Compressed air transmitter
CN1 Plug connection for ADIC
CN2 Plug connection for ADIC
CN3 Plug connection for ADIC
S13 Control switch for brake fluid
S22 Control switch for coolant level
X0/3/2 Weld point for instruments wiring harness,
potential 15/1
X0/3/10 Weld point for instruments wiring harness, turn
signal on right
X0/3/18 Weld point for instruments wiring harness,
potential GND CAN BUS
X0/42/1 Weld point for engine wiring harness,
potential 31
X6/6 Plug connection for instruments wiring harness
*URXQGSRLQWV
X6/8 Plug connection for standard signal socket
[NORMS]
X6/10 Plug connection for left cab wiring harness -
instruments wiring harness [10]
X6/11 Plug connection for standard signal socket,
instruments wiring harness [NORMS]
X10/18 Plug connection for instruments wiring harness
- engine wiring harness [INSTR]
X24/1 Plug connection for instruments wiring harness
- central print [1]
X24/3 Plug connection for instruments wiring harness
- cab wiring harness on right [3]
X29 Standard signal socket

Edition 01-2006
4010A-55
 6KHHW 4010A-56

Sva 6-93360 EN
SS06A029

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Speed sensors, PTO, front and A12 Central print

Sva 6-93360 EN
rear A60 ECCU2
B Switch for reducing speed B7 Rear PTO speed sensor
B8 Front PTO shaft speed sensor
C Switch for HTS
CN2/E ECCU2 plug connection
CN3a ECCU2 plug connection
CN3b ECCU2 plug connection
F32 Fuse for supply, PTO sensors, potential 15/2
S2/15/6 Switch for HTS [HTS]
S2/15/7 Switch for reducing speed
[DREHZAHLABSENKUNG]
X0/7/5 Weld point for wiring harness, cab, right,
potential 15
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/25/2 Weld point for wiring harness, control panel,
right, potential 58
X0/7/5 Weld point for wiring harness, cab, right,
*URXQGSRLQWV potential 31
X0/27/5 Weld point for reverse travel equipment
wiring harness, setting off
X3/21 Plug connection for speed sensor, PTO, front
[PTO]
X24/2 Plug connection for cab wiring harness, right -
central print
X24/5 Plug connection for wiring harness, cab, right
- control panel

Edition 01-2006
4010A-57
 6KHHW 4010A-58

Sva 6-93360 EN
SS06A030

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Supply, control panel, right A12 Central print

Sva 6-93360 EN
A16 EDC print
B Socket, mobile phone, left
E11 Cigarette lighter, right [E11]
C Cigarette lighter with socket on
E11/1 Mobile phone socket, left
right, 2-pin
F13 Fuse, cigarette lighter, 2-pin socket,
D Reserve, EDC print diagnosis socket, EDC print, potential 30
X0/7/17 Weld point for wiring harness, cab, right,
# Variant on sheet 31 handbrake
X0/7/18 Weld point for wiring harness, cab, right 58R
X0/7/23 Weld point for wiring harness, cab, right,
potential 31
X2/1 Socket, 2-pin 30/31 [2/1]
X2/4/1 Plug connection for central print,
potential 15/2
X2/6 Plug connection for lighting, potentiometer
EDC
X6/13 Plug connection for cigarette lighter and
socket, 2-pin
*URXQGSRLQWV X6/15 Plug connection for mobile phone socket, left
X14/4 Plug connection for EDC print - control panel
X24/2 Plug connection for cab wiring harness, right -
central print

Edition 01-2006
4010A-59
 6KHHW 4010A-60

Sva 6-93360 EN
SS06A031

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Supply, control panel, right A12 Central print

Sva 6-93360 EN
B Socket, mobile phone, left for
reverse travel equipment
D Cigarette lighter with socket on
right, 2-pin
E Reserve, EDC print
# Variant on sheet 30
*URXQGSRLQWV
A16 EDC print
E11 Cigarette lighter, right [E11]
E11/1 Mobile phone socket, left
F13 Fuse, cigarette lighter, 2-pin socket, diagnosis
socket, EDC print, potential 30
X0/7/17 Weld point for wiring harness, cab, right,
handbrake
X0/7/18 Weld point for wiring harness, cab, right 58R
X0/7/23 Weld point for wiring harness, cab, right,
potential 31
X0/27/7 Weld point for reverse travel equipment wiring
harness, potential 31
X0/27/15 Weld point for reverse travel equipment wiring
harness, potential 58
X0/28/8 Weld point for roof wiring harness, all-round
lights
X2/1 Socket, 2-pin 30/31 [2/1]
X2/4/1 Plug connection for central print, potential 15/2
X2/6 Plug connection for lighting, potentiometer EDC
X6/13 Plug connection for cigarette lighter and socket,
2-pin
X6/15 Plug connection for mobile phone socket, left
X14/4 Plug connection for EDC print - control panel
X24/2 Plug connection for cab wiring harness, right -
central print

Edition 01-2006
4010A-61
 6KHHW 4010A-62

Sva 6-93360 EN
SS06A032

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Supply, EDC box A12 Central print

Sva 6-93360 EN
A14 Engine print
B# EDC without raise/lower
A55 EDC box
C Power sensors
B9/1 Rotary angle sensor EDC [LAGES]
D Angle of rotation sensor, power B10/1 Power sensor, left
lift, rear B10/2 Power sensor, right
E Solenoid valves, raising, F49 Fuse for supply, potential 15/1 EDC box
lowering F210 Fuse for supply, EDC, potential 30
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
# Variant on sheet 33
X0/7/11 Weld point for cab wiring harness, right,
EDC GND
X0/7/12 Weld point for wiring harness, cab, right,
EDC 9.5V
X0/7/20 Weld point for wiring harness, cab, right,
LOWER valve
X2/12 Plug connection for raise/lower
X6/2 Plug connection for engine print, supply
*URXQGSRLQWV EDC [2]
X24/2 Plug connection for cab wiring harness, right -
central print
X55 Plug connection for EDC box
Y6 Solenoid valve, EDC, RAISE, grey [HEBEN]
Y7 Solenoid valve, EDC, LOWER, black
[SENKEN]

Edition 01-2006
4010A-63
 6KHHW 4010A-64

Sva 6-93360 EN
SS06A033

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Supply, EDC box A12 Central print

Sva 6-93360 EN
A14 Engine print
B# EDC with raise/lower
A55 EDC box
C Power sensors
B9/1 Rotary angle sensor EDC [LAGES]
D Angle of rotation sensor, power B10/1 Power sensor, left
lift, rear B10/2 Power sensor, right
E Solenoid valves, raising, F49 Fuse for supply, potential 15/1 EDC box
lowering F210 Fuse for supply, EDC, potential 30
S28 Changeover switch for raise/lower
X0/7/5 Weld point for wiring harness, cab, right,
# Variant on sheet 32
potential 31
X0/7/11 Weld point for wiring harness, cab, right,
EDC GND
X0/7/12 Weld point for cab wiring harness, right,
EDC 9.5V
X0/7/20 Weld point for wiring harness, cab, right,
LOWER valve
X2/12 Plug connection for raise/lower
*URXQGSRLQWV
X6/2 Plug connection for engine print, supply
EDC [2]
X24/2 Plug connection for cab wiring harness, right -
central print
X55 Plug connection for EDC box
Y6 Solenoid valve, EDC, RAISE, grey [HEBEN]
Y7 Solenoid valve, EDC, LOWER, black
[SENKEN]

Edition 01-2006
4010A-65
 6KHHW 4010A-66

Sva 6-93360 EN
GSV
EDC stop
Transport

lift RAISE
Transport/

lift LOWER
Controlling/

Potential 31
Potential 58

Front loader
Potential 15/1
Potential 15/1

Rapid retraction

Rapid retraction
Supply for EDC stop

External button, front power

External button, front power

SS06A034

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Switch for hydraulic master A12 Central print X0/25/5 Weld point for wiring harness, control panel,

Sva 6-93360 EN
A16 EDC print right GSV1
B Front power lift, Raise / Lower
A55 EDC box X1/FL Plug connection for front loader solenoid valve
C Armrest X10/4 Plug connection for EDC print armrest (GSV)
A60 ECCU2
CN3a ECCU2 plug connection X10/9 Plug connection for wiring harness, cab, right -
F19 Fuse for ARU supply, EDC potential 15/1 control panel
F20 Fuse for ARU supply, EDC potential 15/1 X18/4 Plug connection for cab wiring harness, right -
R3 2 kOhm resistance armrest
R4 2 kOhm resistance X24/2 Plug connection for cab wiring harness, right -
R5 2 kOhm resistance central print
R6 2 kOhm resistance X24/5 Plug connection for wiring harness, cab, right -
control panel
R7 2 kOhm resistance
X55 Plug connection for EDC box
R8 Potentiometer, accelerator pedal
R9 2 kOhm resistance Y60 Front loader solenoid valve
S2/7/3 Switch for hydraulic master [MASTER]
S18/1 External button for AUX BLUE, pressure in -
[ATS]
*URXQGSRLQWV S18/2 External button for AUX BLUE, pressure in +
[ATH]
X0/7/9 Weld point for wiring harness, cab, right GSV4
X0/7/11 Weld point for wiring harness, cab, right,
EDC GND
X0/7/17 Weld point for wiring harness, cab, right,
handbrake
X0/7/18 Weld point for wiring harness, cab, right 58R
X0/7/26 Weld point for wiring harness, cab, right,
transport/control signal
X0/25/1 Weld point for wiring harness, control panel,
right, potential 58
X0/25/2 Weld point for wiring harness, control panel,
right, potential 58
X0/25/3 Weld point for wiring harness, control panel,
right, potential 31
X0/7/5 Weld point for wiring harness, cab, right,
potential 31

Edition 01-2006
4010A-67
 6KHHW 4010A-68

Sva 6-93360 EN
SS06A035

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Speed signal A4 FMGR

Sva 6-93360 EN
A4/2 FMGR plug connection - dark grey [2]
B Raise / Lower button EDC
A55 EDC box
C External button, EDC
S2/15/5 Raise / Lower button [INNEN]
S14/1 External button for LOWER, left [SENKEN]
S14/2 External button for LOWER, right [LOWER]
S15/1 External button for RAISE, left [RAISE]
S15/2 External button for RAISE, right [RAISE]
X0/7/4 Weld point for wiring harness, cab, right, supply
for external pushbutton on right
X0/7/6 Weld point for wiring harness, cab, right, supply
for external pushbutton on left
X0/7/10 Weld point for wiring harness, cab, right, radar
sensor
X0/7/16 Weld point for wiring harness, cab, right,
EDC 9.5V
X0/7/21 Weld point for wiring harness, cab, right, RAISE
pushbutton
*URXQGSRLQWV X0/7/25 Weld point for wiring harness, cab, right,
LOWER
X0/25/1 Weld point for wiring harness, control panel,
right, potential 58
X0/25/3 Weld point for wiring harness, control panel,
right, potential 31
X24/5 Plug connection for wiring harness, cab, right -
control panel
X55 Plug connection for EDC box

Edition 01-2006
4010A-69

Sva 6-93360 EN
transport
Ground during
/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU
A red
B beige
C white
D yellow
E grey
F green
G violet
Edition 01-2006
6KHHW 4010A-70
SS06A036

7\SHRIXVH
Potential 30 (continuous current) H orange VDC stabilised by electric box
-- control line (at ground end) K light blue D+
+ control line (at positive end) L brown Ground above a box
Potential 15 Si (safety) M Ground strip
Potential 58 (lighting) N pink Electric signals
Signal line P colourless Reserve
Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A EDC signal 50% A16 EDC print X3/18 Plug connection for EDC mixing

Sva 6-93360 EN
A55 EDC box potentiometer
B Indicator lights, EDC
A60 ECCU2 X3/19 Plug connection for slip control potentiometer
C Potentiometer, EDC X4/2 Plug connection for diagnosis LED, slip LED
CN3b ECCU2 plug connection
D1 Diode X4/3 Plug connection for raise LED, lower LED
E41 EDC lighting X5/6 Plug connection for nominal value
E42 EDC lighting potentiometer
E43 EDC lighting X10/4 Plug connection for EDC print armrest (GSV)
H2/1 Diagnosis LED X14/4 Plug connection for EDC print - control panel
H2/2 LED for slip
H2/3 LED for raise
H2/4 LED for lower
R1 2 kOhm resistance
R2 2 kOhm resistance
R6 2 kOhm resistance
R6/1 Setpoint potentiometer
R6/2 Lift limitation potentiometer
*URXQGSRLQWV R6/3 Mixing potentiometer
R6/4 Lowering speed potentiometer
R6/5 Slip control potentiometer
R12 0 kOhm resistance
R13 0 kOhm resistance
R14 6.2 kOhm resistance
R19 2 kOhm resistance
X0/7/20 Weld point for wiring harness, cab, right,
LOWER valve
X0/25/3 Weld point for wiring harness, control panel,
right, potential 31
X2/6 Plug connection for lighting, potentiometer EDC
X3/16 Plug connection for potentiometer, lowering
speed
X3/17 Plug connection for potentiometer, raising
speed

Edition 01-2006
4010A-71
 6KHHW 4010A-72

Sva 6-93360 EN
Signal
Engine back
pressure brake

0.8V to 4.4V
0V to 5.8V
Signal
Handbrake
Signal
Seat switch

5.8 V
3V
Ground
5.8 V

Ground
5.6V
1.1V to 4V
4.4V to 0.8V
Ground

Potential 30
GSV3

Potential 31
Potential 15/1
Signal 80%
Accelerator
pedal signal
SS06A037

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Supply, FMGR A3 EEM3 control unit X24/2 Plug connection for cab wiring harness, right -

Sva 6-93360 EN
A4 FMGR central print
B# Clutch switch 80%
A4/1 FMGR plug connection (white) [1] X24/3 Plug connection for instruments wiring harness
C# Angle of rotation sensor, - cab wiring harness on right [3]
A4/2 FMGR plug connection - dark grey [2]
coupling X24/5 Plug connection for wiring harness, cab, right -
A4/3 FMGR plug connection (blue) [3]
D# Potentiometer, accelerator pedal A4/4 FMGR plug connection (grey) [4] control panel
E# Parking interlock switch A12 Central print X89/1 Plug connection for EEM3 engine control unit -
B17 Angle of rotation sensor, clutch engine wiring harness
F# Limit load potentiometer
F14 Fuse, FMGR, potential 30
G# Switch for engine back pressure
F51 Fuse, supply for potential 15/1 FMGR
brake
R8 Potentiometer, accelerator pedal
H# Switch for handbrake, seat
R23 Limit load potentiometer
switch
S2/61 Parking interlock switch [PARKBREMSE]
S8 Seat switch
# Variants on sheet 38, 39 S20 Engine back pressure brake switch
S21 Switch for handbrake
S46 Clutch switch 80%
*URXQGSRLQWV X0/3/1 Weld point for instruments wiring harness,
potential 58L
X0/3/2 Weld point for instruments wiring harness,
potential 15/1
X0/3/15 Weld point for instruments wiring harness,
CAN H
X0/7/2 Weld point for wiring harness, cab, right,
accelerator pedal
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/7/24 Weld point for wiring harness, cab, right GSV3
X3/23 Plug connection for full-load potentiometer
X4/25 Plug connection for handbrake switch [25]
X4/61 Plug connection for Grammer seat
X4/70 Plug connection for accelerator pedal [70]
X10/18 Plug connection for instruments wiring harness
- engine wiring harness [INSTR]

Edition 01-2006
4010A-73
 6KHHW 4010A-74

Sva 6-93360 EN
5.6V
Ground

1.1V to 4V

Potential 31
Signal 80%
Ground
0.8V to 4.4V

Potential 30
4.4V to 0.8V

Potential 15/1
5.8 V

signal
Accelerator pedal

SS06A038

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A# Supply, FMGR A3 EEM3 control unit X0/27/14 Weld point for reverse travel equipment wiring

Sva 6-93360 EN
A4 FMGR harness, coupling
B# Clutch switch 80% for reverse
A4/1 FMGR plug connection (white) [1] X4/70 Plug connection for accelerator pedal [70]
travel equipment
A4/3 FMGR plug connection (blue) [3] X4/70/1 Plug connection for accelerator pedal
C# Angle of rotation sensor, [FAHRPEDAL]
A4/4 FMGR plug connection (grey) [4]
coupling with reverse travel
A12 Central print X10/18 Plug connection for instruments wiring harness
equipment
B17 Angle of rotation sensor, clutch - engine wiring harness [INSTR]
D# Potentiometer, accelerator pedal B17/1 Angle of rotation sensor, clutch, reverse travel X24/2 Plug connection for cab wiring harness, right -
for reverse travel equipment equipment central print
F14 Fuse, FMGR, potential 30 X24/3 Plug connection for instruments wiring harness
# Variants on sheet 37, 39 F51 Fuse, supply for potential 15/1 FMGR - cab wiring harness on right [3]
K5/60 Relay for clutch [KUPPLUNG] X89/1 Plug connection for EEM3 engine control unit -
engine wiring harness
K5/61 Relay for front accelerator pedal
[FAHRPEDAL1]
K5/62 Relay for rear accelerator pedal
[FAHRPEDAL1]
R8 Potentiometer, accelerator pedal
R8/1 Potentiometer, accelerator pedal, reverse travel
*URXQGSRLQWV
equipment
S46 Clutch switch 80%
S46/1 Clutch switch 80% [KUPPL]
X0/3/15 Weld point for instruments wiring harness,
CAN H
X0/7/2 Weld point for wiring harness, cab, right,
accelerator pedal
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/27/1 Weld point for seat R
X0/27/7 Weld point for reverse travel equipment wiring
harness, potential 31
X0/27/10 Weld point for reverse travel equipment wiring
harness, accelerator pedal 2
X0/27/11 Weld point for reverse travel equipment wiring
harness, accelerator pedal 1
X0/27/13 Weld point for reverse travel equipment wiring
harness, coupling

Edition 01-2006
4010A-75
 6KHHW 4010A-76

Sva 6-93360 EN
Signal
Handbrake
Signal
Seat switch

3V
Ground
0V to 5.8V
5.8 V
Signal
Engine back
pressure brake
GSV3
Signal for reverse
travel equipment
active

SS06A039

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A# Parking interlock switch A4 FMGR X6/23 Plug connection for rear wiper motor

Sva 6-93360 EN
A4/1 FMGR plug connection (white) [1] X6/27 Plug connection for seat switch, ARU console
B# Potentiometer, limit load for
A4/2 FMGR plug connection - dark grey [2] with reverse travel equipment
reverse travel equipment
A4/4 FMGR plug connection (grey) [4] X6/58 Plug connection for seat switch [SITZ RF]
C# Switch for engine back pressure
A70 Seat switch X24/3 Plug connection for instruments wiring harness
brake, handbrake for reverse
H1/1 Signal horn for reverse travel equipment - cab wiring harness on right [3]
travel equipment
R23 Limit load potentiometer X24/5 Plug connection for wiring harness, cab, right -
D# Seat switch for reverse travel S2/61 Parking interlock switch [PARKBREMSE] control panel
equipment
S2/61/1 Switch for parking interlock [PARK]
E# Horn for reverse travel S2/75 Button signal horn [HORN]
equipment S8 Seat switch
S8/1 Reversible seat switch
# Variants on sheet 37, 38 S8/2 Reversible seat switch
S20 Engine back pressure brake switch
S21 Switch for handbrake
X0/3/1 Weld point for instruments wiring harness,
potential 58L
*URXQGSRLQWV X0/3/3 Weld point for instruments wiring harness,
potential 15/2
X0/3/15 Weld point for instruments wiring harness,
CAN H
X0/7/24 Weld point for wiring harness, cab, right GSV3
X0/27/1 Weld point for seat R
X0/27/4 Weld point for parking interlock
X0/27/6 Weld point for GSV3
X0/27/7 Weld point for reverse travel equipment wiring
harness, potential 31
X0/27/8 Weld point, potential 15
X0/27/9 Weld point for reverse travel equipment wiring
harness, GSV2
X0/27/15 Weld point for reverse travel equipment wiring
harness, potential 58
X4/25 Plug connection for handbrake switch [25]
X4/25/1 Plug connection for handbrake switch
[HANDBREMSE]

Edition 01-2006
4010A-77
 6KHHW 4010A-78

Sva 6-93360 EN
4WD
Management
All-wheel drive
ON
Brake oil
cooling valve 2

GSV1
Brake oil
cooling valve 1

Manual mode

0-14 km/h
0-25 km/h
Differential lock ON
Differential lock management
Differential lock solenoid valve

SS06A040

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A# Switch for speed ranges, A4 FMGR

Sva 6-93360 EN
manual mode A4/1 FMGR plug connection (white) [1]
B# Switch for differential lock, all- A4/3 FMGR plug connection (blue) [3]
wheel drive management A16 EDC print
A60 ECCU2
C# Solenoid valves, brake oil
cooling CN3b ECCU2 plug connection
S2/56 Switch for differential lock management
[DIFF HI]
# Variant on sheet 41 S2/58/1 Switch for speed ranges [RANGE]
S2/58/2 Switch for manual mode [MAN.MOD]
S2/59 Switch for 4-wheel drive management [4 WD]
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/25/2 Weld point for wiring harness, control panel,
right, potential 58
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/25/5 Weld point for wiring harness, control panel,
*URXQGSRLQWV right GSV1
X0/25/7 Weld point for wiring harness, control panel,
right GSV1
X10/4 Plug connection for EDC print armrest (GSV)
X14/4 Plug connection for EDC print - control panel
X24/5 Plug connection for wiring harness, cab, right -
control panel
Y10 Differential lock solenoid valve [DIFF]
Y11 Solenoid valve for brake oil cooling 1
Y12 Solenoid valve for brake oil cooling 2

Edition 01-2006
4010A-79
 6KHHW 4010A-80

Sva 6-93360 EN
All-wheel drive
ON

4WD
Management
Brake oil
cooling valve 2

GSV1
Brake oil
cooling valve 1

Manual mode

0-14 km/h
0-25 km/h
Differential lock ON
Differential lock management
Differential lock solenoid valve

SS06A041

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A# Switch for speed ranges, A4 FMGR

Sva 6-93360 EN
manual mode for reverse travel A4/1 FMGR plug connection (white) [1]
equipment A4/3 FMGR plug connection (blue) [3]
B# Switch for differential lock, all- A16 EDC print
wheel drive management for A60 ECCU2
reverse travel equipment CN3b ECCU2 plug connection
C# Solenoid valves, brake oil S2/56 Switch for differential lock management
cooling [DIFF HI]
S2/58/1 Switch for speed ranges [RANGE]
S2/58/2 Switch for manual mode [MAN.MOD]
# Variant on sheet 40 S2/59 Switch for 4-wheel drive management [4 WD]
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/25/2 Weld point for wiring harness, control panel,
right, potential 58
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/25/5 Weld point for wiring harness, control panel,
*URXQGSRLQWV right GSV1
X0/25/7 Weld point for wiring harness, control panel,
right GSV1
X10/4 Plug connection for EDC print armrest (GSV)
X14/4 Plug connection for EDC print - control panel
X24/5 Plug connection for wiring harness, cab, right
- control panel
Y10 Differential lock solenoid valve [DIFF]
Y11 Solenoid valve for brake oil cooling 1
Y12 Solenoid valve for brake oil cooling 2

Edition 01-2006
4010A-81
 6KHHW 4010A-82

Sva 6-93360 EN
Load ground for
reverse gear
with max.
200mA

Reverse
Forwards
Neutral

Dead man
Plug X4/59b in here in
an emergency

BUZZER

SS06A042

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A ICU performance monitor A4 FMGR

Sva 6-93360 EN
A4/2 FMGR plug connection - dark grey [2]
B Gearbox electronics
A12 Central print
C LIMP HOME plug connection
A13 Roof print
D# Shuttle lever A21 SGR transmission controller
E Preparation for buzzer, reverse A23 Linde electronics
gear A24 Hydrostat
F9 Fuse, SGR, potential 30
F18 Fuse, SGR, potential 15/1
# Variant on sheet 43
P8 ICU
S4/4 Shuttle lever
X0/3/15 Weld point for instruments wiring harness,
CAN H
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/28/1 Weld point for roof wiring harness, potential 30,
memory
X0/28/3 Weld point for roof wiring harness, potential 58
*URXQGSRLQWV
X0/28/12 Weld point for roof wiring harness, potential 31
X4/59/a Plug connection for LIMP HOME [A]
X4/59/b Plug connection for LIMP HOME [A]
X4/59/c Plug connection for LIMP HOME [B]
X6/1 Plug connection for Linde electronics
X6/3 Plug connection for instruments wiring harness
- steering column [3]
X6/9 Plug connection for Linde electronics -
hydrostat A24
X10/12 Plug connection for roof wiring harness
X16/21 SGR plug connection
X24/2 Plug connection for cab wiring harness, right -
central print
X24/3 Plug connection for instruments wiring harness
- cab wiring harness on right [3]

Edition 01-2006
4010A-83
 6KHHW 4010A-84

Sva 6-93360 EN
Reverse
Forwards
Neutral

Dead man

In an emergency, plug
X4/59a here

SS06A043

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A ICU performance monitor A4 FMGR X4/59/a Plug connection for LIMP HOME [A]

Sva 6-93360 EN
A4/2 FMGR plug connection - dark grey [2] X4/59/b Plug connection for LIMP HOME [A]
B Gearbox electronics
A12 Central print X4/59/c Plug connection for LIMP HOME [B]
C LIMP HOME plug connection
A13 Roof print X6/1 Plug connection for Linde electronics
D# Shuttle lever A21 SGR transmission controller X6/3 Plug connection for instruments wiring harness
E Display for reverse travel A23 Linde electronics - steering column [3]
equipment A24 Hydrostat X6/9 Plug connection for Linde electronics -
F9 Fuse, SGR, potential 30 hydrostat A24
F18 Fuse, SGR, potential 15/1 X10/12 Plug connection for roof wiring harness
# Variant on sheet 42 X16/21 SGR plug connection
P6 Display for reverse travel equipment
P8 ICU X24/2 Plug connection for cab wiring harness, right -
S4/4 Shuttle lever central print
S4/4/1 Forwards - reverse switch [V/R] X24/3 Plug connection for instruments wiring harness
X0/3/15 Weld point for instruments wiring harness, - cab wiring harness on right [3]
CAN H
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
*URXQGSRLQWV X0/27/2 Weld point for reverse travel equipment wiring
harness „V“
X0/27/3 Weld point for reverse travel equipment wiring
harness „R“
X0/27/5 Weld point for reverse travel equipment wiring
harness, setting off
X0/27/7 Weld point for reverse travel equipment wiring
harness, potential 31
X0/27/8 Weld point, potential 15
X0/27/9 Weld point for reverse travel equipment wiring
harness, GSV2
X0/27/15 Weld point for reverse travel equipment wiring
harness, potential 58
X0/28/1 Weld point for roof wiring harness, potential 30,
memory
X0/28/3 Weld point for roof wiring harness, potential 58
X0/28/12 Weld point for roof wiring harness, potential 31

Edition 01-2006
4010A-85
 6KHHW 4010A-86

Sva 6-93360 EN
Ground

Ground
Ground
Ground

Ground
Ground
4V

Ground
4V
4V
4V
10V
10V
GND opens at a
difference in
pressure of
> 5 bar

4V
4V
4V
10 to 6000Hz
Ground
5V
PTC 1 kOhm to
4.4 kOhm

10 to 6000Hz
Ground

Ground
10 to 6000Hz
10 to 6000Hz
0.2V to 3.1V
0.2V to 1.2V
5V

10 to 6000Hz

SS06A044

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU
A red
B beige
C white
D yellow
E grey
F green
G violet

7\SHRIXVH
Potential 30 (continuous current) H orange VDC stabilised by electric box
-- control line (at ground end) K light blue D+
+ control line (at positive end) L brown Ground above a box
Potential 15 Si (safety) M Ground strip
Potential 58 (lighting) N pink Electric signals
Signal line P colourless Reserve
Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Solenoid valves, cartridge A21 SGR transmission controller

Sva 6-93360 EN
B24 Speed sensor, cartridge input
B Speed sensors, cartridge
B25 Speed sensor, planetary carrier 3/4
C Sensors, cartridge switch
B26 Speed sensor, cartridge output
B26 Speed sensor, cartridge output
B32 Speed sensor, temperature sensor,
transmission oil
B35 Speed sensor, planetary carrier 1/2
B47 Pressure sensor for transmission system
pressure
B51 Pressure sensor for transmission lubricating
pressure
S49/1 Switch, pressure filter, 5bar
X5 Plug connection for pressure filter
X17 Plug connection for parking interlock ground
Y41 Solenoid valve, coupling 1
Y42 Solenoid valve, coupling 2
Y43 Solenoid valve, coupling 3
*URXQGSRLQWV
Y44 Solenoid valve, coupling 4
Y45 Solenoid valve, coupling, forward
Y46 Solenoid valve, coupling, reverse
Y57 Solenoid valve, parking interlock On
Y58 Solenoid valve, parking interlock Off
Y59 All-wheel solenoid valve

Edition 01-2006
4010A-87
 6KHHW 4010A-88

Sva 6-93360 EN
12V for
PTO shaft
at rear active
12V for
PTO shaft
at front active

SS06A045

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Rear PTO shaft A60 ECCU2

Sva 6-93360 EN
CN2/E ECCU2 plug connection
B Front PTO shaft
CN3a ECCU2 plug connection
CN3b ECCU2 plug connection
S2/70/1 Switch for front PTO [PTO VO]
S2/70/2 Switch for rear PTO [PTO HI]
S2/71 Switch for rear PTO, management [PTO M]
S17/1 External button for PTO, rear left
S17/2 External button for PTO, rear right
X0/7/9 Weld point for wiring harness, cab,
right GSV4
X0/25/1 Weld point for wiring harness, control panel,
right, potential 58
X0/25/3 Weld point for wiring harness, control panel,
right, potential 31
X0/25/5 Weld point for wiring harness, control panel,
right GSV1
X24/5 Plug connection for wiring harness, cab, right
*URXQGSRLQWV - control panel
Y4 Solenoid valve for front PTO [PTO VO]
Y5 Solenoid valve for rear PTO [PTO]

Edition 01-2006
4010A-89
 6KHHW 4010A-90

Sva 6-93360 EN
Potential 15/2

12V
as of
during
locked

Ground
Ground
Potential 30

12V during
12V during
v< 14 km/h
12 V during

management

12V during UP
Check for
front axle 12V during UP /
ACTIVE 12V during UP DOWN

12V during
UP / DOWN

12 V
Signal flow
Signal flow
Ground

Ground
12 V
BLUE BLACK GREEN

SS06A046

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Spring-mounted front axle A12 Central print X12/20 Plug connection for control block, sprung front

Sva 6-93360 EN
A60 ECCU2 axle [VA]
B Supply, ECCU2
A61 Electronics, front axle with independent X24/2 Plug connection for cab wiring harness, right -
suspension central print
# Variant on sheet 47 B33/1 Angle of rotation sensor Y14 Solenoid valve for sprung front axle, UP/DOWN
B33/2 Angle of rotation sensor Y15 Solenoid valve for sprung front axle, left
CN1a ECCU2 plug connection Y16 Solenoid valve for sprung front axle, right
CN2/E ECCU2 plug connection
CN3b ECCU2 plug connection
F28 Fuse, sprung front axle, potential 15/2
F10 Fuse, supply, ECCU2, potential 30
F27 Fuse, sprung front axle, potential 30
F50 Switch for supply, potential 15/1 ECCU2
S2/15/1 Switch for sprung front axle UP/DOWN
S2/15/2 Switch for sprung front axle ON/OFF [VA ein]
X0/3/1 Weld point for instruments wiring harness,
potential 58L
*URXQGSRLQWV X0/3/2 Weld point for instruments wiring harness,
potential 15/1
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/7/8 Weld point for wiring harness, cab, right,
potential 15/1
X0/7/9 Weld point for wiring harness, cab, right GSV4
X0/8/1 Weld point for additional line, independent
suspension, sprung front axle, potential 58
X0/8/2 Weld point for additional line, independent
suspension, sprung front axle, potential 31
X0/8/3 Weld point for additional line, independent
suspension, sprung front axle, potential 15/2
X2/45 Plug connection for wiring harness, cab, right -
sprung front axle [45]
X2/46 Plug connection for potential 58/31, sprung
front axle [GE.VA]
X4/45 Plug connection for sprung front axle [45]

Edition 01-2006
4010A-91
 6KHHW 4010A-92

Sva 6-93360 EN
Potential 15/2

UP

12V
as of
during
locked

Ground
Ground
Potential 30

12V during
12V during
12V during
v< 14 km/h
12 V during

management
Check for
front axle 12V during UP /
ACTIVE 12V during UP DOWN

12V during UP /
DOWN

12 V

12 V
Signal flow
Signal flow
Ground

Ground
BLUE BLACK GREEN

SS06A047

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Spring-mounted front axle A12 Central print X2/46 Plug connection for potential 58/31, sprung

Sva 6-93360 EN
A60 ECCU2 front axle [GE.VA]
B Supply, ECCU2 for ISO BUS
A61 Electronics, front axle with independent X2/87 Plug connection for cab wiring harness on
suspension right - instruments wiring harness ISO-BUS
# Variant on sheet 46 B33/1 Angle of rotation sensor X4/45 Plug connection for sprung front axle [45]
B33/2 Angle of rotation sensor X4/85/a Plug connection for cab wiring harness, right
CN1a ECCU2 plug connection - ISO BUS preparation
CN2/E ECCU2 plug connection X4/85/b Plug connection for cab wiring harness, right
CN3b ECCU2 plug connection - ISO BUS preparation
F10 Fuse, supply, ECCU2, potential 30 X12/20 Plug connection for control block, sprung
F27 Fuse for sprung front axle, potential 30 front axle [VA]
F28 Fuse for sprung front axle, potential 15/2 X24/2 Plug connection for cab wiring harness, right -
central print
F50 Switch for supply, potential 15/1 ECCU2
Y14 Solenoid valve for sprung front axle, UP/
S2/15/1 Switch for sprung front axle UP/DOWN
DOWN
S2/15/2 Switch for sprung front axle ON/OFF [VA ein]
Y15 Solenoid valve for sprung front axle, left
X0/3/1 Weld point for instruments wiring harness,
Y16 Solenoid valve for sprung front axle, right
potential 58L
*URXQGSRLQWV X0/3/2 Weld point for instruments wiring harness,
potential 15/1
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/7/8 Weld point for wiring harness, cab, right,
potential 15/1
X0/7/9 Weld point for wiring harness, cab, right
GSV4
X0/8/1 Weld point for additional line, independent
suspension, sprung front axle, potential 58
X0/8/2 Weld point for additional line, independent
suspension, sprung front axle, potential 31
X0/8/3 Weld point for additional line, independent
suspension, sprung front axle, potential 15/2
X2/45 Plug connection for wiring harness, cab, right
- sprung front axle [45]

Edition 01-2006
4010A-93
 6KHHW 4010A-94

Sva 6-93360 EN
SS06A048

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Power lift, front, management A60 ECCU2

Sva 6-93360 EN
B19 Angle of rotation sensor [LAGESENSOR VO]
B Angle of rotation sensor, power
lift, front CN1a ECCU2 plug connection
CN3a ECCU2 plug connection
C External button, AUX, front
CN3b ECCU2 plug connection
D External button, power lift, front S14/3 External button for front power lift, LOWER
[Senken]
S15/3 External button for front power lift, RAISE
[Heben]
S19/1 External button for AUX BROWN, pressure in -
[Senken]
S19/2 External button for AUX BROWN, pressure in +
[Heben]
S28/1 Button for front power lift management
X0/7/9 Weld point for wiring harness, cab, right GSV4
X0/23/1 Weld point for additional line, external
pushbutton for front power lift GSV4
X3/22 Plug connection for angle of rotation sensor,
*URXQGSRLQWV front power lift [LAGE]
X4/69 Plug connection for external button, front power
lift [FHW]
X4/72 Plug connection for external button, front AUX
brown [EHS]
X18/4 Plug connection for cab wiring harness, right -
armrest

Edition 01-2006
4010A-95
 6KHHW 4010A-96

Sva 6-93360 EN
SS06A049

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A CAN BUS A1 ADIC

Sva 6-93360 EN
A3 EEM3 control unit
A65 KEY PADS
CN3 ADIC plug connection
P8 ICU
P8/1 Plug connection ICU CAN [DISP]
P8/2 Plug connection ICU CAN
X0/3/6 Weld point for instruments wiring harness,
potential GSV2
X0/3/7 Weld point for instruments wiring harness
CAN L
X0/3/8 Weld point for instruments wiring harness
CAN H
X0/3/9 Weld point for instruments wiring harness,
potential 30
X4/63 Plug connection for KEY PADS
X10/14 Plug connection for wiring harness for roof
supply
*URXQGSRLQWV X10/18 Plug connection for instruments wiring
harness - engine wiring harness [INSTR]
X14/14 Plug connection for roof supply [14]
X89/1 Plug connection for EEM3 engine control unit -
engine wiring harness

Edition 01-2006
4010A-97
 6KHHW 4010A-98

Sva 6-93360 EN
Plug for service tool

SS06A050

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A CAN BUS A4 FMGR

Sva 6-93360 EN
A4/4 FMGR plug connection (grey) [4]
A21 SGR transmission controller
A30 ARU print
X0/7/17 Weld point for wiring harness, cab, right,
handbrake
X0/7/23 Weld point for wiring harness, cab, right,
potential 31
X0/7/32 Weld point for wiring harness, cab, right,
CAN H
X0/7/33 Weld point for wiring harness, cab, right, CAN L
X0/7/36 Weld point for wiring harness, cab, right,
CAN H
X0/7/37 Weld point for wiring harness, cab, right, CAN L
X0/7/52 Weld point for wiring harness, cab, right,
CAN H
X0/7/53 Weld point for wiring harness, cab, right, CAN L
X9/17 Socket for diagnosis service tool [DIAGNOSE]
*URXQGSRLQWV X16/21 SGR plug connection
X18/4 Plug connection for cab wiring harness, right -
armrest

Edition 01-2006
4010A-99
 6KHHW 4010A-100

Sva 6-93360 EN
SS06A051

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A CAN BUS A4 FMGR

Sva 6-93360 EN
A4/3 FMGR plug connection (blue) [3]
A12 Central print
A55 EDC box
A60 ECCU2
CN1a ECCU2 plug connection
F16 Fuse for reserve, potential 15/2
F47 Fuse for supply, AUX potential 15/1
X0/7/40 Weld point for wiring harness, cab, right,
CAN H
X0/7/41 Weld point for wiring harness, cab, right, CAN L
X0/7/44 Weld point for wiring harness, cab, right,
CAN H
X0/7/45 Weld point for wiring harness, cab, right, CAN L
X0/7/48 Weld point for cab wiring harness, right CAN H
X0/7/49 Weld point for cab wiring harness, right, CAN L
X24/2 Plug connection for cab wiring harness, right -
central print
*URXQGSRLQWV
X55 Plug connection for EDC box

Edition 01-2006
4010A-101
 6KHHW 4010A-102

Sva 6-93360 EN
SS06A052

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A AUX valves A60 ECCU2

Sva 6-93360 EN
CN3b ECCU2 plug connection
B Heating valve for hydraulic oil
X0/7/5 Weld point for wiring harness, cab, right,
potential 31
X0/9/10 Weld point for wiring harness, AUX potential 15
CAN BUS
X0/9/11 Weld point for wiring harness, AUX potential 31
CAN BUS
X0/9/12 Weld point for wiring harness, AUX CAN H
X0/9/13 Weld point for wiring harness, AUX CAN L
X0/9/22 Weld point for wiring harness, AUX CAN H
X0/9/23 Weld point for wiring harness, AUX CAN L
X0/9/32 Weld point for wiring harness, AUX CAN H
X0/9/33 Weld point for wiring harness, AUX CAN L
X0/9/42 Weld point for wiring harness, AUX CAN H
X0/9/43 Weld point for wiring harness, AUX CAN L
X0/9/50 Weld point AUX CAN H
X0/9/51 Weld point for wiring harness, AUX CAN L
*URXQGSRLQWV
X3/10 Plug connection for terminating resistor
X4/83 Plug connection for remote control valves
[EHS]
X4/90 Plug connection AUX 1
X4/91 Plug connection AUX 2
X4/92 Plug connection AUX 3
X4/93 Plug connection AUX 4
X4/94 Plug connection AUX 5
Y8 Heating valve

Edition 01-2006
4010A-103
 6KHHW 4010A-104

Sva 6-93360 EN
Supply for EDC stop

Transport

Lighting, potential 58
External button, power lift, front, raise
EDC stop
Potential 31
Potential 15
GSV
Controlling

External button, power lift, front, lower

Front loader solenoid valve
Output for EDC stop

Rapid retraction
Interface, wiring harness, cab, right

SS06A053

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Interface, wiring harness, cab, A30 ARU print

Sva 6-93360 EN
right C1 Condenser
B Armrest, electronics C2 Condenser
C3 Condenser
C4 Condenser
L1 Disturbance protection
L2 Disturbance protection
V1/1 Diode
V1/2 Z diode
V1/3 Protective diode CAN H
V1/4 Protective diode CAN L
X18/4 Plug connection for cab wiring harness, right -
armrest
X30/1 Plug connection for supply, armrest
X30/7 Plug connection for CAN BUS

*URXQGSRLQWV

Edition 01-2006
4010A-105
 6KHHW 4010A-106

Sva 6-93360 EN
SS06A054

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Joystick with button A29 Joystick

Sva 6-93360 EN
A30 ARU print
B Control handle for AUX
B28 Manual accelerator slider
C Manual accelerator slider
B30 Longitudinal joystick
D Armrest, electronics B31 Transverse joystick
B52 Control lever
S35 Joystick button
X30/3 Plug connection for ARU - man. oper.
accelerator slider
X30/4 Plug connection for ARU - AUX control lever
X30/5 Plug connection for ARU - AUX joystick

*URXQGSRLQWV

Edition 01-2006
4010A-107
 6KHHW 4010A-108

Sva 6-93360 EN
SS06A055

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A# AUX5 button A30 ARU print

Sva 6-93360 EN
E28/1 Lighting ARU
B Reserve
R12 0 kOhm resistance
C Button, rapid retraction
R13 0 kOhm resistance
D Button, EDC - stop and lighting R14 6.2 kOhm resistance
E Armrest, electronics R15 1.2 kOhm resistance
R16 6.2 kOhm resistance
R17 2 kOhm resistance
S2/72 Rapid retraction button
S33 EDC stop button
S34 5th AUX button
X30/2 Plug connection for ARU - rapid retraction
button
X30/6 Plug connection for ARU - AUX button
X30/8 Plug connection for ARU reserve
X30/9 Plug connection for ARU - switch lighting
X30/13 Plug connection for ARU lighting
*URXQGSRLQWV X30/14 Plug connection for ARU button, EDC stop

Edition 01-2006
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 6KHHW 4010A-110

Sva 6-93360 EN
POTI_4 POTI_3 POTI_2 POTI_1 POTI_0

SS06A056

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Potentiometer, AUX remote A30 ARU print

Sva 6-93360 EN
control valves R20/1 Potentiometer for 1st AUX
B Armrest, electronics R20/2 Potentiometer for 2nd AUX
R20/3 Potentiometer for 3rd AUX
R20/4 Potentiometer for 4th AUX
R20/5 Potentiometer for 5th AUX
R28/1 470 Ohm resistance
R28/2 560 Ohm resistance
R28/3 470 Ohm resistance
R28/4 560 Ohm resistance
R28/5 470 Ohm resistance
R28/6 560 Ohm resistance
R28/7 470 Ohm resistance
R28/8 560 Ohm resistance
R28/9 470 Ohm resistance
R28/10 560 Ohm resistance
X30/12 Plug connection for ARU - potentiometer
*URXQGSRLQWV AUX 5
X30/15 Plug connection for ARU - potentiometer
AUX 3 and AUX 4
X30/16 Plug connection for ARU - potentiometer
AUX 1 and AUX 2

Edition 01-2006
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 6KHHW 4010A-112

Sva 6-93360 EN
SS06A057

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A Multicontroller II A30 ARU print

Sva 6-93360 EN
A31 Multicontroller II
B Armrest, electronics
S60/1 F/R button
S60/2 Cruise control button
S60/3 Speed button +
S60/4 Speed button -
S60/5 HTS button
S60/6 AUX blue button
S60/7 EDC Transport/control button
S60/8 Shift button (Schwimmstellung)
X4 Plug connection for ARU multicontroller II - print
X21 Plug connection for multicontroller II - print
X30/11 Plug connection for supply - multicontroller print
X30/19 Plug connection for shift button (float position)

*URXQGSRLQWV

Edition 01-2006
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 6KHHW 4010A-114

Sva 6-93360 EN
SS06A058

/LQHFRORXUVDQGRUFRGLQJLQDFFRUGDQFHZLWKVWDQGDUG
&RGHOHWWHU &RORXU 7\SHRIXVH
A red Potential 30 (continuous current) H orange VDC stabilised by electric box
B beige -- control line (at ground end) K light blue D+
C white + control line (at positive end) L brown Ground above a box
D yellow Potential 15 Si (safety) M Ground strip
E grey Potential 58 (lighting) N pink Electric signals
F green Signal line P colourless Reserve
G violet Potential 15 (15/1 or 15/2) switched current downstream of S black Ground directly at ground point
start switch

Edition 01-2006
 'HVLJQDWLRQRIVHFWLRQV (OHFWULFDOHTXLSPHQW

A ISO-BUS A12 Central print X1/30/ISO Screw connection for engine print, potential 30

Sva 6-93360 EN
A14 Engine print X2/11 Plug connection for engine print ISO-BUS
B ISO-BUS
A60 ECCU2 X2/86 Plug connection for socket LBS ISO-BUS
CN1a ECCU2 plug connection X3/85 Plug connection for terminating resistor
CN3b ECCU2 plug connection ISO-BUS
CN4 Plug connection for ECCU2 ISO-BUS X4/85/a Plug connection for cab wiring harness, right -
F50 Switch for supply, potential 15/1 ECCU2 ISO BUS preparation
F219 Fuse for ISO-BUS, potential 30 X4/85/b Plug connection for cab wiring harness, right -
F220 Fuse for ISO-BUS, potential 30 ISO BUS preparation
F222 Fuse for ISO-BUS, potential 30 X9/17 Socket for diagnosis service tool [DIAGNOSE]
K5/80 Relay, potential 15, ISO-BUS X9/20 Socket for ISO-BUS
K5/81 Relay for ECU power, ISO-BUS X12/8 Plug connection for Virtual Terminal ISO-BUS
K5/82 Relay for power socket, ISO-BUS X24/2 Plug connection for cab wiring harness, right -
P9 Virtual terminal central print
V8/1 ISO-BUS diode group X85 Socket for LBS, ISO-BUS
X0/7/8 Weld point for wiring harness, cab, right,
potential 15/1
*URXQGSRLQWV X0/32/1 Weld point for wiring harness, ISO-BUS
potential 31
X0/32/2 Weld point for wiring harness, ISO-BUS
potential 30
X0/32/3 Weld point for wiring harness ISO-BUS CAN H
X0/32/4 Weld point for wiring harness, ISO-BUS
potential 15/1
X0/32/5 Weld point for wiring harness, ISO-BUS
potential 15/1
X0/32/6 Weld point for wiring harness, ISO-BUS
potential 30
X0/32/7 Weld point for wiring harness ISO-BUS CAN L
X0/32/8 Weld point for wiring harness, ISO-BUS CAN L
X0/32/9 Weld point for wiring harness, ISO-BUS CAN H
X0/32/10 Weld point for wiring harness ISO-BUS,
potential 30
X0/32/12 Weld point for wiring harness, ISO-BUS CAN L
X0/32/13 Weld point for wiring harness, ISO-BUS CAN H

Edition 01-2006
4010A-115
 Chapter
4011

4011
FAULTCODES

CNH Österreich GmbH Sva 6-52632 EN © 2006 CNH Österreich GmbH

Technical documentation June, 2006
A - 4300 St. Valentin, Steyrer Straße 32
 4011-3

TABLE OF CONTENTS

TEST ADAPTER ..................................................................................................................... 5

GENERAL ............................................................................................................................... 8
Handling Chapter 4011 .................................................................................................................... 8
General advise ................................................................................................................................. 8
Abbreviations .................................................................................................................................... 8
INTERROGATING AND DELETING ERROR CODE .............................................................. 9
CAN BUS FUSES .................................................................................................................. 10
RESISTANCE VALUES - CAN H TO CAN L ........................................................................ 11
VOLTAGES - CAN H, CAN L ................................................................................................ 11
FUNCTION OF THE TERMINATING RESISTOR ................................................................. 12
SCHEMATIC DIAGRAM FOR CAN BUS UP TO DBD094270 ............................................. 13
SCHEMATIC DIAGRAM FOR CAN BUS FROM DBD094271 UP TO DBD100000 ............. 14
SCHEMATIC DIAGRAM FOR CAN BUS FROM DBD100001 .............................................. 15
SCHEMATIC DIAGRAM FOR ISO BUS UP TO DBD100000 ............................................... 17
SCHEMATIC DIAGRAM FOR ISO BUS FROM DBD100001 ............................................... 18
FAULTCODES ADIC and ICU ............................................................................................... 19
FAULTCODES ARU UP TO DBD094270 ............................................................................. 41
FAULTCODES ARU FROM DBD094271 .............................................................................. 85
FAULTCODES AUX ............................................................................................................ 135
FAULTCODES ECCU2 ....................................................................................................... 181
FAULTCODES EDC ............................................................................................................ 253
FAULTCODES EEM2 UP TO DBD100000 ......................................................................... 303
FAULTCODES EEM3 FROM DBD100001 ......................................................................... 351
FAULTCODES FMGR ......................................................................................................... 469
FAULTCODES SGR ............................................................................................................ 629

Sva 6-52632 EN Edition 06-2006

4011-4

BLANK PAGE

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 4011-5

TEST ADAPTER

DIAGNOSTIC BOX, 100-POLE 380000058 MULTIMETER (Fluke 79 or similar)

(1TSW 528-1) (1TSW 516-1)

MEASURING CABLES (pin diameter - 4 mm) TEST LAMP (with 21 W bulb)

(1TSW 528-11) (1TSW 528-2)

"Y" ADAPTER, 26-POLE (ADIC) 380001492 "Y" ADAPTER, 2-POLE 380000060

Sva 6-52632 EN Edition 06-2006

4011-6

"Y" ADAPTER, 3-POLE 380000061 "Y" ADAPTER, 3-POLE 380000070

"Y" ADAPTER, 4-POLE 380000062 "Y" ADAPTER (EDC) 380000074

"Y" ADAPTER, 2-POLE 380000066 "Y" ADAPTER (EDC) 380000075

"Y" ADAPTER, 3-POLE 380000067 "Y" ADAPTER (FMGR) 380000076

Sva 6-52632 EN Edition 06-2006

 4011-7

"Y" ADAPTER, 4-POLE 380001588 "Y" ADAPTER, 3-POLE 380002717

"Y" ADAPTER, 2-POLE 380002716 "Y" ADAPTER, 3-POLE 380002718

Sva 6-52632 EN Edition 06-2006

4011-8

GENERAL
Handling Chapter 4011
The error descriptions are arranged by controller and in ascending error number order. The connector and compon-
ents are always shown at the end of the controller in question in the component overview. The function diagrams for
the error codes are located after the component overview.
The technical data of the individual components can be obtained from Chapter 4009 (up to DBD100000) or 4009A
(from DBD100001).

General advise
The connector module A28 and the can module A27 was fitted in tractors up to chassis number DBD094270.
From DBD094271 the two modules are replaced by one module A30. The new module has no influence in function
and has the same connectors like the two old modules. On the new modul A30 the two connectors YA1 and YB1 will
be dropped (no more needed).

Abbreviations
ADIC................................................................................................................................ Analogue / digital instrument
ARU...................................................................................................................................................................Armrest
AUX ..............................................................................................................................................Remote control valve
BB light ........................................................................................................................... Turn signal / side marker light
DMM...................................................................................................................................................Digital multimeter
DZG................................................................................................... Signal of crankshaft position (upper dead point)
ECCU2 ............................................................................................................................................ Central control unit
EDC.................................................................................................................................... Electronic power lift control
EEM2................................................................................................................................................Engine control unit
EEM3................................................................................................................................................Engine control unit
FMGR................................................................................................................. Vehicle/engine/transmissioncontroller
GSV.......................................................................................................................................................... Cyclic supply
HTS .................................................................................................. Field end management (headland management)
ICU ...............................................................................................................................................Performance monitor
ID module .................................................................................................. Identification module for engine electronics
KEY PAD´S ............................................................................................ Function keys for analogue/digital instrument
NTC ............................................................................................................................Negative temperature coefficient
PCB .................................................................................... Printed circuit board (relay switching, terminal resistance)
PCU............................................................................................................................... Electronic pumps - control unit
PTC ............................................................................................................................ Positive temperature coefficient
SBB light........................................................................................................... Tail light, turn signal / side marker light
SGR.......................................................................................................................................... Transmission controller

NOTE: The name in the square brackets [xx] is inscribed on the plug.

Sva 6-52632 EN Edition 06-2006

 4011-9

INTERROGATING AND DELETING ERROR CODE

The error codes can be interrogated and deleted via the ICU (performance monitor). The driver is informed of the
occurrence of an error by a warning symbol displayed in the ADIC and a beeping tone.
A "serious error" is also indicated on the ICU by the "STOP" warning symbol and a continuous tone.
NOTE: The engine is automatically shut down 30 seconds after a serious error occurs!

Interrogating error code

Simultaneously press (approx. 4 sec.) the two arrow keys
on the ICU (UP and DOWN keys) to reach the "Error co-
de" menu.

Use the arrow keys to select the controller required and

then confirm by pressing the OK button.

SS05F003

The last 10 error codes to occur are displayed in descen-

ding order of operating hours.
NOTE: An error code is only displayed once. If an error
occurs repeatedly, the last error code to occur is dis-
played.
Press the ESC button to return to the "Error code" menu.

SS05F004

Deleting error code

Set the arrow in the display to CL by pressing the arrow
keys.
The errors of all controllers are deleted by pressing the
OK button.
NOTE: The error codes of the controller FMGR and
SGR are retained in the extended error memory and can
therefore be interrogated later on using the service tool.

SS05F005

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4011-10

CAN BUS FUSES

BUS USER LOCATION
ARU (armrest) F19 ................................................................................................................. 5 A (+15/1) A12
F20 ................................................................................................................. 5 A (+15/1) A12
ADIC (A1) F6 ................................................................................................................... 5 A (+15/1) A12
F93 up to DBD100000 ................................................................................... 5 A (+30) A14
F212 from DBD100001 .................................................................................. 5 A (+30) A14
AUX 1 to 5 F47 ................................................................................................................ 5 A (+15/1) A12
ICU (P8) F45 ................................................................................................................ 5 A (+15/1) A12
F93 up to DBD100000 ................................................................................... 5 A (+30) A14
F212 from DBD100001 .................................................................................. 5 A (+30) A14
EEM2 (A2) F92 up to DBD100000 ................................................................................. 10 A (+30) A14
F94 up to DBD100000 .................................................................................. 25A (+30) A14
F97 up to DBD100000 ................................................................................. 10 A (+15/2) A14
EEM3 (A3) F203 from DBD100001 ................................................................................ 30 A (+30) A14
F207 from DBD100001 .................................................................................. 5 A (+15) A14
ECCU2 (A60) F10 ................................................................................................................ 5 A (+30) A12
F50 .............................................................................................................. 25 A (+15/1) A12
EDC (A55) F49 ............................................................................................................. 7.5 A (+15/1) A12
F91 up to DBD100000 ................................................................................ 7.5 A (+30) A14
F210 from DBD100001 ............................................................................... 7.5 A (+30) A14
F21 ................................................................................................................ 5 A (D+) A12
FMGR (A4) F14 ............................................................................................................. 7.5 A (+30) A12
F51 .............................................................................................................. 10 A (+15/1) A12
SGR (A21) F9 ................................................................................................................ 10 A (+30) A12
F18 ................................................................................................................ 5 A (+15/1) A12

ISO BUS up to DBD100000

F80 ............................................................................................................... 20A (+30)
F81 ............................................................................................................... 25A (+30)
F82 ............................................................................................................... 40A (+30)
F200 ............................................................................................................ 200A (+30)

ISO BUS from DBD100001

F219 ............................................................................................................. 20A (+30) A14
F220 ............................................................................................................. 25A (+30) A14
F222 ............................................................................................................. 40A (+30) A14

Sva 6-52632 EN Edition 06-2006

 4011-11

RESISTANCE VALUES - CAN H TO CAN L

Vehicle bus / Transmission bus
Turn the ignition switch to the OFF position)

Resistance of one terminating resistor: 120 ohms + / - 10 %.

Both terminating resistors connected to the CAN data bus:

CANH to CANL: 60 ohms + / - 10 %.

Only one terminating resistor connected to the CAN data bus:

CANH to CANL: 120 ohms +/- 10 %.
ISO bus
(Turn the ignition switch to the OFF position)

Resistance of the terminating resistor in the ISO bus: 120 ohms + / - 10 %.

Resistance of the terminating resistor in the ISO bus socket: 150 ohms + / - 10 %.

Both terminating resistors connected to the ISO data bus:

CANH to CANL: 66.666 ohms + / - 10 %.

Only the terminating resistor in the vehicle connected to the CAN data bus:
CANH to CANL: 120 ohms +/- 10 %.
Only the terminating resistor in the ISO bus socket connected to the ISO data bus:
CANH to CANL: 150 ohms +/- 10 %.

VOLTAGES - CAN H, CAN L

Vehicle bus
(Turn the ignition switch to the ON position)

Both terminating resistors connected to the CAN data bus:

CANH to GND: 2.5V to 4V nominally, (really approx. 2.5V).
CANL to GND: 1V to 2.5V nominally, (really approx. 2.3V).
Transmission bus
(Turn the ignition switch to the ON position)

Both terminating resistors connected to the CAN data bus:

CANH to GND: 2.5V to 4V nominally, (really approx. 2.5V).
CANL to GND: 1V to 2.5V nominally, (really approx. 2.3V).
ISO bus
(Turn the ignition switch to the ON position)

Both terminating resistors connected to the CAN data bus:

CANH to GND: 2.5V to 4V nominally, (really approx. 2.5V).
CANL to GND: 1V to 2.5V nominally, (really approx. 2.3V).

Sva 6-52632 EN Edition 06-2006

4011-12

FUNCTION OF THE TERMINATING RESISTOR

The terminating resistors ensure the correct transmission of information at the data bus. Without the terminating re-
sistors the signals could be disturbed by external electromagnetic pulses and thus lose their reliability. Communica-
tion problems can be caused by a faulty terminating resistor or faulty plug-in connections to it.
Every data bus (vehicle bus, gearbox bus or ISO bus) is equipped with two terminating resistors.
The setpoint value for a terminating resistor is 120 ohms (with the exception of the terminating resistor in the ISO bus
socket = 150 ohms)
Terminating resistors are integrated in control units, e.g. in the EEM (engine control unit), as well as in the plug hou-
sing.
The CANH and CANL signal lines are connected parallel by the terminating resistors. The equivalent resistance bet-
ween the two data bus lines is thus 60 ohms for the vehicle bus and transmission bus and 66.66 ohms for the ISO bus.
If a terminating resistor is disconnected from the data bus (vehicle bus, transmission bus), the resistance is 120 ohms.
If a terminating resistor is disconnected from the ISO bus, the resistance is 120 / 150 ohms.
NOTE: At least one terminating resistor is required to reach the correct signal levels.
In general, the data bus operates perfectly with only one terminating resistor. The second terminating resistor is used
to provide additional system reliability. When only one terminating resistor is used during operation, data transmission
can be disturbed temporarily, especially in the range of radio waves (radio, mobile, radar, etc.). Temporary transmis-
sion disturbances are noticeable when sometimes offline messages appear on the display and subsystems are swit-
ched off until the ignition switch is turned to the OFF position and then back to ON. Due to the fault management
system, some subsystems must switch off when communication is disturbed as transmission faults in the respective
subsystem are not acceptable.

Sva 6-52632 EN Edition 06-2006

 4011-13

SCHEMATIC DIAGRAM FOR CAN BUS UP TO DBD094270

SS06F006

Sva 6-52632 EN Edition 06-2006

 4011-14

SCHEMATIC DIAGRAM FOR CAN BUS FROM DBD094271 UP TO DBD100000

SS06F007

Sva 6-52632 EN Edition 06-2006

 4011-15

SCHEMATIC DIAGRAM FOR CAN BUS FROM DBD100001

SS06E002

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4011-16

BLANK PAGE

Sva 6-52632 EN Edition 06-2006

 4011-17

SCHEMATIC DIAGRAM FOR ISO BUS UP TO DBD100000

SS06F008

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 4011-18

SCHEMATIC DIAGRAM FOR ISO BUS FROM DBD100001

SS06E003

Sva 6-52632 EN Edition 06-2006

 4011-19

FAULTCODES ADIC and ICU

ADIC - 1 Processor memory fault (EEPROM checksum fault) ........................................................................... 21
ADIC - 10 Signal from fuel tank level sensor B2/1 faulty (line interrupted or shorted to +12V) .......................... 21
ADIC - 11 Signal from fuel tank level sensor B2/1 faulty (shorted to GND) ........................................................ 22
ADIC - 20 Signal from pressure sensor B3 faulty (line interrupted or shorted to +12V) ..................................... 23
ADIC - 250 CAN bus OFF up to DBD100000 ..................................................................................................... 24
ADIC - 250 CAN bus OFF from DBD100001 ...................................................................................................... 26
ICU - 2 CAN bus OFF up to DBD100000 ............................................................................................................ 28
ICU - 2 CAN bus OFF from DBD100001 ............................................................................................................ 29
COMPONENTS SUMMARY ............................................................................................................................... 30
FUNCTIONAL SCHEMATIC DIAGRAM FOR ADIC UP TO DBD100000 .......................................................... 37
FUNCTIONAL SCHEMATIC DIAGRAM FOR ADIC FROM DBD100001 ........................................................... 39

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ADIC - 1 Processor memory fault (EEPROM checksum fault)

Cause:
A non-volatile number is stored in the ADIC which allows its software to be diagnosed. The ADIC uses a specific al-
gorithm and the data in the EEPROM to calculate a checksum.
If the calculated checksum does not agree with the checksum stored internally, a fault has occurred.

The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. The EEPROM is defective.
2. The controller is defective.
3. The connections between EEPROM and controller on the printed board are faulty.
Remedy:
Cancel fault. Turn ignition switch to OFF position, turn back to ON position after min. 5 seconds and check whether
the fault is no longer displayed.
Should the fault still occur, there is a defect in the ADIC electronics.
The ADIC must be replaced.

ADIC - 10 Signal from fuel tank level sensor B2/1 faulty

(line interrupted or shorted to +12V)
Cause:
The signal from level sensor B2/1 (fuel tank) is routed to the ADIC.
The sensor’s resistance ranges from 10 ohms (tank empty) to 180 ohms (tank full).
If the ADIC detects a resistance value > 900 ohms or a signal voltage > 4.5V, a fault has occurred.
The fault code is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. The level sensor is defective.
2. The wiring between level sensor and ADIC has a contact fault or is interrupted or shorted to +12V.
3. The ADIC is defective.
Remedy:
1. Remove the plug from level sensor B2/1 and check the resistance values of the sensor:

Fuel level Resistance in ohms

0 10 ±2.5

1/2 95 ±5

1 180 ±12

2. Disconnect plugs CN3 and CN1 from the ADIC. Measure the resistance between lines CN3 PIN14 (signal) and
CN1 PIN22 (GND - sensor). If the value is < 7.5 ohms or > 192 ohms and if the sensor itself is ok (determined by
the measurement in step 1), the fault is caused by the wiring.
3. If you cannot detect a fault in steps 1 to 2, the fault is caused by the ADIC. In this case, the ADIC must be replaced.

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ADIC - 11 Signal from fuel tank level sensor B2/1 faulty

(shorted to GND)
Cause:
The signal from level sensor B2/1 (fuel tank) is routed to the ADIC.
The sensor’s resistance ranges from 10 ohms (tank empty) to 180 ohms (tank full).
If the ADIC detects a resistance value < 3.6 ohms, a fault has occurred.
The fault code is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. The sensor is defective.
2. The wiring between sensor and ADIC is defective (short circuit).
3. The ADIC is defective.
Remedy:
1. Remove the plug from level sensor B2/1 and check the resistance values of the sensor:

Fuel level Resistance in ohms

0 10 ±2.5

½ 95 ±5

1 180 ±12

2. With the ADIC disconnected, measure the resistance between the two lines CN3 PIN14 (signal) and CN1 PIN22
(sensor GND). If the value is < 10 ohms and if the sensor itself is ok (determined by the measurement in step 1),
the fault is caused by the wiring.
3. If you cannot detect a fault in steps 1 - 2, the fault is caused by the ADIC. In this case, the ADIC must be replaced.

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ADIC - 20 Signal from pressure sensor B3 faulty (line interrupted or

shorted to +12V)
Cause:
The signal from pressure sensor B3 (reservoir pressure for compressed air brake of trailer) is routed to the ADIC. The
sensor’s resistance ranges from 10 ohms at 0 bar to approx. 184 ohms at 10 bar.
If the ADIC detects a resistance value > 9830 ohms or a signal voltage > 4.9V, a fault has occurred.
The fault code is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. The pressure sensor is defective.
2. The wiring between pressure sensor and ADIC has a contact fault or is interrupted or shorted to +12V.
3. The ADIC is defective.
Remedy:
1. Remove the plug from pressure sensor B3 and check the resistance values of the pressure sensor:

Pressure in bar Resistance in ohms

0 10

2 52

4 88

6 124

8 155

10 184

2. Disconnect plugs CN3 and CN1 from the ADIC. Measure the voltage between the following lines (CN3 PIN15
(signal) against CN1 PIN22 (GND - sensor). If a voltage is present here, the fault is caused by the wiring.
3. Measure the resistance between the following lines (CN3 PIN15 (signal) against CN1 PIN22 (GND - sensor). If
the value is > 184 ohms and if the sensor itself is ok (determined by the measurement in step 1), the fault is
caused by the wiring.
4. If you cannot detect a fault in steps 1 to 2, the fault is caused by the ADIC. In this case, the ADIC must be replaced.

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ADIC - 250 CAN bus OFF up to DBD100000

Cause:
Data transfer between ADIC and vehicle bus does not function.
The ADIC has not transmitted a message correctly or the CAN wiring between ADIC and vehicle bus is faulty.

The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. The supply to the ADIC is faulty.
2. Interruption or contact fault on the CAN BUS (vehicle bus), e.g. in the line to the ADIC.
3. Conductive connection or short-circuit between the data lines (terminating resistors excluded) or to other lines
(insulation fault, dirt or moisture between plug-in contacts).
4. Terminating resistor is defective.
5. The screening of the CAN wiring is faulty.
6. The ADIC is defective.
Remedy:
Use the "CONTROL modulE status" Service Tool to check whether other users of the vehicle bus are also offline.
1. Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine again and check whe-
ther fault 250 is active again.
If fault ADIC 250 is active again or if other bus users on the vehicle bus are signalling faults in connection with
the CAN bus, check the CAN bus fuses.
a) If all fuses are ok, go to step 2.
b) Replace defective fuses. Then turn the ignition switch to the ON position. If faults are active again, go to step 2.
2. Continue fault diagnostics, starting with a quick check of the "Vehicle bus status" (steps b and c).
a) Detach the plug of Service Tool DPA from diagnosis socket X9/17. Use switch S31 to select the vehicle bus
(turn switch S31 to upper position). Turn ignition switch to ON position.
b) Check voltages - CAN H and CAN L at diagnosis socket (X9/17con).
PINC (CANH) and PIND (CANL) against PINA (GND).
If the voltages are in the specified range, you can assume that the data lines are neither shorted to GND (supply
or screening), nor to a plus supply or to plus 1, plus 2 or plus 3 (12 V screening). Go to step c.
c) Check resistances - CAN H against CAN L at diagnosis socket (X9/17con).
PINC (CANH) and PIND (CANL) (to do so turn ignition switch to OFF position).
If the resistance considerably deviates from the setpoint when CANH is measured against CANL, the terminating
resistors must be checked one by one (see step 4) and the CAN wiring must be checked for interruptions or short-
circuits (see steps 3b and 3c).
d) Check the supply (12V) to the ADIC.
e) Check the voltages CANH (yellow) and CANL (green) at the ADIC, plug CN3 (setpoints see step 2b).
Turn ignition switch to ON position. PIN26 (CANH, yellow) and PIN25 (CANL, green) against (GND).
f) Check the screening of the data lines:
Red line (12V) against black line (GND).

NOTE: The screening and the data lines are twisted together. It ends freely in front of the ADIC. It is therefore not
routed up to the ADIC.

If the power supply, the voltage values of CANH and CANL at plug CN3 of the ADIC and the screening are ok,
the ADIC must be replaced.
3. Voltages - CANH and CANL at the ADIC not ok: Carry out a continuity check at the data lines.
a) Disconnect plug CN3 from the ADIC, plug X70 from the EEM2 and plug X10/14. Use an ohmmeter to check
the line from one plug to the next (setpoint < 1 ohm).
If the resistance is > 1 ohm, check the line, plug-in contacts and crimp connections and repair or replace them if
necessary.
b) Short-circuit check between the data lines:
At plug X10/14, connect an ohmmeter between two pins at a time:
The lines must be interrupted relative to each other (display = infinite).
If an unintended electrical connection is established between the lines: Repair the wiring or replace single lines
or the cable harness.

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4. Check the terminating resistors (for configuration see diagram of CAN bus).
On the vehicle bus, one terminating resistor is integrated in motor control unit EEM2 and another terminating re-
sistor is integrated in plug X3/10. (Setpoint of a resistor: 120 ohms).
a) If the data lines do not have any contact faults on the one hand, and, one the other hand, are not shorted to
each other, and if both terminating resistors are ok, the resistance of the two data lines relative to each other
(CANH against CANL) must be 60 ohms. Check the resistance at the following measuring points:
Diagnosis socket X9/17 and plug CN3 on the ADIC. If the setpoint is not met, check the terminating resistors one
by one. Go to step b.
b) Individual check of the terminating resistors:
Turn ignition switch to OFF position. Disconnect plug X3/10. Check resistance between PINA and PINB Setpoint
120 ohms. At the plug part of the cable harness also check the resistance between PINA and PINB: Setpoint
120 ohms.
If the setpoint of approx. 120 ohms is also reached with this measurement, the terminating resistor in the EEM
and the lines CANH and CANL between the terminating resistors are ok. If the resistance considerably deviates
from the setpoint, the terminating resistor in the EEM and each data line must be checked separately.
Detach plug X70 from the EEM. Check the terminating resistance between PIN18 (CANH) and PIN42 (CANL) at
the con EEM. Setpoint 120 ohms.
5. Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start engine and check that fault is no
longer active.

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ADIC - 250 CAN bus OFF from DBD100001

Cause:
Data transfer between ADIC and vehicle bus does not function.
The ADIC has not transmitted a message correctly or the CAN wiring between ADIC and vehicle bus is faulty.

The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. The supply to the ADIC is faulty.
2. Interruption or contact fault on the CAN BUS (vehicle bus), e.g. in the line to the ADIC.
3. Conductive connection or short-circuit between the data lines (terminating resistors excluded) or to other lines
(insulation fault, dirt or moisture between plug-in contacts).
4. Terminating resistor is defective.
5. The ADIC is defective.
Remedy:
Use the "CONTROL modulE status" Service Tool to check whether other users of the vehicle bus are also offline.
1. Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine again and check whe-
ther fault 250 is active again.
If fault ADIC 250 is active again or if other bus users on the vehicle bus are signalling faults in connection with
the CAN bus, check the CAN bus fuses.
a) If all fuses are ok, go to step 2.
b) Replace defective fuses. Then turn the ignition switch to the ON position. If faults are active again, go to step 2.
2. Continue fault diagnostics, starting with a quick check of the "Vehicle bus status" (steps b and c).
a) Detach the plug of Service Tool DPA from diagnosis socket X9/17. Turn ignition switch to ON position.
b) Check voltages - CAN H and CAN L at diagnosis socket (X9/17 con).
PINC (CANH) and PIND (CANL) against PINA (GND).
If the voltages are in the specified range, you can assume that the data lines are neither shorted to GND, nor to
a plus supply. Go to step c.
c) Check resistances - CAN H against CAN L at diagnosis socket (X9/17 con).
PINC (CANH) and PIND (CANL) (to do so turn ignition switch to OFF position).
If the resistance considerably deviates from the setpoint when CANH is measured against CANL, the terminating
resistors must be checked one by one (see step 4) and the CAN wiring must be checked for interruptions or short-
circuits (see steps 3b and 3c).
d) Check the supply (12V) to the ADIC.
e) Check the voltages CAN H (yellow) and CAN L(green) at the ADIC, plug CN3 (setpoints see step 2b).
Turn ignition switch to ON position. PIN26 (CANH, yellow) and PIN25 (CANL, green) against (GND).

If the power supply, the voltage values of CANH and CANL at plug CN3 of the ADIC are ok, the ADIC must be
replaced.
3. Voltages - CANH and CANL at the ADIC not ok: Carry out a continuity check at the data lines.
a) Disconnect plug CN3 from the ADIC, plug X89/1 from the EEM3 and plug X10/14. Use an ohmmeter to check
the line from one plug to the next (setpoint < 1 ohm).
If the resistance is > 1 ohm, check the line, plug-in contacts and crimp connections and repair or replace them if
necessary.
b) Short-circuit check between the data lines:
At plug X10/14, connect an ohmmeter between two pins at a time:
The lines must be interrupted relative to each other (display = infinite).
If an unintended electrical connection is established between the lines: Repair the wiring or replace single lines
or the cable harness.
4. Check the terminating resistors (for configuration see diagram of CAN bus).
On the vehicle bus, one terminating resistor is integrated in motor control unit EEM3 and another terminating re-
sistor is integrated in plug X3/10. (Setpoint of a resistor: 120 ohms).
a) If the data lines do not have any contact faults on the one hand, and, one the other hand, are not shorted to
each other, and if both terminating resistors are ok, the resistance of the two data lines relative to each other
(CANH against CANL) must be 60 ohms. Check the resistance at the following measuring points:
Diagnosis socket X9/17 and plug CN3 on the ADIC. If the setpoint is not met, check the terminating resistors one
by one. Go to step b.

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b) Individual check of the terminating resistors:
Turn ignition switch to OFF position. Disconnect plug X3/10. Check resistance between PINA and PINB:
Setpoint 120 ohms. At the plug part of the cable harness also check the resistance between PINA and PINB:
Setpoint 120 ohms.
If the setpoint of approx. 120 ohms is also reached with this measurement, the terminating resistor in the EEM
and the lines CANH and CANL between the terminating resistors are ok. If the resistance considerably deviates
from the setpoint, the terminating resistor in the EEM and each data line must be checked separately.
Detach plug X89/1 from the EEM3. Check the terminating resistance between PIN35 (CANH) and PIN34 (CANL)
at the con EEM3. Setpoint 120 ohms.
5. Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start engine and check that fault is no
longer active.

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ICU - 2 CAN bus OFF up to DBD100000

Cause:
The display (ICU) has not sent a message correctly.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. The supply to the ICU is faulty.
2. CANH or CANL is shorted to plus or GND.
3. Short-circuit between CANH and CANL.
4. A terminating resistor in the CAN bus wiring is defective.
5. The screening is faulty.
6. Temporary electromagnetic interference
7. The display (ICU) is defective.
Remedy:
Use Service Tool "CONTROL module status" to check whether other bus users are also offline. If this is the case,
continue fault diagnostics as follows:
1. Cancel fault. Turn ignition switch to OFF position, turn back to ON position after min. 5 seconds. If fault 2 is not
displayed any more, the fault was perhaps caused by temporary electromagnetic interference.
If fault 2 is active again, continue fault diagnostics as follows:
2. Check fuses F93 (A14) 5A and F45 (A12) 5A. Repeat test step 1. If fault 2 is active again, continue fault diagno-
stics as follows:
3. Disconnect plug X14/14. Cancel fault. Turn ignition switch to OFF position, turn back to ON position after min. 5
seconds. If fault 2 is no longer displayed, the fault has probably occurred in the section between plug X14/14 and
EEM2, or in the plug X10/14, the weld points ADIC or KEY PAD`S or in the plug X23/1. There could also be an
internal fault in the ICU. Continue fault diagnostics as follows:
4. a) Disconnect the plug of Service Tool DPA from diagnosis socket X9/17. Use switch S31 to select the vehicle
bus (turn switch S31 to upper position). Turn ignition switch to ON position.
b) Check voltages - CAN H and CAN L at diagnosis socket (X9/17 con pin).
5. Check the resistance values - CAN H against CAN L at diagnosis socket (X9/17 con pin). If the setpoints are not
met, check the resistance values - CANH against CANL at the EEM2 and in plug X3/10. If the terminating resi-
stors are ok, go to steps 6 and 7.
6. Check the CAN bus line from X3/10 PINA and PINB to the ICU (P8) plug P8/1 [DISP.] PIN3 and PIN4.
7. Check the CAN bus line from X70 PIN18 and PIN42 to the ICU, plug P8/2 PIN3 and PIN4.
NOTE: If you cannot detect a fault during the checks made in steps 4b to 7, there is an internal fault in the ICU.
Replace the ICU.

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ICU - 2 CAN bus OFF from DBD100001

Cause:
The display (ICU) has not sent a message correctly.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. The supply to the ICU is faulty.
2. CANH or CANL is shorted to plus or GND.
3. Short-circuit between CANH and CANL.
4. A terminating resistor in the CAN bus wiring is defective.
5. Temporary electromagnetic interference
6. The display (ICU) is defective.
Remedy:
Use Service Tool "CONTROL module status" to check whether other bus users are also offline. If this is the case,
continue fault diagnostics as follows:
1. Cancel fault. Turn ignition switch to OFF position, turn back to ON position after min. 5 seconds. If fault 2 is not
displayed any more, the fault was perhaps caused by temporary electromagnetic interference.
If fault 2 is active again, continue fault diagnostics as follows:
2. Check fuses F212 (A14) 5A and F45 (A12) 5A. Repeat test step 1. If fault 2 is active again, continue fault diagno-
stics as follows:
3. Disconnect plug X14/14. Cancel fault. Turn ignition switch to OFF position, turn back to ON position after min. 5
seconds. If fault 2 is no longer displayed, the fault has probably occurred in the section between plug X14/14 and
EEM3, or in the plug X10/14, the weld points ADIC or KEY PAD`S or in the plug X10/18. There could also be an
internal fault in the ICU. Continue fault diagnostics as follows:
4. a) Disconnect the plug of Service Tool DPA from diagnosis socket X9/17. Turn ignition switch to ON position.
b) Check voltages - CAN H and CAN L at diagnosis socket (X9/17 con pin).
5. Check the resistance values - CAN H against CAN L at diagnosis socket (X9/17 con pin). If the setpoints are not
met, check the resistance values - CANH against CANL at the EEM3 and in plug X3/10. If the terminating resi-
stors are ok, go to steps 6 and 7.
6. Check the CAN bus line from X3/10 PINA and PINB to the ICU (P8) plug P8/1 [DISP.] PIN3 and PIN4.
7. Check the CAN bus line from X89/1 PIN35 and PIN34 to the ICU, plug P8/2 PIN3 and PIN4.
NOTE: If you cannot detect a fault during the checks made in steps 4b to 7, there is an internal fault in the ICU.
Replace the ICU.

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COMPONENTS SUMMARY
A1 ADIC ................................................................................................................................................. Fig. 1
A2 EEM2 control unit up to DBD100000 ................................................................................................ Fig. 2
A3 EEM3 control unit from DBD100001................................................................................................. Fig. 3
B2/1 Sensor for tank content, left .............................................................................................................. Fig. 4
B3 Sensor for compressed air................................................................................................................ Fig. 5
CN1 Plug connection, ADIC...................................................................................................................... Fig. 6
CN3 Plug connection, ADIC...................................................................................................................... Fig. 7
P8 ICU ................................................................................................................................................... Fig. 1
P8 Plug connection, ICU ........................................................................................................................ Fig. 8
P8/1 Plug connection, ICU CAN [DISP] .................................................................................................... Fig. 9
P8/2 Plug connection, ICU CAN ............................................................................................................... Fig. 8
S31 Changeover switch for CAN SGR/FMGR up to DBD100000 ......................................................... Fig. 10
X3/10 Plug connection, terminal resistance ...............................................................................................Fig. 11
X9/17 Socket for diagnosis service tool .................................................................................................... Fig. 12
X10/14 Plug connection, instruments wiring harness - supply for roof wiring harness [14] ........................ Fig. 13
X10/18 Plug connection, instruments wiring harness -
engine wiring harness [INSTR] from DBD100001 .......................................................................... Fig. 14
X14/14 Plug connection, roof supply [14].................................................................................................... Fig. 15
X23/1 Plug connection, instruments wiring harness - engine wiring harness up to DBD100000.............. Fig. 16
X70 Plug connection, EEM2 engine control unit up to DBD100000 ...................................................... Fig. 17
X89/1 Plug connection, engine - EEM3 engine control unit wiring harness from DBD100001 ................. Fig. 18

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Fig. 1 Fig. 5 up to DBD100000

Fig. 2 up to DBD100000 Fig. 5 from DBD100001

Fig. 3 from DBD100001 Fig. 6 up to DBD100000

Fig. 4 Fig. 6 from DBD100001

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Fig. 7 up to DBD100000 Fig. 9 from DBD100001

Fig. 7 from DBD100001 Fig. 10 up to DBD100000

Fig. 8 Fig. 11

Fig. 9 up to DBD100000 Fig. 12 up to DBD100000

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Fig. 12 from DBD100001 Fig. 13 from DBD100001

Fig. 13 up to DBD100000

Fig. 14 from DBD100001

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Fig. 15 up to DBD100000 Fig. 16 up to DBD100000

Fig. 15 from DBD100001 Fig. 17 up to DBD100000

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Fig. 18 from DBD100001

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FUNCTIONAL SCHEMATIC DIAGRAM FOR ADIC UP TO DBD100000

A14 A12
F93 5A F6 5A F29 10A
+30 +15/1 +15/2
A2 EEM2 31

X20/1 8 X18/1 11 X24/1 16 X24/1 4

X23/1
A4 FMGR A60 ECCU2
Q

CN1 26 16 24 23
A1 ADIC
Supply
A4/3 17 18 CN1a 15 16
X70 CN3
CAN H Pilot lamps and displays controlled
18 26
CAN L via CAN BUS
42 25
X6/11 X6/8 X29
Pilot lamps and displays 5 5 6
CN1 Speed signal
Generator D+ CN2 6 6 7
25 Starter switch position ON = 0.7V transmission 14 km/h = 504 Hz
16 1 1 2
Engine ON = 12V (Light OFF) Radar screen 14 km/h = 504 Hz
A61 A12 CN3 15 2 2 1
X12/20 X4/45 PTO shaft speed 1000 rpm = 100 Hz
18 High beam ON = 12V 14 3 3 3
11 3 Button transport 12V, button control 0V
17 4 4 4
X24/1 CN1
5 15 Lighting ON = 12V

X4/52 X4/51 2 A1 ADIC

5 Turn signal left
3 4 A2 EEM2
S50 A4 FMGR
4 3 31 6 Turn signal right A4/3 15-pin plug connection
p A12 Central print
A14 Engine print
CN3 A60 ECCU2
16 Turn signal trailer I A61 Electronics, suspended front axle
B2/1 Fuel tank level transmitter, left
S13 2 (11) X23/1 13 B3 Compressed air transmitter
Turn signal trailer II
1 M CN1 26-pin plug connection
X24/3 CN1 CN1a 26-pin plug connection
1 9 Suspended front axle OFF = 11.7 V, CN2 26-pin plug connection
13 CN3 26-pin plug connection
ACTIVE = 0V (Light ON)
S23 2 CN3 S3 Test switch for air filter
p 3 p >10 bar = 0 V S13 Control switch for brake fluid
S22 Control switch for coolant level
- (16) S23 Test switch for charge pressure 1bar
CN1 S50 Pushbutton for trailer brake valve
S3 + 7 Brake fluid level OK = 11 V X4/45 4-pin plug connection
p 12 DMD Feed pump pressure OK (>1 bar) = 12 V X4/51 4-pin plug connection
X23/1
X4/52 4-pin plug connection
J 11 Air filter OK = 11 V X6/8 6-pin plug connection
1
K 17 Coolant level OK = 12 V X6/10 6-pin plug connection
S22 2 X6/11 6-pin plug connection
X24/3 B3 X24/3 CN3 X12/20 12-pin plug connection
2 G 3 15 Compressed air 8.1 bar = 155 Ω X18/1 18-pin plug connection
X20/1 20-pin plug connection
(11) CN1 X23/1 23-pin plug connection
GND X24/1 24-pin plug connection
22 X24/3 24-pin plug connection
180 Ω X29 Standard signal socket,
X70 70-pin plug connection
95 Ω Fuel tank level (11) Ground point, engine device carrier
X6/10 B2/1 X6/10 CN3 (16) Ground point, starter
1 2 1 3 14 10 Ω

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FUNCTIONAL SCHEMATIC DIAGRAM FOR ADIC FROM DBD100001

A14 A12
F212 5A F6 5A F29 10A
+30 +15/1 +15/2
A3 EEM3 31

X10/3 6 X18/1 11 X24/1 16 X24/1 4

A4 FMGR A60 ECCU2

CN1 26 16 24 23
A1 ADIC
Supply
A4/3 17 18 CN1a 15 16
X89/1 CN3
CAN H Pilot lamps and displays controlled
35 26
CAN L via CAN BUS
34 25
X6/11 X6/8 X29
Pilot lamps and displays 5 5 6
CN1 Speed signal
Generator D+ CN2 6 6 7
25 Starter switch position ON = 0.7V transmission 14 km/h = 504 Hz
16 1 1 2
Engine ON = 12V (Light OFF) Radar screen 14 km/h = 504 Hz
A61 A12 CN3 15 2 2 1
X12/20 X4/45 PTO shaft speed 1000 min-1 = 100 Hz
18 High beam ON = 12V 14 3 3 3
11 3 Button transport 12V, button control 0V
17 4 4 4
X24/1 CN1
5 15 Lighting ON = 12V

X4/52 X4/51 2 A1 ADIC

5 Turn signal left
3 4 31 16 A3 EEM3
S50 A4 FMGR
4 3 31 6 Turn signal right A4/3 15-pin plug connection
p A12 Central print
A14 Engine print
CN3 A60 ECCU2
16 Turn signal trailer I A61 Electronics, suspended front axle
B2/1 Fuel tank level transmitter, left
S13 2 13 B3 Compressed air transmitter
Turn signal trailer II
1 CN1 26-pin plug connection
X24/3 CN1 CN1a 26-pin plug connection
1 9 Suspended front axle OFF = 11.7 V, CN2 26-pin plug connection
13 CN3 26-pin plug connection
ACTIVE = 0V (Light ON)
S23 2 CN3 S3 Test switch for air filter
p 3 p >10 bar = 0 V S13 Control switch for brake fluid
S22 Control switch for coolant level
- (11) S23 Test switch for charge pressure 1bar
CN1 S50 Pushbutton for trailer brake valve
S3 + 7 Brake fluid level OK = 11 V X4/45 4-pin plug connection
p 12 DMD Feed pump pressure OK. (>1 bar) = 12 V X4/51 4-pin plug connection
X10/18
X4/52 4-pin plug connection
6 11 Air filter OK = 11 V X6/8 6-pin plug connection
1
7 17 Coolant level OK = 12 V X6/10 6-pin plug connection
S22 2 X6/11 6-pin plug connection
X24/3 B3 X24/3 CN3 X10/3 10-pin plug connection
2 G 3 15 Compressed air 8.1 bar = 155 Ω X10/18 10-pin plug connection
X12/20 12-pin plug connection
CN1 X18/1 18-pin plug connection
GND X24/1 24-pin plug connection
22 X24/3 24-pin plug connection
180 Ω X29 Standard signal socket
X89/1 89-pin plug connection
95 Ω Fuel tank level (11) Ground point, engine component carrier, rear
X6/10 B2/1 X6/10 CN3
1 2 1 3 14 10 Ω

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FAULTCODES ARU UP TO DBD094270

ARU - 1 Processor fault (register check) ............................................................................................................. 43
ARU - 2 Processor fault (flash memory) ............................................................................................................. 43
ARU - 5 Processor fault (data memory) .............................................................................................................. 44
ARU - 10 Acknowledgement message from AUX1 was not received correctly after reprogramming from 0 to 1 44
ARU - 11 Acknowledgement message from AUX2 was not received correctly after reprogramming from 0 to 2 45
ARU - 12 Acknowledgement message from AUX3 was not received correctly after reprogramming from 0 to 3 46
ARU - 13 Acknowledgement message from AUX4 was not received correctly after reprogramming from 0 to 4 47
ARU - 14 Acknowledgement message from AUX5 was not received correctly after reprogramming from 0 to 5 48
ARU - 20 Supply voltage too low (< 8V) ............................................................................................................. 49
ARU - 21 Supply voltage too high (>18V) ........................................................................................................... 50
ARU - 30 Signal from AUX stick with latch (AUX1) below valid range ................................................................ 51
ARU - 31 Signal from AUX stick with latch (AUX1) above valid range ............................................................... 52
ARU - 32 Signal from AUX stick without latch (AUX2) below valid range ........................................................... 53
ARU - 33 Signal from AUX stick without latch (AUX2) above valid range .......................................................... 54
ARU - 34 Signal from AUX stick (AUX3) below valid range ................................................................................ 55
ARU - 35 Signal from AUX stick (AUX3) above valid range ............................................................................... 56
ARU - 36 Signal from throttle lever below valid range ........................................................................................ 57
ARU - 37 Signal from throttle lever above valid range ........................................................................................ 58
ARU - 38 Signal voltage from Resume Cruise Control button below valid range ............................................... 59
ARU - 39 Signal voltage from Resume Cruise Control button above valid range ............................................... 60
ARU - 40 Signal voltage from + button below valid range .................................................................................. 61
ARU - 41 Signal voltage from + button above valid range .................................................................................. 62
ARU - 50 Signal from oil flow potentiometer 1 (AUX1) outside valid range ........................................................ 63
ARU - 52 Signal from oil flow potentiometer 2 (AUX2) outside valid range ........................................................ 64
ARU - 54 Signal from oil flow potentiometer 3 (AUX3) outside valid range ........................................................ 66
ARU - 56 Signal from oil flow potentiometer 4 (AUX4) outside valid range ........................................................ 67
ARU - 58 Signal from oil flow potentiometer 5 (AUX5) outside valid range ........................................................ 69
ARU - 71 CAN Bus OFF ..................................................................................................................................... 71
COMPONENTS SUMMARY ............................................................................................................................... 74
FUNCTIONAL SCHEMATIC DIAGRAM FOR REMOTE CONTROL VALVES ................................................... 79
FUNCTIONAL SCHEMATIC DIAGRAM FOR EEM2 .......................................................................................... 81
FUNCTIONAL SCHEMATIC DIAGRAM FOR FMGR - SGR .............................................................................. 83

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ARU - 1 Processor fault (register check)

Cause:
The processor's register appears to be defective.
The fault is stored and indicated by a warning triangle on the display.
Remedy:
Turn the ignition switch to the OFF position and then back to ON. The CAN module must be replaced if the fault is
activated again.
1. Remove the armrest:
Turn the ignition switch to the OFF position and remove the armrest.
Remove the lower armrestcover.
2. Replace the CAN module:
Unlock and disconnect plugs YB1 and YA1. Remove the ribbon cable connection.
Replace the CAN module, carefully tightening the four securing screws.
Check the plug-in contacts on the ribbon cable connection. Connect plugs YB1 and YA1 on the ribbon cable con-
nection paying attention to the housing profile. Secure both plugs.
3. Turn the ignition switch to the ON position and cancel the fault. Turn the ignition switch to the OFF position. After
waiting for at least 5 secs. turn the ignition switch to the ON position and check whether the fault is activated
again.
4. Attach the lower armrest cover. Fit the armrest.

ARU - 2 Processor fault (flash memory)

Cause:
Program memory fault: The program or memory could be defective.
The fault is stored and indicated by a warning triangle on the display.
Remedy:
Turn the ignition switch to the OFF position. Start the engine. (the number on the fault counter must have increased
by 1 if it is not already 13). If the same behaviour occurs again, then the CAN module in the armrest must be replaced.
1. Remove the armrest:
Turn the ignition switch to the OFF position and remove the armrest.
Remove the lower armrest cover.
2. Replace the CAN module:
Unlock and disconnect plugs YB1 and YA1. Remove the ribbon cable connection.
Replace the CAN module, carefully tightening the four securing screws.
Check the plug-in contacts on the ribbon cable connection. Connect plugs YB1 and YA1 on the ribbon cable con-
nection paying attention to the housing profile. Secure both plugs.
3. Turn the ignition switch to the ON position and cancel the fault. Turn the ignition switch to the OFF position. After
waiting for at least 5 secs. turn the ignition switch to the ON position and check whether the fault is activated
again.
4. Attach the lower armrest cover. Fit the armrest.

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ARU - 5 Processor fault (data memory)

Cause:
The processor's data memory appears to be defective.
The fault is stored and indicated by a warning triangle on the display.
Remedy:
Turn the ignition switch to the OFF position. Start the engine. (the number on the fault counter must have increased
by 1 if it is not already 13). If the same behaviour occurs again, then the CAN module in the armrest must be replaced.
1. Remove the armrest:
Turn the ignition switch to the OFF position and remove the armrest.
Remove the lower armrestcover.
2. Replace the CAN module:
Unlock and disconnect plugs YB1 and YA1. Remove the ribbon cable connection.
Replace the CAN module, carefully tightening the four securing screws.
Check the plug-in contacts on the ribbon cable connection. Connect plugs YB1 and YA1 on the ribbon cable con-
nection paying attention to the housing profile. Secure both plugs.
3. Turn the ignition switch to the ON position and cancel the fault. Turn the ignition switch to the OFF position. After
waiting for at least 5 secs. turn the ignition switch to the ON position and check whether the fault is activated
again.
4. Attach the lower armrest cover. Fit the armrest.

ARU - 10 Acknowledgement message from AUX1 was not received

correctly after reprogramming from 0 to 1
Cause:
The fault is stored and indicated by a warning triangle on the display.

Every AUX is assigned with a number (1 to 5) in the armrest.

The assignment (between 1 and 5) is included in the address of every message that is transmitted to all bus users
via the CAN BUS and thus to all AUX's as well. If an AUX is replaced by a "new" one, then this is normally assigned
with "0". After assembly, once the plug-in connection has been re-established and the ignition switch is turned to the
ON position, the number of the "previously installed" AUX is automatically assigned to the "newly installed" AUX (in
this case, No.1). The AUX then automatically sends an acknowledgement message (reply parameter) to the data bus.

If the acknowledgement message is not received correctly at the CAN module in the armrest, two further attempts are
automatically made before the fault is activated and stored.
Remedy:
1. Use the Service Tool menu function "CONFIGURATION OF THE AUXILIARY VALVES".

a) Check whether the "newly installed" AUX has sent the acknowledgement message to the data bus: If the as-
signed number of the "previously installed" AUX appears in the left-hand column, then the Service Tool has re-
ceived the acknowledgement message.
b) Check the number of AUX's at the data bus. The number of AUX's connected to the data bus (and installed in
the tractor) is indicated in the left-hand column of the Service Tool ("EXISTING NUMBER OF AUXILIARY VAL-
VES").
2. If the "newly installed" AUX is connected to the CAN bus, but the number of AUX's is not displayed in the left-
hand column on the Service Tool, then the data bus cabling between the previously installed AUX and the CAN
module in the armrest must be checked (see fault code ARU 71 and CAN BUS scheme).
3. If the fault is activated again even though the cabling is ok, then the following steps must be performed:
a) Replace the "newly installed" AUX with another one (connect it to the CAN BUS) and check repeatedly with
the Service Tool to see whether the assigned number of the "previously installed" AUX is displayed. If the number
is still not displayed, the CAN module in the armrest could be defective.
b) Replace the CAN module: (see fault code ARU 1, steps 1 to 4).
c) Repeat the check using the Service Tool.

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ARU - 11 Acknowledgement message from AUX2 was not received

correctly after reprogramming from 0 to 2
Cause:
The fault is stored and indicated by a warning triangle on the display.

Every AUX is assigned with a number (1 to 5) in the armrest.

The assignment (between 1 and 5) is included in the address of every message that is transmitted to all bus users
via the CAN BUS and thus to all AUX's as well. If an AUX is replaced by a "new" one, then this is normally assigned
with "0". After assembly, once the plug-in connection has been re-established and the ignition switch is turned to the
ON position, the number of the "previously installed" AUX is automatically assigned to the "newly installed" AUX (in
this case, No. 2). The AUX then automatically sends an acknowledgement message (reply parameter) to the data
bus.

If the acknowledgement message is not received correctly at the CAN module in the armrest, two further attempts are
automatically made before the fault is activated and stored.
Remedy:
1. Use the Service Tool menu function "CONFIGURATION OF THE AUXILIARY VALVES".

a) Check whether the "newly installed" AUX has sent the acknowledgement message to the data bus: If the as-
signed number of the "previously installed" AUX appears in the left-hand column, then the Service Tool has re-
ceived the acknowledgement message.
b) Check the number of AUX's at the data bus. The number of AUX's connected to the data bus (and installed in
the tractor) is indicated in the left-hand column of the Service Tool ("EXISTING NUMBER OF AUXILIARY VAL-
VES").
2. If the "newly installed" AUX is connected to the CAN bus, but the number of AUX's is not displayed in the left-
hand column on the Service Tool, then the data bus cabling between the previously installed AUX and the CAN
module in the armrest must be checked (see fault code ARU 71 and CAN BUS).
3. If the fault is activated again even though the cabling is ok, then the following steps must be performed:
a) Replace the "newly installed" AUX with another one (connect it to the CAN BUS) and check repeatedly with
the Service Tool to see whether the assigned number of the "previously installed" AUX is displayed. If the number
is still not displayed, the CAN module in the armrest could be defective.
b) Replace the CAN module: (see fault code ARU 1, steps 1 to 4).
c) Repeat the check using the Service Tool.

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ARU - 12 Acknowledgement message from AUX3 was not received

correctly after reprogramming from 0 to 3
Cause:
The fault is stored and indicated by a warning triangle on the display.

Every AUX is assigned with a number (1 to 5) in the armrest.

The assignment (between 1 and 5) is included in the address of every message that is transmitted to all bus users
via the CAN BUS and thus to all AUX's as well. If an AUX is replaced by a "new" one, then this is normally assigned
with "0". After assembly, once the plug-in connection has been re-established and the ignition switch is turned to the
ON position, the number of the "previously installed" AUX is automatically assigned to the "newly installed" AUX (in
this case, No. 3). The AUX then automatically sends an acknowledgement message (reply parameter) to the data
bus.

If the acknowledgement message is not received correctly at the CAN module in the armrest, two further attempts are
automatically made before the fault is activated and stored.
Remedy:
1. Use the Service Tool menu function "CONFIGURATION OF THE AUXILIARY VALVES".

a) Check whether the "newly installed" AUX has sent the acknowledgement message to the data bus: If the as-
signed number of the "previously installed" AUX appears in the left-hand column, then the Service Tool has re-
ceived the acknowledgement message.
b) Check the number of AUX's at the data bus. The number of AUX's connected to the data bus (and installed in
the tractor) is indicated in the left-hand column of the Service Tool ("EXISTING NUMBER OF AUXILIARY
VALVES").
2. If the "newly installed" AUX is connected to the CAN bus, but the number of AUX's is not displayed in the left-
hand column on the Service Tool, then the data bus cabling between the previously installed AUX and the CAN
module in the armrest must be checked (see fault code ARU 71 and CAN BUS).
3. If the fault is activated again even though the cabling is ok, then the following steps must be performed:
a) Replace the "newly installed" AUX with another one (connect it to the CAN BUS) and check repeatedly with
the Service Tool to see whether the assigned number of the "previously installed" AUX is displayed. If the number
is still not displayed, the CAN module in the armrest could be defective.
b) Replace the CAN module: (see fault code ARU 1, steps 1 to 4).
c) Repeat the check using the Service Tool.

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ARU - 13 Acknowledgement message from AUX4 was not received

correctly after reprogramming from 0 to 4
Cause:
The fault is stored and indicated by a warning triangle on the display.

Every AUX is assigned with a number (1 to 5) in the armrest.

The assignment (between 1 and 5) is included in the address of every message that is transmitted to all bus users
via the CAN BUS and thus to all AUX's as well. If an AUX is replaced by a "new" one, then this is normally assigned
with "0". After assembly, once the plug-in connection has been re-established and the ignition switch is turned to the
ON position, the number of the "previously installed" AUX is automatically assigned to the "newly installed" AUX (in
this case, No. 4). The AUX then automatically sends an acknowledgement message (reply parameter) to the data
bus.

If the acknowledgement message is not received correctly at the CAN module in the armrest, two further attempts are
automatically made before the fault is activated and stored.
Remedy:
1. Use the Service Tool menu function "CONFIGURATION OF THE AUXILIARY VALVES".

a) Check whether the "newly installed" AUX has sent the acknowledgement message to the data bus: If the as-
signed number of the "previously installed" AUX appears in the left-hand column, then the Service Tool has re-
ceived the acknowledgement message.
b) Check the number of AUX's at the data bus. The number of AUX's connected to the data bus (and installed in
the tractor) is indicated in the left-hand column of the Service Tool ("EXISTING NUMBER OF AUXILIARY
VALVES").
2. If the "newly installed" AUX is connected to the CAN bus, but the number of AUX's is not displayed in the left-
hand column on the Service Tool, then the data bus cabling between the previously installed AUX and the CAN
module in the armrest must be checked (see fault code ARU 71 and CAN BUS).
3. If the fault is activated again even though the cabling is ok, then the following steps must be performed:
a) Replace the "newly installed" AUX with another one (connect it to the CAN BUS) and check repeatedly with
the Service Tool to see whether the assigned number of the "previously installed" AUX is displayed. If the number
is still not displayed, the CAN module in the armrest could be defective.
b) Replace the CAN module: (see fault code ARU 1, steps 1 to 4).
c) Repeat the check using the Service Tool.

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ARU - 14 Acknowledgement message from AUX5 was not received

correctly after reprogramming from 0 to 5
Cause:
The fault is stored and indicated by a warning triangle on the display.

Every AUX is assigned with a number (1 to 5) in the armrest.

The assignment (between 1 and 5) is included in the address of every message that is transmitted to all bus users
via the CAN BUS and thus to all AUX's as well. If an AUX is replaced by a "new" one, then this is normally assigned
with "0". After assembly, once the plug-in connection has been re-established and the ignition switch is turned to the
ON position, the number of the "previously installed" AUX is automatically assigned to the "newly installed" AUX (in
this case, No. 5). The AUX then automatically sends an acknowledgement message (reply parameter) to the data
bus.

If the acknowledgement message is not received correctly at the CAN module in the armrest, two further attempts are
automatically made before the fault is activated and stored.
Remedy:
1. Use the Service Tool menu function "CONFIGURATION OF THE AUXILIARY VALVES".

a) Check whether the "newly installed" AUX has sent the acknowledgement message to the data bus: If the as-
signed number of the "previously installed" AUX appears in the left-hand column, then the Service Tool has re-
ceived the acknowledgement message.
b) Check the number of AUX's at the data bus. The number of AUX's connected to the data bus (and installed in
the tractor) is indicated in the left-hand column of the Service Tool ("EXISTING NUMBER OF AUXILIARY
VALVES").
2. If the "newly installed" AUX is connected to the CAN bus, but the number of AUX's is not displayed in the left-
hand column on the Service Tool, then the data bus cabling between the previously installed AUX and the CAN
module in the armrest must be checked (see fault code ARU 71 and CAN BUS).
3. If the fault is activated again even though the cabling is ok, then the following steps must be performed:
a) Replace the "newly installed" AUX with another one (connect it to the CAN BUS) and check repeatedly with
the Service Tool to see whether the assigned number of the "previously installed" AUX is displayed. If the number
is still not displayed, the CAN module in the armrest could be defective.
b) Replace the CAN module: (see fault code ARU 1, steps 1 to 4).
e) Repeat the check using the Service Tool.

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ARU - 20 Supply voltage too low (< 8V)

Cause:
The supply voltage of the CAN module is < 8V (12V nominal).
The fault is stored and indicated by a warning triangle on the display.

Possible causes:
1. Contact resistance at electrical connections too high:
a) Plug-in contacts, screwed / crimped connections oxidized.
b) Contacts loose, bent or pushed back (not engaged) in the plug housing.
c) The CAN module is defective.
2. Voltage drop too high during the starting procedure:
a) Battery charge is insufficient or the battery is defective.
b) Plug module in the armrest is defective (buffer capacity too small).
Remedy:
General:
Once the ignition switch is turned to the ON position, the CAN module is supplied with 12V (nominal) via the plug
module for fuse F20, 5A (15/1), on central print A12.
The voltage should be 12.5 to 14 V when the engine is running and the charging indicator has gone out.
In order to ensure a reliable supply to the CAN module under all operating conditions, the plug module is equipped
with the following safety components:
Safety diode V1/1, overload protection V1/2, capacities C1 and C2 as a buffer against short dips in the supply voltage
(caused by operating loads outside the armrest).

For voltage measurements, the ignition switch must be turned to the ON position.
1. Cancel the fault. Turn the ignition switch to the ON position.
a) If fault ARU 20 is activated again, go to step 2.
b) If fault ARU 20 is not activated, start the engine. If fault ARU 20 is activated again, go to step 2.
2. Check the supply voltage (12V nominal):

Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover.

a) Check the voltage between PIN9 (12V) and PIN8 (GND) on plug X28/1 of the plug module (at least 12V). If
there is no voltage, go to step b.
NOTE: When checking the voltage at plug X28/1, load the supply with a 12V 21W bulb (during operation there is an
additional load due to the switching of the front loader switch.
If a voltage of 12V is available, go to step c.

b) Check the supply voltage at plug X18/4:

Turn the ignition switch to the OFF position. Remove the lower right-hand covering in the cab.
Plug X18/4 PIN9 (at least 12V) to PIN10 (GND). If the voltage is available, rectify the fault in the cabling between
plug X18/4 and plug X28/1 on the plug module.
If the voltage is not available, rectify the fault in the cabling between fuse F20 and plug X18/4 with the help of the
circuit diagram.

c) Check the supply voltage at plug YB1 on the CAN module and on plug YA1 on the plug module (ribbon cable
connection):
PIN1 and PIN3 (12V) to PIN2 and PIN4 (GND).
If the voltage drop between plugs X28/1 and YA1 on the plug module is > 0.2V, check the continuity using an
ohmmeter (setpoint value < 1 ohm). Replace the faulty plug module. The same applies to the ribbon cable con-
nection.

d) If a supply voltage of 12V is available at plug YB1 on the CAN module, cancel the fault. Then turn the ignition
switch to the OFF position. After waiting for at least 5 secs., start the engine. If fault ARU 20 is activated again,
then the CAN module must be replaced (see fault code ARU 1, steps 1 to 4).

e) Refit the lower armrest cover. Fit the armrest. Start the engine and check that fault ARU 20 is no longer acti-
vated.

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ARU - 21 Supply voltage too high (>18V)

Cause:
The supply voltage is > 18VDC.
The fault is stored and indicated by a warning triangle on the display.

Possible causes:
1. The alternator voltage regulator is defective.
2. Ground connection between the alternator / battery and CAN module faulty.
3. CAN module defective.
Remedy:
With the engine running (charging indicator lamp has gone out), check the charge voltage of the alternator
(G2/2, G2/3, G2/2/2) and the battery voltage. The charge voltage should be 13.8 to 14.5 V at various engine speeds.
If the charge voltage is much higher, go to step 2.
1. If the charge voltage is ok, check the ground connection from the generator via the battery to the CAN module,
plug YB1, PIN1 and 3 (12V) to PIN2 and 4 (GND); repair if necessary. With the engine running (charging indicator
lamp has gone out), check the supply voltage at the CAN module, plug YB1, PIN1 and 3 (12V) to PIN2 and 4
(GND) (12.5 to 14.5 V). If the cabling and supply voltage at the CAN module are ok, but fault 21 is activated again
after starting the engine once again, then the CAN module must be replaced (see fault code ARU 1, steps 1 to 4).
2. If the charge voltage is not within the specified value limits, then the alternator voltage regulator must be replaced.
Then start the engine. When the charging indicator lamp has gone out, check the charge voltage at various engine
speeds and check whether fault 21 is still activated.

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ARU - 30 Signal from AUX stick with latch (AUX1) below valid range
Cause:
The signal voltage from the AUX stick B30 is < 0.2V.
The fault is stored and indicated by a warning triangle on the display.

The signal voltage must lie within a certain voltage range (0.2 to 4.8V) over the entire control range.

Possible causes:
1. Short-circuit between the signal line and ground (GND).
2. Contact fault or interruption in the signal line from the AUX stick via the plug module up to the CAN module (re-
sistance too high).
3. Contact fault in the supply line (5V) from the CAN module via the plug module up to the AUX stick (resistance too
high), thus voltage at AUX stick < 5V.
4. AUX stick defective (mechanical or electrical fault).
5. CAN module defective (e.g. load resistance for signal < 20 kohms).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 30 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"AUX1 RAISE / LOWER OIL FLOW SETPOINT" to check the functionality of the AUX stick.
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Carry out the following voltage measurements at the plug module, plug X28/5:
PIN1 (5V) to PIN3 (GND): Supply voltage approx. 5.0V (plug X28/5 disconnected; the AUX stick supply is thus
not on-load).
The AUX stick has a maximum power consumption of 10 mA.
Supply voltage approx. 5.0V (plug X28/5 connected).
PIN2 (signal) to PIN3 (GND): The signal voltage must change from 0.2 to 4.8V when the AUX stick is moved from
limit to limit (plug X28/5 connected).
Signal voltage between 2.33 and 2.67V (2.5V nominal), when the AUX stick B30 is in the Neutral position (plug
X28/5 connected).
If the supply voltage and the signal voltage correspond with the setpoints, then the AUX stick and the cabling bet-
ween the AUX stick and plug X28/5 on the plug module are ok. Go to step 5.
If the signal voltage at plug X28/5 PIN2 is < 0.2V, go to step 3.
3. Check the plug-in contacts and lines to the AUX stick. Detach PIN2 (signal) from the plug housing (it is thus not
on-load). Check the AUX stick signal voltage from detached PIN2 to PIN3 (GND). If the signal voltage is still
< 0.2V in this state, then the AUX stick must be replaced.
However, if the signal voltage is ok, the next step is to ensure that the signal line between plug X28/5 on the plug
module and plug YB1 on the CAN module does not make contact with other lines and does not have a contact
fault (faulty plug-in / crimped / soldered connection).
If this section of the signal line is ok and the signal voltage at plug X28/5 is ok with PIN2 detached, go to step 4.
4. Check the signal voltage at plug YB1 on the ribbon cable connection at the CAN module:
PIN37 (signal) to PIN39 and 40 (GND for "hall elements" such as AUX sticks, etc.).
Setpoint values as in step 2. If the measured values correspond with the setpoint values, then the CAN module
has a defect and must be replaced (see fault code ARU 1, steps 1 to 3).
If the signal voltage is < 0.2V, then the CAN module also has a defect and must be replaced (see fault code
ARU 1, steps 1 to 3).
5. Attach the lower armrest cover and fit the armrest.

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ARU - 31 Signal from AUX stick with latch (AUX1) above valid range
Cause:

The signal voltage from the AUX stick B30 is > 4.8 V.
The fault is stored and indicated by a warning triangle on the display.

The signal voltage must lie within a certain voltage range (0.2 to 4.8 V) over the entire control range.

Possible causes:
1. Short-circuit between the signal line and supply voltage (5V).
2. Contact fault or interruption in the ground line (GND) from the CAN module via the plug module up to the AUX
stick (resistance too high).
3. AUX stick defective (mechanical or electrical fault).
4. Supply voltage < 5V > 12V (CAN module defective).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 31 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"AUX1 RAISE / LOWER OIL FLOW SETPOINT" to check the functionality of the AUX stick.
1. Turn the ignition switch to the OFF position. Remove the armrest and the lower cover.
2. Check the supply voltage (setpoint value approx. 5.0V):
At the plug module, plug X28/5 PIN1 (5V) to PIN3 (GND).
At CAN module, plug YB1 PIN6 and 8 (5V) to PIN2 and 4 (GND).
3. Check the signal voltage (setpoint value from 0.2 to 4.8V; move the AUX stick when doing so). Signal voltage
between 2.33 and 2.67V (2.5V nominal) when the AUX stick B30 is in the Neutral position:
At the plug module, plug X28/5 PIN2 (signal) to PIN3 (GND).
At CAN module, plug YB1 PIN37 (signal) to PIN39 and 40 (GND for "hall elements" such as AUX sticks, etc.).
If the signal voltage is > 4.8V, go to step 5.
If the supply voltage and the signal voltage correspond with the setpoints, then the CAN module is defective. Re-
place the CAN module (see fault code ARU 1, steps 1 and 2).
4. Supply voltage > 5V, <12V):
Turn the ignition switch to the OFF position. Check the ground line (GND) between plug X28/5 and plug YB1.
Rectify any contact faults that are found or replace the units.
If the ground line is ok, then the CAN module must be replaced (see fault code ARU 1, steps 1 and 2).
5. Disconnect plug X28/5 at the plug module. Cancel fault 31. Turn the ignition switch to the ON position.
If fault 31 is no longer activated, check plug X28/5 and the cabling to the AUX stick.
If the check does not reveal a fault, then the AUX stick must be replaced.
6. Attach the lower armrest cover and fit the armrest.

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 4011-53

ARU - 32 Signal from AUX stick without latch (AUX2) below valid
range
Cause:
The signal voltage from the AUX stick B31 is < 0.2V.
The fault is stored and indicated by a warning triangle on the display.

The signal voltage must lie within a certain voltage range (0.2 to 4.8V) over the entire control range.

Possible causes:
1. Short-circuit between the signal line and ground (GND).
2. Contact fault or interruption in the signal line from the AUX stick via the plug module up to the CAN module (re-
sistance too high).
3. Contact fault in the supply line (5V) from the CAN module via the plug module up to the AUX stick (resistance too
high), thus voltage at AUX stick < 5V.
4. AUX stick defective (mechanical or electrical fault).
5. CAN module defective (e.g. load resistance for signal < 20 kohms).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 32 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"AUX2 RAISE / LOWER OIL FLOW SETPOINT" to check the functionality of the AUX stick.
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Carry out the following voltage measurements at plug module, plug X28/5:
PIN5 (5V) to PIN7 (GND): Supply voltage approx. 5.0V (plug X28/5 disconnected; the AUX stick supply is thus
not on-load).
The AUX stick has a maximum power consumption of 10 mA.
Supply voltage approx. 5.0V (plug X28/5 connected).
PIN6 (signal) to PIN7 (GND): The signal voltage must change from 0.2 to 4.8V when the AUX stick is moved from
limit to limit (plug X28/5 connected).
Signal voltage between 2.33 and 2.67V (2.5V nominal), when the AUX stick B31 is in the Neutral position (plug
X28/5 connected).
If the supply voltage and the signal voltage correspond with the setpoints, then the AUX stick and the cabling bet-
ween the AUX stick and plug X28/5 on the plug module are ok. Go to step 5.
If the signal voltage at plug X28/5 PIN6 is < 0.2V, go to step 3.
3. Check the plug-in contacts and lines to the AUX stick. Detach PIN6 (signal) from the plug housing (it is thus not
on-load). Check the AUX stick signal voltage from detached PIN6 to PIN7 (GND). If the signal voltage is still
< 0.2V in this state, then the AUX stick must be replaced.
However, if the signal voltage is ok, the next step is to ensure that the signal line between plug X28/5 on the plug
module and plug YB1 on the CAN module does not make contact with other lines and does not have a contact
fault (faulty plug-in / crimped / soldered connection).
If this section of the signal line is ok and the signal voltage at plug X28/5 is ok with PIN6 detached, go to step 4.
4. Check the signal voltage at plug YB1 on the CAN module:
PIN29 (signal) to PIN39 and 40 (GND for "hall elements" such as AUX sticks, etc.).
Setpoint values as in step 2. If the measured values correspond with the setpoint values, then the CAN module
has a defect and must be replaced (see fault code ARU 1, steps 1 to 3).
If the signal voltage is < 0.2V, then the CAN module also has a defect and must be replaced (see fault code
ARU 1, steps 1 to 3).
5. Attach the lower armrest cover and fit the armrest.

Sva 6-52632 EN Edition 06-2006

4011-54

ARU - 33 Signal from AUX stick without latch (AUX2) above valid
range
Cause:

The signal voltage from the AUX stick B31 is > 4.8 V.
The fault is stored and indicated by a warning triangle on the display.

The signal voltage must lie within a certain voltage range (0.2 to 4.8V) over the entire control range.

Possible causes:
1. Short-circuit between the signal line and supply voltage (5V).
2. Contact fault or interruption in the ground line (GND) from the CAN module via the plug module up to the AUX
stick (resistance too high).
3. AUX stick defective (mechanical or electrical fault).
4. Supply voltage < 5V > 12V (CAN module defective).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 33 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"AUX2 RAISE / LOWER OIL FLOW SETPOINT" to check the functionality of the AUX stick.
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover.
2. Check the supply voltage (setpoint value approx. 5.0V):
At the plug module, plug X28/5 PIN5 (5V) to PIN7 (GND).
At the CAN module, plug YB1 PIN6 and 8 (5V) to PIN2 and 4 (GND).
3. Check the signal voltage (setpoint value from 0.2 to 4.8V; move the AUX stick when doing so). Signal voltage
between 2.33 and 2.67V (2.5V nominal) when the AUX stick B31 is in the Neutral position:
At the plug module, plug X28/5 PIN6 (signal) to PIN7 (GND).
At the CAN module, plug YB1 PIN29 (signal) to PIN39 and 40 (GND for "hall elements" such as AUX sticks, etc.).
If the signal voltage is > 4.8V, go to step 5.
If the supply voltage and the signal voltage correspond with the setpoints, then the CAN module is defective. Re-
place the CAN module (see fault code ARU 1, steps 1 and 2).
4. Supply voltage > 5V, <12V):
Turn the ignition switch to the OFF position. Check the ground line (GND) between plug X28/5 and plug YB1.
Rectify any contact faults that are found or replace the units.
If the ground line is ok, then the CAN module must be replaced (see fault code ARU 1, steps 1 and 2).
5. Disconnect plug X28/5 at the plug module. Cancel fault 33. Turn the ignition switch to the ON position.
If fault 33 is no longer activated, check plug X28/5 and the cabling to the AUX stick.
If the check does not reveal a fault, then the AUX stick must be replaced.
6. Attach the lower armrest cover and fit the armrest.

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 4011-55

ARU - 34 Signal from AUX stick (AUX3) below valid range

Cause:
The signal voltage from the AUX stick B52 is < 0.2V.
The fault is stored and indicated by a warning triangle on the display.

The signal voltage must lie within a certain voltage range (0.2 to 4.8V) over the entire control range.

Possible causes:
1. Short-circuit between the signal line and ground (GND).
2. Contact fault or interruption in the signal line from the AUX stick via the plug module up to the CAN module (re-
sistance too high).
3. Contact fault in the supply line (5V) from the CAN module via the plug module up to the AUX stick (resistance too
high), thus voltage at AUX stick < 5V.
4. AUX stick defective (mechanical or electrical fault).
5. CAN module defective (e.g. load resistance for signal < 20 kohms).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 34 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"AUX3 RAISE / LOWER OIL FLOW SETPOINT" to check the functionality of the AUX stick.
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Carry out the following voltage measurements at the plug module, plug X28/4:
PIN1 (5V) to PIN4 (GND): Supply voltage approx. 5.0V (plug X28/4 disconnected; the AUX stick supply is thus
not on-load).
The AUX stick has a maximum power consumption of 10 mA.
Supply voltage approx. 5.0V (plug X28/4 connected).
PIN2 (signal) to PIN4 (GND): The signal voltage must change from 0.2 to 4.8V when the AUX stick is moved from
limit to limit (plug X28/4 connected).
Signal voltage between 2.33 and 2.67V (2.5V nominal), when the AUX stick B52 is in the Neutral position (plug
X28/4 connected).
If the supply voltage and the signal voltage correspond with the setpoints, then the AUX stick and the cabling bet-
ween the AUX stick and plug X28/4 on the plug module are ok. Go to step 5.
If the signal voltage at plug X28/4 PIN2 is < 0.2V, go to step 3.
3. Check the plug-in contacts and lines to the AUX stick. Detach PIN2 (signal) from the plug housing (it is thus not
on-load). Check the AUX stick signal voltage from detached PIN2 to PIN4 (GND). If the signal voltage is still
< 0.2V in this state, then the AUX stick must be replaced.
However, if the signal voltage is ok, the next step is to ensure that the signal line between plug X28/4 on the plug
module and plug YB1 on the CAN module does not make contact with other lines and does not have a contact
fault (faulty plug-in / crimped / soldered connection).
If this section of the signal line is ok and the signal voltage at plug X28/4 is ok with PIN2 detached, go to step 4.
4. Check the signal voltage at plug YB1 on the CAN module:
PIN27 (signal) to PIN39 and 40 (GND for "hall elements" such as AUX sticks, etc.).
Setpoint values as in step 2. If the measured values correspond with the setpoint values, then the CAN module
has a defect and must be replaced (see fault code ARU 1, steps 1 to 3).
If the signal voltage is < 0.2V, then the CAN module also has a defect and must be replaced (see fault code
ARU 1, steps 1 to 3).
5. Attach the lower armrest cover and fit the armrest.

Sva 6-52632 EN Edition 06-2006

4011-56

ARU - 35 Signal from AUX stick (AUX3) above valid range

Cause:

The signal voltage from the AUX stick B52 is > 4.8 V.
The fault is stored and indicated by a warning triangle on the display.

The signal voltage must lie within a certain voltage range (0.2 to 4.8V) over the entire control range.

Possible causes:
1. Short-circuit between the signal line and supply voltage (5V).
2. Contact fault or interruption in the ground line (GND) from the CAN module via the plug module up to the AUX
stick (resistance too high).
3. AUX stick defective (mechanical or electrical fault).
4. Supply voltage < 5V > 12V (CAN module defective).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 35 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"AUX3 RAISE / LOWER OIL FLOW SETPOINT" to check the functionality of the AUX stick.
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover.
2. Check the supply voltage (setpoint value approx. 5.0V):
At the plug module, plug X28/4 PIN1 (5V) to PIN4 (GND).
At the CAN module, plug YB1 PIN6 and 8 (5V) to PIN2 and 4 (GND).
3. Check the signal voltage (setpoint value from 0.2 to 4.8V; move the AUX stick when doing so). Signal voltage
between 2.33 and 2.67V (2.5V nominal) when the AUX stick B52 is in the Neutral position:
At the plug module, plug X28/4 PIN2 (signal) to PIN4 (GND).
At the CAN module, plug YB1 PIN27 (signal) to PIN39 and 40 (GND for "hall elements" such as AUX sticks, etc.).
If the signal voltage is > 4.8V, go to step 5.
If the supply voltage and the signal voltage correspond with the setpoints, then the CAN module is defective. Re-
place the CAN module (see fault code ARU 1, steps 1 and 2).
4. Supply voltage > 5V, <12V):
Turn the ignition switch to the OFF position. Check the ground line (GND) between plug X28/4 and plug YB1.
Rectify any contact faults that are found or replace the units.
If the ground line is ok, then the CAN module must be replaced (see fault code ARU 1, steps 1 and 2).
5. Disconnect plug X28/4 at the plug module. Cancel fault 35. Turn the ignition switch to the ON position.
If fault 35 is no longer activated, check plug X28/4 and the cabling to the AUX stick.
If the check does not reveal a fault, then the AUX stick must be replaced.
6. Attach the lower armrest cover and fit the armrest.

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 4011-57

ARU - 36 Signal from throttle lever below valid range

Cause:
The signal voltage from the throttle lever B28 is < 0.2V.
The fault is stored and indicated by a warning triangle on the display.

The signal voltage must lie within a certain voltage range (0.2 to 4.8V) over the entire control range.

Possible causes:
1. Short-circuit between the signal line and ground (GND).
2. Contact fault or interruption in the signal line from the throttle lever via the plug module up to the CAN module
(resistance too high).
3. Contact fault in the supply line (5V) from the CAN module via the plug module up to the throttle lever (resistance
too high), thus voltage at the throttle lever < 5V.
4. Throttle lever defective (mechanical or electrical fault).
5. CAN module defective (e.g. load resistance for signal < 4.5k ohms).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 36 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"THROTTLE LEVER" to check the functionality of the throttle lever.
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Carry out the following voltage measurements at the plug module, plug X28/3:
PIN1 (5V) to PIN4 (GND): Supply voltage approx. 5.0V (plug X28/3 disconnected; the throttle lever supply is thus
not on-load).
The throttle lever has a maximum power consumption of 15 mA.
Supply voltage approx. 5.0V (plug X28/3 connected).
PIN2 (signal) to PIN4 (GND): The signal voltage must not be < 0.2V and > 4.8V when the throttle lever is moved
from limit to limit (plug X28/3 connected).
If the supply voltage and the signal voltage correspond with the setpoints, then the throttle lever and the cabling
between the throttle lever and plug X28/3 on the plug module is ok. Go to step 5.
If the signal voltage at plug X28/3 PIN2 is < 0.2V, go to step 3.
3. Check the plug-in contacts and lines to the throttle lever. Detach PIN2 (signal) from the plug housing (it is thus
not on-load). Check the throttle lever signal voltage from detached PIN2 to PIN4 (GND). If the signal voltage is
still < 0.2V in this state, then the throttle lever must be replaced.
However, if the signal voltage is ok, the next step is to ensure that the signal line between plug X28/3 on the plug
module and plug YB1 on the CAN module does not make contact with other lines and does not have a contact
fault (faulty plug-in / crimped / soldered connection).
If this section of the signal line is ok and the signal voltage at plug X28/3 is ok with PIN2 detached, go to step 4.
4. Check the signal voltage at plug YB1on the CAN module:
PIN25 (signal) to PIN39 and 40 (GND for "hall elements" such as throttle lever, etc.).
Setpoint values as in step 2. If the measured values correspond with the setpoint values, then the CAN module
has a defect and must be replaced (see fault code ARU 1, steps 1 to 3).
If the signal voltage is < 0.2V, then the CAN module also has a defect and must be replaced (see fault code
ARU 1, steps 1 to 3).
5. Attach the lower armrest cover and fit the armrest.

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4011-58

ARU - 37 Signal from throttle lever above valid range

Cause:
The signal voltage from the throttle lever B28 is > 4.8V.
The fault is stored and indicated by a warning triangle on the display.

The signal voltage must lie within a certain voltage range (0.2 to 4.8V) over the entire control range.

Possible causes:
1. Short-circuit between the signal line and supply voltage (5V).
2. Contact fault or interruption in the ground line (GND) from the CAN module via the plug module up to the throttle
lever (resistance too high).
3. Throttle lever defective (mechanical or electrical fault).
4. Supply voltage < 5V >12V (CAN module defective).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 37 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"THROTTLE LEVER" to check the functionality of the throttle lever.
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover.
2. Check the supply voltage (setpoint value approx. 5.0V):
At the plug module, plug X28/3 PIN1 (5V) to PIN4 (GND).
At the CAN module, plug YB1 PIN6 and 8 (5V) to PIN2 and 4 (GND).
3. Check the signal voltage (setpoint value from 0.2 to 4.8V; move the throttle lever B28 from limit to limit when doing
so):
At the plug module, plug X28/3 PIN2 (signal) to PIN4 (GND).
At the CAN module, plug YB1 PIN25 (signal) to PIN39 and 40 (GND for "hall elements" such as AUX sticks, etc.).
If the signal voltage is > 4.8V, go to step 5.
If the supply voltage and the signal voltage correspond with the setpoints, then the CAN module is defective. Re-
place the CAN module (see fault code ARU 1, steps 1 and 2).
4. Supply voltage > 5V, <12V):
Turn the ignition switch to the OFF position. Check the ground line (GND) between plug X28/3 and plug YB1.
Rectify any contact faults that are found or replace the units.
If the ground line is ok, then the CAN module must be replaced (see fault code ARU 1, steps 1 and 2).
5. Disconnect plug X28/3 at the plug module. Cancel fault 37. Turn the ignition switch to the ON position.
If fault 37 is no longer activated, check plug X28/3 and the cabling to the throttle lever.
If the check does not reveal a fault, then the throttle lever must be replaced.
6. Attach the lower armrest cover and fit the armrest.

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 4011-59

ARU - 38 Signal voltage from Resume Cruise Control button below

valid range
Cause:
The signal voltage from the Resume Cruise Control button S60/2 is < 0.2V.
The fault is stored and indicated by a warning triangle on the display.

The signal voltage must lie within a certain voltage range:

Cruise Control button not depressed: 0.2 - 2.3V (actual approx. 1V).
Cruise Control button depressed: 2.4 - 4.8V (actual approx. 4V).
The CAN module supplies a supply voltage of 5V for the pushbutton function on the multi-controller.
Possible causes:
1. Multi-controller defective
2. Plug module defective
3. Ribbon cable connection defective.
4. CAN module defective
Remedy:
Start the engine again and check whether the fault is activated again.
Use the Service Tool monitor:
"RESUME CRUISE CONTROL BUTTON" to check the pushbutton function.
If fault 38 is activated again, continue troubleshooting as follows:
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Check the supply voltage (5V):
Plug YB1, ribbon cable connection on the CAN module, PIN6 and PIN8 (5V) to PIN2 and PIN4 (GND).
Plug YA1, ribbon cable connection on the plug module, PIN6 and PIN8 to PIN2 and PIN4 (GND)
Plug X28/11 on the plug module, PIN1 (5V) to PIN9 (GND) and plug X21 on the print of the multi-controller II,
PIN1 (5V) to PIN2 (GND).
If a voltage of 5V is available at plug YB1, but not up to plug X21, then there is an interruption in between or a
poor line connection. Check the individual plugs and sections; replace faulty units. Go to step 3 when there is a
supply voltage of 5V at plug X21.
3. Check the signal voltage (from the keyboard up to the CAN module):
Plug X21 on the print of the multi-controller II, PIN11 to PIN2 (GND).
Plug X28/11 on the plug module, PIN11 to PIN9 (GND); plug YA1, ribbon cable connection on the plug module,
PIN13 to PIN2 and PIN4 (GND) and plug YB1, ribbon cable connection on the CAN module, PIN13 to PIN2 and
PIN4 (GND).
Button not depressed 0.2V - 2.3V; button depressed 2.4 - 4.8V. If the signal voltage is < 0.2V, go to step 4.
If the supply voltage and the signal voltage are in the specified range, then the CAN module must be replaced
(see fault code ARU 1, steps 1 and 2).
If the signal voltage at plug X28/11 PIN11 is ok, but < 0.2V at plug YB1, check the individual sections in between.
If the signal voltage at plug X28/11 is already < 0.2V, go to step 4.
4. Disconnect plug X28/11 and measure the resistance at the plug connection to multi-controller II (from PIN11 to
PIN1).
Button not depressed: approx. 8.2 kohms. Button depressed approx. 480 ohms.
If the setpoint values are attained, the button's resistor circuit is ok.
If the setpoint values are not attained, go to step 5.
5. Unscrew the screw on the grip housing on the multi-controller II. Carefully detach the keyboard from the grip hou-
sing. Disconnect plug X21 at the keyboard (14-pole) and measure the resistance at the connection on the key-
board (from PIN1 to PIN11):
a) Button not depressed, approx. 8.2 kohms.
b) Button depressed, approx. 480 ohms.
If the setpoint values are not attained, the fault is in the keyboard. Replace the keyboard. If the setpoint values
are attained, the fault in the line between plug X28/11 and plug X21 must be rectified or the line replaced.
If the resistance setpoint values are now attained at plug X28/11, reconnect the plug. Turn the ignition switch to
the ON position and check whether the signal voltage reaches the setpoint values at plug YB1 on the
CAN module.
Cancel fault 38 and check whether the fault is activated again.
6. Attach the lower armrest cover and fit the armrest.

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4011-60

ARU - 39 Signal voltage from Resume Cruise Control button above

valid range
Cause:
The signal voltage from the Resume Cruise Control button S60/2 is > 4.8V.
The fault is stored and indicated by a warning triangle on the display.

The signal voltage must lie within a certain voltage range:

Cruise Control button not depressed: 0.2 - 2.3V (actual approx. 1V).
Cruise Control button depressed: 2.4 - 4.8V (actual approx. 4V).
Possible causes:
1. Signal voltage too high due to a short-circuit to another signal in the armrest or to the 5V or 12V supply.
2. Fault in the resistor circuit on the print of the multi-controller II. Supply voltage to the keyboard too high (> 5V)
due to:
3. Faulty ground supply (GND) to the CAN module.
4. CAN module defective.
Remedy:
Start the engine again and check whether the fault is activated again.
Use the Service Tool monitor:
"RESUME CRUISE CONTROL BUTTON" to check the pushbutton function.
If fault 39 is activated again, continue troubleshooting as follows:
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Check the supply voltage (5V):
Plug X28/11 on the plug module, PIN1 (5V) to PIN9 (GND).
Plug YB1 on the CAN module, PIN6 and PIN8 (5V) to PIN2 and PIN4 (GND).
If the supply voltage of 5V is exceeded, then the CAN module must be replaced
(see fault code ARU 1, steps 1 and 2).
If the supply voltage of 5V is not exceeded, go to step 3.
3. Check the signal voltage (from pushbutton function to CAN module) at the following points:
Plug X28/11 on plug module, PIN11 to PIN9 (GND) and
plug YB1 ribbon cable connection on CAN module, PIN13 to PIN2 and PIN4 (GND).
Button not depressed: 0.2 - 2.3V, button depressed: 2.4 - 4.8V. If the signal voltage at plug YB1 is ok, the ground
line (GND) and plug-in connections from plug X18/4 to plug YB1 on the CAN module still have to be checked.
If the ground line is ok and the signal voltage too high, go to step 4.
4. Turn the ignition switch to the OFF position and disconnect plug X28/11 at the plug module.
Measure the resistance at the plug connection to the multi-controller II (from PIN11 to PIN1). Button not depres-
sed: approx. 8.2 kohms, button depressed: approx. 480 ohms.
If the setpoint values are attained, the button's resistor circuit is ok.
The next step is to check whether the signal line between plug X28/11 and plug YB1 has a short-circuit to another
signal line or to a supply (+).
If the setpoint values are not attained (e.g. the resistance is much lower), continue troubleshooting as follows:
Unscrew the screw on the grip housing on the multi-controller II and carefully detach the pushbutton function unit
from the grip housing. Disconnect plug X21 (14-pole) at the keyboard and measure the resistance from PIN1 to
PIN11 on the keyboard:
a) Button not depressed: approx. 8.2 kohms,
b) Button depressed: approx. 480 ohms.
If the setpoint values are not attained, the fault is in the keyboard. Replace it. If the setpoint values are attained,
the fault in the line between plug X28/11 and plug X21 must be rectified or the line replaced.
5. Cancel the fault, start the engine again and check whether the fault is activated again.
6. Attach the lower armrest cover and fit the armrest.

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 4011-61

ARU - 40 Signal voltage from + button below valid range

Cause:
The signal voltage from the "+" button S60/3 is < 0.2V.
The fault is stored and indicated by a warning triangle on the display.
The signal voltage must lie within a certain voltage range:
Button "+" not depressed: 0.2 -2.3V (actual approx. 1V).
Button "+" depressed: 2.4 - 4.8V (actual approx. 4V).
The CAN module supplies a supply voltage of 5V for the pushbutton function on the multi-controller II
Possible causes:
1. Multi-controller II defective
2. Plug module defective
3. Ribbon cable connection defective.
4. CAN module defective
Remedy:
Start the engine again and check whether the fault is activated again.
Use the Service Tool monitor:
"MULTI-CONTROLLER II + BUTTON" to check the pushbutton function.
If fault 38 is activated again, carry out troubleshooting as follows:
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Check the supply voltage (5V):
Plug YB1 ribbon cable connection on the CAN module, PIN6 and PIN8 (5V) to PIN2 and PIN4 (GND), plug YA1
ribbon cable connection on the plug module, PIN6 and PIN8 to PIN2 and PIN4 (GND), plug X28/11 on the plug
module, PIN1 (5V) to PIN9 (GND) and plug X21 on the multi-controller II keyboard, PIN1 (5V) to PIN2 (GND). If
a voltage of 5V is available at plug YB1, but not up to plug X21, then there is an interruption in between or a poor
line connection. Check the individual plugs and sections; replace faulty units. Go to step 3 when there is a supply
voltage of 5V at plug X21.
3. Check the signal voltage (from the keyboard up to the CAN module):
Plug X21 on the multi-controller II keyboard, PIN10 to PIN2 (GND).
Plug X28/11 on the plug module, PIN12 to PIN9 (GND); plug YA1, ribbon cable connection on the plug module,
PIN15 to PIN2 and PIN4 (GND) and plug YB1, ribbon cable connection on the CAN module, PIN15 to PIN2 and
PIN4 (GND).
Button not depressed 0.2 - 2.3V; button depressed 2.4 - 4.8V. If the signal voltage is < 0.2V, go to step 4.
If the supply voltage and the signal voltage are in the specified range, then the CAN module must be replaced
(see fault code ARU 1, steps 1 and 2).

If the signal voltage at plug X28/11 PIN12 is ok, but < 0.2V at plug YB1 PIN15, check the individual sections in
between. If the signal voltage at plug X28/11 is already < 0.2V, go to step 4.
4. Disconnect plug X28/11. Measure the resistance at the plug connection to the multi-controller II (from PIN12 to
PIN1).
a) Button not depressed: Setpoint value approx. 8.2 kohms,
b) Button depressed: Setpoint value approx. 480 ohms.
If the setpoint values are attained, the button's resistor circuit is ok.
If the setpoint values are not attained, go to step 5.
5. Unscrew the screw on the grip housing on the multi-controller II. Carefully detach the keyboard from the grip hou-
sing. Disconnect plug X21 at the keyboard (14-pole) and measure the resistance at the plug connection on the
keyboard (from PIN10 to PIN1):
a) Button not depressed, approx. 8.2 kohms.
b) Button depressed, approx. 480 ohms.
If the setpoint values are not attained, the fault is in the keyboard. Replace the keyboard. If the setpoint values
are attained, the fault in the line between plug X28/11 and plug X21 must be rectified or the line replaced.
If the resistance setpoint values are now attained at plug X28/11, reconnect the plug. Turn the ignition switch to
the ON position and check whether the signal voltage reaches the setpoint values at plug YB1 on the CAN mo-
dule.
Cancel fault 40 and check whether the fault is activated again.
6. Attach the lower armrest cover and fit the armrest.

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ARU - 41 Signal voltage from + button above valid range

Cause:
The signal voltage from the "+" button S60/3 is > 4.8V.
The fault is stored and indicated by a warning triangle on the display.

The signal voltage must lie within a certain voltage range:

Button "+" not depressed: 0.2 - 2.3V (actual approx. 1V).
Button "+" depressed: 2.4 - 4.8V (actual approx. 4V).

Possible causes:
1. Signal voltage too high due to a short-circuit to another signal in the armrest or to the 5V or 12V supply.
2. Fault in the resistor circuit of the multi-controller II pushbutton function. Supply voltage to the keyboard too high
(> 5V) due to:
3. Faulty ground supply (GND) to the CAN module.
4. CAN module defective.
Remedy:
Start the engine again and check whether the fault is activated again.
Use the Service Tool monitor:
"MULTI-CONTROLLER II + BUTTON" to check the pushbutton function.
If fault 41 is activated again, continue troubleshooting as follows:
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Check the supply voltage (5V)
Plug X28/11 on the plug module, PIN1 (5V) to PIN9 (GND).
Plug YB1 in the CAN module, PIN6 and PIN8 (5V) to PIN2 and PIN4 (GND).
If the supply voltage of 5V is exceeded, then the CAN module must be replaced
(see fault code ARU 1, steps 1 and 2).
If the supply voltage of 5V is not exceeded, go to step 3.
3. Check the signal voltage (from pushbutton function to CAN module) at the following points:
Plug X28/11 on plug module, PIN12 to PIN9 (GND) and
plug YB1, ribbon cable connection on CAN module, PIN15 to PIN2 and PIN4 (GND).
Button not depressed: 0.2 - 2.3V, button depressed: 2.4 - 4.8V. If the signal voltage at plug YB1 is ok, the ground
line (GND) and plug-in connections from plug X18/4 to plug YB1 on the CAN module still have to be checked.
If the ground line is ok and the signal voltage too high, go to step 4.
4. Turn the ignition switch to the OFF position and disconnect plug X28/11 at the plug module.
Measure the resistance at the plug connection to the multi-controller II (from PIN12 to PIN1). Button not depres-
sed: approx. 8.2 kohms, button depressed: approx. 480 ohms.
If the setpoint values are attained, the button's resistor circuit is ok.
The next step is to check whether the signal line between plug X28/11 and plug YB1 has a short-circuit to another
signal line or to a supply (+).
If the setpoint values are not attained (e.g. the resistance is much lower), continue troubleshooting as follows:
Unscrew the screw on the grip housing on the multi-controller II and carefully detach the pushbutton function unit
from the grip housing. Disconnect plug X21 (14-pole) at the keyboard and measure the resistance from PIN1 to
PIN10 on the keyboard:
a) Button not depressed: approx. 8.2 kohms,
b) Button depressed: approx. 480 ohms.
If the setpoint values are not attained, the fault is in the keyboard. Replace it. If the setpoint values are attained,
the fault in the line between plug X28/11 and plug X21 must be rectified or the line replaced.
5. Cancel the fault, start the engine again and check whether the fault is activated again.
6. Attach the lower armrest cover and fit the armrest.

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ARU - 50 Signal from oil flow potentiometer 1 (AUX1) outside valid

range
Cause:
The signal voltage is < 0.43 or > 4.70V.
The fault is stored and indicated by a warning triangle on the display.
The signal voltage must lie within a certain range (> 0.43 and < 4.70V).

Possible causes:
1. Contact fault in the signal line between potentiometer R20/1 and the CAN module in the armrest.
2. Short-circuit in the signal line to supply (5V) between the potentiometer and CAN module.
3. Contact fault in the supply line (5V) between the CAN module and potentiometer.
4. Contact fault in the GND potentiometer line between the CAN module and potentiometer.
5. The potentiometer R20/1 is defective.
6. Plug module is defective (e.g. resistors R28/7 or R28/8 have an interruption).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again and check whether fault 50 is activated again.
Use the Service Tool monitor:
"AUX1 FLOW COMMAND SETPOINT" (signal value in %)
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Check the supply voltage for the operating controls (5V) at the plug module:
Plug X28/11 PIN1 (5V) to PIN9 (GND) and plug X28/11 PIN1 (5V) to plug YA1 PIN34 (GND for potentiometer) on
the plug module and plug YB1 PIN34 (GND for potentiometer) on the CAN module: Setpoint value approx. 5V. If
a voltage of 5V is not available, check the supply voltage at plug YB1 on the CAN module.
PIN6 and PIN8 (5V) to PIN2 and PIN4 (GND).
If the voltage difference between plug X28/11 and YB1 is > 0.1V, then the ground line between YB1 PIN2 and
PIN4 (GND) to PIN34 (GND potentiometer) and to plug X28/11 PIN9 (GND) must also be checked. Check the
plug-in contacts and lines of the individual sections (plug module, ribbon cable connection). Replace the individual
units as required.
If the supply voltage already deviates substantially from 5V at plug YB1, then the CAN module must be replaced
(see fault code ARU 1, steps 1 and 2).
If the supply voltage of 5V is available at plug X28/11, go to step 3.
3. Check the supply voltage for potentiometer R20/1 at the plug module (after resistor R28/7). When doing so, plug
X28/16 (potentiometer R20/1) must be connected to the plug module.
Plug X28/16 PIN4 to plug X28/11 PIN9 (GND): Setpoint value 4.55-4.70V.
Check the supply (GND) for potentiometer R20/1 at the plug module (before resistor R28/8):
Plug X28/16 PIN6 to plug YA1 PIN34 (GND - potentiometer) and to plug X28/11 PIN9 (GND):
Setpoint value 0.43-0.48V.
If the setpoint values are attained at plug X28/16, go to step 4
If the supply voltage is 5V at plug X28/11, but the voltages deviate substantially from the setpoint values at plug
X28/16, go to step 5.
4. Check the signal voltage at the CAN module:
Plug YB1 PIN24 to PIN34 (GND for potentiometer):
Setpoint value 0.43 to 4.70V (depending on the position of the potentiometer).
If the signal voltage is in the specified range, then the CAN module must be replaced
(see fault code ARU 1,
steps 1 and 2).
If the signal voltage is below or above the specified range, refer to the checks in steps 5, 6 and 7.
5. Check the resistance at the two assigned series resistors on the plug module:
Turn the ignition switch to the OFF position and disconnect plug X28/16 at the plug module.
Plug X28/11 PIN1 to plug X28/16 PIN4, setpoint value 470 ohms.
Plug X28/16 PIN6 to plug YA1 PIN34, setpoint value 560 ohms.
If a resistance value deviates substantially from the setpoint value, then the plug module must be replaced.
If the signal voltage does not reach the setpoint values (see step 4) or if the signal voltage is a constant 5V or 0V
even though the resistance values at the plug module are in the specified range, go to step 6.

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6. Check the resistance of potentiometer R20/1 (plug X28/16 disconnected):
Plug X28/16 PIN4 to PIN6, setpoint value 5 kohms ± 5% (any potentiometer position).
Plug X28/16 PIN4 to PIN5, setpoint value 0 ohms to 5 kohms ± 5%
(depending on the position of the potentiometer).
Plug X28/16 PIN5 to PIN6, setpoint value 0 ohms to 5 kohms ± 5%
(depending on the position of the potentiometer).
If the resistance deviates from the setpoint value, the resistance must be checked directly at the potentiometer
R20/1. Do do so, remove the plug module and disconnect the tab connections at potentiometer R20/1. If the set-
point value is attained at the potentiometer R20/1, then the individual lines between the potentiometer and plug
X28/16 must be checked. (Resistance < 1 ohm). Resistance between the individual lines: infinite. Repair or re-
place faulty lines.
Replace faulty potentiometer R20/1 as required.
7. If the signal voltage at plug X28/16 is outside the setpoint value even though the supply voltage (5V) at plug
X28/11 and the resistance values are ok, then the signal line between plug X28/16 and plug YB1 must be chek-
ked. The resistance must be < 1 ohm. Furthermore, there must be no connection to another line.
8. Cancel the fault and check whether fault 50 is activated again. Attach the lower armrest cover and fit the armrest.

ARU - 52 Signal from oil flow potentiometer 2 (AUX2) outside valid

range
Cause:
The signal voltage is < 0.43 or > 4.70V.
The fault is stored and indicated by a warning triangle on the display.
The signal voltage must lie within a certain range (> 0.43 and < 4.70V).

Possible causes:
1. Contact fault in the signal line between potentiometer R20/2 and the CAN module in the armrest.
2. Short-circuit in the signal line to supply (5V) between the potentiometer and CAN module.
3. Contact fault in the supply line (5V) between the CAN module and potentiometer.
4. Contact fault in the GND potentiometer line between the CAN module and potentiometer.
5. Potentiometer R20/2 is defective.
6. Plug module is defective (e.g. resistors R28/5 or R28/6 have an interruption).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again and check whether fault 52 is activated again.
Use the Service Tool monitor: "AUX2 FLOW COMMAND SETPOINT" (signal value in %)
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Check the supply voltage for the operating controls (5V) at the plug module:
Plug X28/11 PIN1 (5V) to PIN9 (GND) and plug X28/11 PIN1 (5V) to plug YA1 PIN34 (GND for potentiometer) on
the plug module and plug YB1 PIN34 (GND for potentiometer) on the CAN module. Setpoint value approx. 5V. If
a voltage of 5V is not available, check the supply voltage at plug YB1 on the CAN module:
PIN6 and PIN8 (5V) to PIN2 and PIN4 (GND).
If the voltage difference between plug X28/11 and YB1 is > 0.1V, then the ground line between YB1 PIN2 and
PIN4 (GND) to PIN34 (GND potentiometer) and to plug X28/11 PIN9 (GND) must also be checked. Check the
plug-in contacts and lines of the individual sections (plug module, ribbon cable connection). Replace the individual
units as required.
If the supply voltage already deviates substantially from 5V at plug YB1, then the CAN module must be replaced
(see fault code ARU 1, steps 1 and 2).
If the supply voltage of 5V is available at plug X28/11, go to step 3.
3. Check the supply voltage for potentiometer R20/2 at the plug module (after resistor R28/5). When doing so, plug
X28/16 (potentiometer R20/2) must be connected to the plug module.
Plug X28/16 PIN1 to plug X28/11 PIN9 (GND): Setpoint value 4.55-4.70V.
Check the supply (GND) for potentiometer R20/2 at the plug module (before resistor R28/6).
Plug X28/16 PIN3 to plug YA1 PIN34 (GND - potentiometer) and to plug X28/11 PIN9 (GND):
Setpoint value 0.43-0.48V.
If the setpoint values are attained at plug X28/16, go to step 4
If the supply voltage is 5V at plug X28/11, but the voltages deviate substantially from the setpoint values at plug
X28/16, go to step 5.

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4. Check the signal voltage at the CAN module:
Plug YB1 PIN26 to PIN34 (GND for potentiometer):
Setpoint value 0.43 to 4.70V (depending on the position of the potentiometer).
If the signal voltage is in the specified range, then the CAN module must be replaced
(see fault code ARU 1, steps 1 and 2).
If the signal voltage is below or above the specified range, refer to the checks in steps 5, 6 and 7.
5. Check the resistance at the two assigned series resistors on the plug module:
Turn the ignition switch to the OFF position and disconnect plug X28/16 at the plug module.
Plug X28/11 PIN1 to plug X28/16 PIN1, setpoint value 470 ohms.
Plug X28/16 PIN3 to plug YA1 PIN34, setpoint value 560 ohms.
If a resistance value deviates substantially from the setpoint value, then the plug module must be replaced.
If the signal voltage does not reach the setpoint values (see step 4) or if the signal voltage is a constant 5V or 0V
even though the resistance values at the plug module are in the specified range, go to step 6.
6. Check the resistance of potentiometer R20/2 (plug X28/16 disconnected):
Plug X28/16 PIN1 to PIN3, setpoint value 5 kohms ± 5% (any potentiometer position).
Plug X28/16 PIN1to PIN2, setpoint value 0 ohms to 5 kohms ± 5%
(depending on the position of the potentiometer).
Plug X28/16 PIN2to PIN3, setpoint value 0 ohms to 5 kohms ± 5%
(depending on the position of the potentiometer).
If the resistance deviates from the setpoint value, the resistance must be checked directly at potentiometer
R20/2 . Do do so, remove the plug module and disconnect the tab connections at potentiometer R20/2. If the set-
point value is attained at the potentiometer R20/2, then the individual lines between the potentiometer and plug
X28/16 must be checked. (Resistance < 1 ohm). Resistance between the individual lines: infinite. Repair or re-
place faulty lines.
Replace faulty potentiometer R20/2 as required.
7. If the signal voltage at plug X28/16 is outside the setpoint value even though the supply voltage (5V) at plug
X28/11 and the resistance values are ok, then the signal line between plug X28/16 and plug YB1 must be chek-
ked. The resistance must be < 1 ohm. Furthermore, there must be no connection to another line.
8. Cancel the fault and check whether fault 52 is activated again. Attach the lower armrest cover and fit the armrest.

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ARU - 54 Signal from oil flow potentiometer 3 (AUX3) outside valid

range
Cause:
The signal voltage is < 0.43 or > 4.70V.
The fault is stored and indicated by a warning triangle on the display.

The signal voltage must lie within a certain range (> 0.43 and < 4.70V).

Possible causes:
1. Contact fault in the signal line between potentiometer R20/3 and the CAN module in the armrest.
2. Short-circuit in the signal line to supply (5V) between the potentiometer and CAN module.
3. Contact fault in the supply line (5V) between the CAN module and potentiometer.
4. Contact fault in the GND potentiometer line between the CAN module and potentiometer.
5. Potentiometer R20/3is defective.
6. Plug module is defective (e.g. resistors R28/3 or R28/4 have an interruption).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again and check whether fault 54 is activated again.
Use the Service Tool monitor:
"AUX3 FLOW COMMAND SETPOINT" (signal value in %)
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Check the supply voltage for the operating controls (5V) at the plug module:
Plug X28/11 PIN1 (5V) to PIN9 (GND) and plug X28/11 PIN1 (5V) to plug YA1 PIN34 (GND for potentiometer) on
the plug module and plug YB1 PIN34 (GND for potentiometer) on the CAN module: Setpoint value approx. 5V. If
a voltage of 5V is not available, check the supply voltage at plug YB1 on the CAN module:
PIN6 and PIN8 (5V) to PIN2 and PIN4 (GND).
If the voltage difference between plug X28/11 and YB1 is > 0.1V, then the ground line between YB1 PIN2 and
PIN4 (GND) to PIN34 (GND potentiometer) and to plug X28/11 PIN9 (GND) must also be checked. Check the
plug-in contacts and lines of the individual sections (plug module, ribbon cable connection). Replace the individual
units as required.
If the supply voltage already deviates substantially from 5V at plug YB1, then the CAN module must be replaced
(see fault code ARU 1, steps 1 and 2).
If the supply voltage of 5V is available at plug X28/11, go to step 3.
3. Check the supply voltage for potentiometer R20/3 at the plug module (after resistor R28/3). When doing so, plug
X28/15 (potentiometer R20/3) must be connected to the plug module.
Plug X28/15 PIN4 to plug X28/11 PIN9 (GND): Setpoint value 4.55-4.70V.
Check the supply (GND) for potentiometer R20/3 at the plug module (before resistor R28/4):
Plug X28/15 PIN6 to plug YA1 PIN34 (GND - potentiometer) and to plug X28/11 PIN9 (GND):
Setpoint value 0.43-0.48V.
If the setpoint values are attained at plug X28/15, go to step 4
If the supply voltage is 5V at plug X28/11, but the voltages deviate substantially from the setpoint values at plug
X28/15, go to step 5.
4. Check the signal voltage at the CAN module:
Plug YB1 PIN28 to plug PIN34 (GND for potentiometer):
Setpoint value 0.43 to 4.70V (depending on the position of the potentiometer).
If the signal voltage is in the specified range, then the CAN module must be replaced
(see fault code ARU 1, steps 1 and 2).
If the signal voltage is below or above the specified range, refer to the checks in steps 5, 6 and 7.
5. Check the resistance at the two assigned series resistors on the plug module:
Turn the ignition switch to the OFF position and disconnect plug X28/15 at the plug module.
Plug X28/11 PIN1 to plug X28/15 PIN4, setpoint value 470 ohms.
Plug X28/15 PIN6 to plug YA1 PIN34, setpoint value 560 ohms.
If a resistance value deviates substantially from the setpoint value, then the plug module must be replaced.
If the signal voltage does not reach the setpoint values (see step 4) or if the signal voltage is a constant 5V or 0V
even though the resistance values at the plug module are in the specified range, go to step 6.

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6. Check the resistance of potentiometer R20/3 (plug X28/15 disconnected):
Plug X28/15 PIN4 to PIN6, setpoint value 5 kohms ± 5% (any potentiometer position).
Plug X28/15 PIN4 to PIN5, setpoint value 0 ohms to 5 kohms ± 5%
(depending on the position of the potentiometer).
Plug X28/15 PIN5 to PIN6, setpoint value 0 ohms to 5 kohms ± 5%
(depending on the position of the potentiometer).
If the resistance deviates from the setpoint value, the resistance must be checked directly at potentiometer
R20/3. Do do so, remove the plug module and disconnect the tab connections at potentiometer R20/3. If the set-
point value is attained at the potentiometer R20/3, then the individual lines between potentiometer and plug
X28/15 must be checked. (Resistance < 1 ohm). Resistance between the individual lines: infinite. Repair or re-
place faulty lines.
Replace faulty potentiometer R20/3 as required.
7. If the signal voltage at plug X28/15 is outside the setpoint value even though the supply voltage (5V) at plug
X28/11 and the resistance values are ok, then the signal line between plug X28/15 and plug YB1 must be chek-
ked. The resistance must be < 1 ohm. Furthermore, there must be no connection to another line.
8. Cancel the fault and check whether fault 54 is activated again. Attach the lower armrest cover and fit the armrest.

ARU - 56 Signal from oil flow potentiometer 4 (AUX4) outside valid

range
Cause:
The signal voltage is < 0.43 or > 4.70V.
The fault is stored and indicated by a warning triangle on the display.
The signal voltage must lie within a certain range (> 0.43 and < 4.70V).

Possible causes:
1. Contact fault in the signal line between potentiometer R20/4 and the CAN module in the armrest.
2. Short-circuit in the signal line to supply (5V) between the potentiometer and CAN module.
3. Contact fault in the supply line (5V) between the CAN module and potentiometer.
4. Contact fault in the GND potentiometer line between the CAN module and potentiometer.
5. Potentiometer R20/4 is defective.
6. Plug module is defective (e.g. resistors R28/1 or R28/2 have an interruption).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again and check whether fault 56 is activated again.
Use the Service Tool monitor: "AUX4 FLOW COMMAND SETPOINT" (signal value in %)
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Check the supply voltage for the operating controls (5V) at the plug module:
Plug X28/11 PIN1 (5V) to PIN9 (GND) and plug X28/11 PIN1 (5V) to plug YA1 PIN34 (GND for potentiometer) on
the plug module and plug YB1 PIN34 (GND for potentiometer) on the CAN module: Setpoint value approx. 5V. If
a voltage of 5V is not available, check the supply voltage at plug YB1on the CAN module:
PIN6 and PIN8 (5V) to PIN2 and PIN4 (GND).
If the voltage difference between plug X28/11 and YB1 is > 0.1V, then the ground line between YB1 PIN2 and
PIN4 (GND) to PIN34 (GND potentiometer) and to plug X28/11 PIN9 (GND) must also be checked. Check the
plug-in contacts and lines of the individual sections (plug module, ribbon cable connection). Replace the individual
units as required.
If the supply voltage already deviates substantially from 5V at plug YB1, then the CAN module must be replaced
(see fault code ARU 1, steps 1 and 2).
If the supply voltage of 5V is available at plug X28/11, go to step 3.
3. Check the supply voltage for potentiometer R20/4 at the plug module (after resistor R28/1).
When doing so, plug X28/15 (potentiometer R20/4) must be connected to the plug module.
Plug X28/15 PIN1 to plug X28/11 PIN9 (GND): Setpoint value 4.55-4.70V.
Check the supply (GND) for potentiometer R20/4 at the plug module (before resistor R28/2):
Plug X28/15 PIN3 to plug YA1 PIN34 (GND - potentiometer) and to plug X28/11 PIN9 (GND):
Setpoint value 0.43-0.48V.
If the setpoint values are attained at plug X28/15, go to step 4
If the supply voltage is 5V at plug X28/11, but the voltages deviate substantially from the setpoint values at plug
X28/15, go to step 5.

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4. Check the signal voltage at the CAN module:
Plug YB1 PIN30 to plug PIN34 (GND for potentiometer):
Setpoint value 0.43 to 4.70V (depending on the position of the potentiometer).
If the signal voltage is in the specified range, then the CAN module must be replaced
(see fault code ARU 1, steps 1 and 2).
If the signal voltage is below or above the specified range, refer to the checks in steps 5, 6 and 7.
5. Check the resistance at the two assigned series resistors on the plug module:
Turn the ignition switch to the OFF position and disconnect plug X28/15 at the plug module.
Plug X28/11 PIN1 to plug X28/15 PIN1, setpoint value 470 ohms.
Plug X28/15 PIN3 to plug YA1 PIN34, setpoint value 560 ohms.
If a resistance value deviates substantially from the setpoint value, then the plug module must be replaced.
If the signal voltage does not reach the setpoint values (see step 4) or if the signal voltage is a constant 5V or 0V
even though the resistance values at the plug module are in the specified range, go to step 6.
6. Check the resistance of potentiometer R20/4 (plug X28/15 disconnected):
Plug X28/15 PIN1 to PIN3, setpoint value 5 kohms ± 5% (any potentiometer position).
Plug X28/15 PIN1 to PIN2, setpoint value 0 ohms to 5 kohms ± 5%
(depending on the position of the potentiometer).
Plug X28/15 PIN2 to PIN3, setpoint value 0 ohms to 5 kohms ± 5%
(depending on the position of the potentiometer).
If the resistance deviates from the setpoint value, the resistance must be checked directly at potentiometer
R20/4. Do do so, remove the plug module and disconnect the tab connections at the potentiometer R20/4. If the
setpoint value is attained at the potentiometer R20/4, then the individual lines between the potentiometer and plug
X28/15 must be checked. (Resistance < 1 ohm). Resistance between the individual lines: infinite. Repair or re-
place faulty lines.
Replace faulty potentiometer R20/4 as required.
7. If the signal voltage at plug X28/15 is outside the setpoint value even though the supply voltage (5V) at plug
X28/11 and the resistance values are ok, then the signal line between plug X28/15 and plug YB1 must be chek-
ked. The resistance must be < 1 ohm. Furthermore, there must be no connection to another line.
8. Cancel the fault and check whether fault 56 is activated again. Attach the lower armrest cover and fit the armrest.

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ARU - 58 Signal from oil flow potentiometer 5 (AUX5) outside valid

range
Cause:
The signal voltage is < 0.43 or > 4.70V.
The fault is stored and indicated by a warning triangle on the display.

The signal voltage must lie within a certain range (> 0.43 and < 4.70V).

Possible causes:
1. Contact fault in the signal line between the potentiometer R20/5 and the CAN module in the armrest.
2. Short-circuit in the signal line to supply (5V) between the potentiometer and CAN module.
3. Contact fault in the supply line (5V) between the CAN module and potentiometer.
4. Contact fault in the GND potentiometer line between the CAN module and potentiometer.
5. Potentiometer R20/5 is defective.
6. Plug module is defective (e.g. resistors R28/9 or R28/10 have an interruption).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again and check whether fault 58 is activated again.
Use the Service Tool monitor:
"AUX5 FLOW COMMAND SETPOINT" (signal value in %)
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Check the supply voltage for the operating controls (5V) at the plug module:
Plug X28/11 PIN1 (5V) to PIN9 (GND) and plug X28/11 PIN1 (5V) to plug YA1 PIN34 (GND for potentiometer) on
the plug module and plug YB1 IN34 (GND for potentiometer) on the CAN module: Setpoint value approx. 5V. If a
voltage of 5V is not available, check the supply voltage at plug YB1 on the CAN module:
PIN6 and PIN8 (5V) to PIN2 and PIN4 (GND).
If the voltage difference between plug X28/11 and YB1 is > 0.1V, then the ground line between YB1 PIN2 and
PIN4 (GND) to PIN34 (GND potentiometer) and to plug X28/11 PIN9 (GND) must also be checked. Check the
plug-in contacts and lines of the individual sections (plug module, ribbon cable connection). Replace the individual
units as required.
If the supply voltage already deviates substantially from 5V at plug YB1, then the CAN module must be replaced
(see fault code ARU 1, steps 1 and 2).
If the supply voltage of 5V is available at plug X28/11, go to step 3.
3. Check the supply voltage for the potentiometer R20/5 on the plug module (after resistor R28/9). When doing so,
plug X28/12 must be connected to the plug module.
Plug X28/12 PIN1 to plug X28/11 PIN9 (GND): Setpoint value 4.55-4.70V.
Check the supply (GND) for the potentiometer R20/5 at the plug module (before resistor R28/10):
Plug X28/12 PIN4 to plug YA1 PIN34 (GND - potentiometer) and to plug X28/11 PIN9 (GND):
Setpoint value 0.43-0.48V.
If the setpoint values are attained at plug X28/12, go to step 4
If the supply voltage is 5V at plug X28/11, but the voltages deviate substantially from the setpoint values at plug
X28/12, go to step 5.
4. Check the signal voltage at the CAN module:
Plug YB1 PIN32 to plug PIN34 (GND for potentiometer):
Setpoint value 0.43 to 4.70V (depending on the position of the potentiometer).
If the signal voltage is in the specified range, then the CAN module must be replaced
(see fault code ARU 1, steps 1 and 2).
If the signal voltage is below or above the specified range, refer to the checks in steps 5, 6 and 7.
5. Check the resistance at the two assigned series resistors on the plug module:
Turn the ignition switch to the OFF position and disconnect plug X28/12 at the plug module.
Plug X28/11 PIN1 to plug X28/12 PIN1, setpoint value 470 ohms.
Plug X28/12 PIN4 to plug YA1 PIN34, setpoint value 560 ohms.
If a resistance value deviates substantially from the setpoint value, then the plug module must be replaced.
If the signal voltage does not reach the setpoint values (see step 4) or if the signal voltage is a constant 5V or 0V
even though the resistance values at the plug module are in the specified range, go to step 6.

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6. Check the resistance of the potentiometer R20/5 (plug X28/12 disconnected):
Plug X28/12 PIN1 to PIN4, setpoint value 5 kohms ± 5% (any potentiometer position).
Plug X28/12 PIN1to PIN2, setpoint value 0 ohms to 5 kohms ± 5%
(depending on the position of the potentiometer).
Plug X28/12 PIN2 to PIN4, setpoint value 0 ohms to 5 kohms ± 5%
(depending on the position of the potentiometer).
If the resistance deviates from the setpoint value, the resistance must be checked directly at the potentiometer
R20/5 . Do do so, remove the plug module and disconnect the tab connections at the potentiometer R20/5. If the
setpoint value is attained at the potentiometer R20/5, then the individual lines between the potentiometer and plug
X28/12 must be checked. (Resistance < 1 ohm). Resistance between the individual lines: infinite. Repair or re-
place faulty lines.
Replace faulty potentiometer R20/5 as required.
7. If the signal voltage at plug X28/12 is outside the setpoint value even though the supply voltage (5V) at plug
X28/11 and the resistance values are ok, then the signal line between plug X28/12 and plug YB1 must be chek-
ked. The resistance must be < 1 ohm. Furthermore, there must be no connection to another line.
8. Cancel the fault and check whether fault 58 is activated again. Attach the lower armrest cover and fit the armrest.

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ARU - 71 CAN Bus OFF

Cause:
Data transfer between armrest and vehicle bus does not function.
The CAN module has not transmitted a message correctly or the CAN wiring between CAN module and vehicle bus
is faulty.

The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. The supply to CAN module A27 in the armrest is faulty.
2. Interruption or contact fault on the CAN (vehicle bus), e.g. in the spur line to the CAN module.
3. Conductive connection or short-circuit between the data lines (terminating resistances excluded) or to other lines
(insulation fault, dirt or moisture between plug-in contacts).
4. Terminating resistor is defective or plug-in contacts at X3/10 are faulty.
5. The screening of the CAN wiring is faulty.
6. The CAN module is defective.
Remedy:
Use Service Tool "CONTROL modulE status" to check whether other bus users are also offline.
Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine again and check whether
the fault is active again.
1. If fault ARU 71 is active again or if other bus users on the vehicle bus are signalling faults in connection with the
CAN bus, check the CAN bus fuses.
a) If all fuses are ok, go to step 2.
b) Replace defective fuses. Then turn the ignition switch to the ON position. If faults are active again, go to step 2.
2. Continue fault diagnostics, starting with a quick check of the "Vehicle bus status" (steps b and c).
a) Detach the plug of Service Tool DPA from diagnosis socket X9/17. Use switch S31 to select the vehicle bus
(turn switch S31 to upper position). Turn ignition switch to ON position.
b) Check voltages - CAN H and CAN L at diagnosis socket (X9/17 con pin ) .
PINC (CANH) and PIND (CANL) against PINA (GND).
If the voltages are in the specified range, you can assume that the data lines are neither shorted to GND (supply
or screening), nor to a plus supply or to plus 1, plus 2 or plus 3 (12 V screening). Go to step c.
c) Check resistance values - CAN H against CAN L at diagnosis socket .
PINC (CANH) and PIND (CANL) (to do so turn ignition switch to OFF position).
If the resistance considerably deviates from the setpoint when CANH is measured against CANL, the terminating
resistors must be checked one by one (see step 4) and the CAN wiring must be checked for interruptions or short-
circuits (see steps 3b and 3c).
d) Check supply voltage (12V) to the CAN module in the armrest:
Turn ignition switch to ON position.
Plug YB1 PIN1 and 3 (12V) against PIN2 and PIN4 (GND).
If the voltage is >12V (<8V), it is faulty and must be repaired. For details on fault rectification, refer to fault code
ARU 20 (this fault code is active as soon as the supply voltage is < 8V).
e) Check supply (5V) to CAN module A27:
NOTE: A voltage regulator at the CAN module is supplied with 12 V. This supplies 5V to specific components on the
CAN module and to specific control elements.
Turn ignition switch to ON position.
Plug YB1 PIN6, 8 and 10 (5V) against PIN2 and PIN4 (GND).
If the voltage (5V) is not present, detach the plugs to the multi-controller II and to the other control elements at
plug module A28. If the supply (5V) is present, there is a short-circuit in the control elements or in their wiring. If
the supply (5V) is not present, there could be other faults: CAN module defective or short-circuit at the plug mo-
dule or short-circuit in the ribbon cable connection between YA1 and YB1.
f) Check the voltages - CANH and CANL at CAN module plug YB1:
Turn ignition switch to ON position. PIN5 (CANH) and PIN7 (CANL) against PIN2 and PIN4 (GND).
g) Check the screening of the data lines:
Violet line (12V) against black line (GND).
NOTE: The screening and the data lines are twisted together. It ends freely in front of plug X28/7 on the plug
module. It is therefore not routed up to the CAN module.
If the power supply, the voltage values of CAN H and CAN L at plug YB1 of the CAN module and the screening
are ok, the CAN module must be replaced (see fault code ARU 1, steps 1 to 4).
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4011-72
3. Voltages - CANH and CANL at the CAN module not ok:
a) Carry out a voltage check at the plugs in the following sequence:
Plug X28/7 at the plug module:
PIN3 (CANH) and PIN4 (CANL) against plug X28/1 PIN8 (GND).
If voltages are not ok, detach plug X28/7. Check voltages at the plug part of the CAN wiring. If voltages are not
ok, check data lines between plug X28/7 and the weld points of the spur line (measure e.g. against diagnosis
socket X9/17). If the voltages at plug X28/7 are ok, check the voltages at plug YA1 on the plug module:
PIN5 (CANH) and PIN7 (CANL) against PIN2 and PIN4 (GND). Check faulty sections of the data line. Replace
plug module or ribbon cable connection if necessary.
b) Continuity check at data lines:
Detach the plugs on the line section concerned. Use an ohmmeter to check the line from one plug to the next
(setpoint < 1 ohm).
If the resistance is > 1 ohm, check the line, plug-in contacts and crimp connections and repair or replace them if
necessary.
c) Short-circuit check between the data lines:
Disconnect plugs X18/4 and YB1.
At plug YB1, connect an ohmmeter between two pins at a time:
The lines must be interrupted relative to each other (display = infinite).
If an unintended electrical connection is established between the lines: Repair the wiring or replace single lines
or the cable harness.
4. Check the terminating resistors in accordance with the CAN bus diagram
On the vehicle bus, one terminating resistor is integrated in motor control unit EEM2and another terminating re-
sistor is integrated in plug X3/10. (Setpoint of a resistor: 120 ohms).
a) If the data lines do not have any contact faults on the one hand, and, one the other hand, are not shorted to
each other, and if both terminating resistors are ok, the resistance of the two data lines relative to each other
(CANH against CANL) must be 60 ohms at the following measuring points:
Diagnosis socket X9/17, X18/4 (armrest), X28/7 and YA1 (plug module A28) as well as YB1 (CAN module A27).
b) Check of the individual terminating resistors:
Turn ignition switch to OFF position. Disconnect plug X3/10. Check resistance between PINA and PINB:
Setpoint 120 ohms. At the plug part of the cable harness also check the resistance between PINA and PINB:
Setpoint 120 ohms.
If the setpoint of approx. 120 ohms is also reached with this measurement, the terminating resistor in the EEM2
and the lines CANH and CANL between the terminating resistors are ok. If the resistance considerably deviates
from the setpoint, the terminating resistor in the EEM2 and each data line must be checked separately.
Detach plug X70 from the EEM2. Check the terminating resistance between PIN18 (CANH) and PIN42 (CANL)
at the EEM2. Setpoint 120 ohms.

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COMPONENTS SUMMARY
ARU Armrest ............................................................................................................................................. Fig. 1
AUX1 1st remote control valve.................................................................................................................... Fig. 1
AUX2 2nd remote control valve .................................................................................................................. Fig. 1
AUX3 3rd remote control valve ................................................................................................................... Fig. 1
AUX4 4th remote control valve ................................................................................................................... Fig. 1
AUX5 5th remote control valve ................................................................................................................... Fig. 1
A2 EEM2 control unit ............................................................................................................................. Fig. 1
B28 Manual accelerator slider ................................................................................................................. Fig. 2
B30 Longitudinal joystick.......................................................................................................................... Fig. 2
B31 Transverse joystick ........................................................................................................................... Fig. 2
B52 Shift lever for AUX (black)................................................................................................................. Fig. 2
G2/2 Generator Magneton 120A .............................................................................................................. Fig. 3
G2/2/2 2nd generator Magneton 95A ........................................................................................................... Fig. 4
G2/3 Generator Denso 140A..................................................................................................................... Fig. 5
R20/1 Potentiometer 1st AUX ..................................................................................................................... Fig. 2
R20/2 Potentiometer 2nd AUX .................................................................................................................... Fig. 2
R20/3 Potentiometer 3rd AUX..................................................................................................................... Fig. 2
R20/4 Potentiometer 4th AUX ..................................................................................................................... Fig. 2
R20/5 Potentiometer 5th AUX ..................................................................................................................... Fig. 2
S31 Changeover switch for CAN SGR/FMGR ......................................................................................... Fig. 6
S60/2 Cruise control button......................................................................................................................... Fig. 7
S60/3 Speed button +.................................................................................................................................. Fig. 7
X3/10 Plug connection, terminal resistance ................................................................................................ Fig. 8
X18/4 Plug connection, wiring harness, cab right - armrest ........................................................................ Fig. 9
X21 Plug connection, multicontroller II - print......................................................................................... Fig. 10
X28/1 Plug connection, ARU - wiring harness, cab right ...........................................................................Fig. 11
X28/3 Plug connection, ARU - manual accelerator slider ......................................................................... Fig. 12
X28/4 Plug connection, ARU - AUX control lever ..................................................................................... Fig. 13
X28/5 Plug connection, ARU - AUX joystick ............................................................................................. Fig. 14
X28/7 Plug connection, ARU CAN - BUS ................................................................................................. Fig. 15
X28/11 Plug connection, ARU - multicontroller II ....................................................................................... Fig. 16
X28/12 Plug connection, ARU - potentiometer R20/5 ................................................................................. Fig. 17
X28/15 Plug connection, ARU - potentiometer R20/3 and R20/4 ............................................................... Fig. 18
X28/16 Plug connection, ARU - potentiometer R20/1 and R20/2 ............................................................... Fig. 19
X70 Plug connection, engine control unit EEM2 .................................................................................... Fig. 20
YA1 Plug connection, ARU connector module - CAN module ................................................................ Fig. 7
YB1 Plug connection, ARU CAN module - connector module ................................................................ Fig. 7

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ARU up to DBD094270 4011-75

Fig. 1 Fig. 5

Fig. 2 Fig. 6

Fig. 3 Fig. 7

Fig. 4 Fig. 8

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 4011-76

Fig. 9 Fig. 12

Fig. 13

Fig. 10

Fig. 14

Fig. 11

Fig. 15

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ARU up to DBD094270 4011-77

Fig. 16 Fig. 20

Fig. 17

Fig. 18

Fig. 19

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BLANK PAGE

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ARU up to DBD094270 4011-79

*) see Note page 8 ARMREST FUNCTIONAL SCHEMATIC DIAGRAM FOR REMOTE

S60/6
A31
X21
*A28 PLUG MODULE
X11 *A30 PRINT ARU
X24/2
F19 5A
CONTROL VALVES
17 A12 X4/83 X4/90 AUX 1
8 6 F20 5A CAN H
18 +15/1 3 3
7 13 X1 X18/4 F16 5A CAN L
5V 2 +15/2
X24/2 4 2
1 1 7 13 F47 5A CAN +
+15/1 24 1 1
6 10 9 9 CAN -
GND 2 4
X19 2 1 8 10 (16)
CAN +
X7 15 X5/1
S60/8 CAN - X4/91 AUX 2
2 16 CAN H
CAN H 3
3 17 CAN L
A29 X5 CAN L 2
GND GND 4 18 CAN +
3 1
S2/7/3
X

5V CAN -
B30 1 4
0
2 1
GND 3
7 3 X4/92 AUX 3
X

B31 5V CAN H
5 6 1 3
GSV4 CAN L
6 8 2 2
5V CAN +
4 1
S35 CAN -
8 X10/9 2 X10/9 6 8 4
X4 CN1a 10
GND
4 CAN - X4/93 AUX 4
17 A60 ECCU2
X

5V 5V CN3a CAN H
3
1 CAN +
6.4 V with EDC and AUX ON 4 CAN L
B52 2 CAN L 2
16 6.4 V with EDC ON 1 CAN +
X16 CAN H 1
R20/1 0.5 V 560Ω
GND
15 CAN -
6 4
470Ω
4.7 V
4 X10/11 X14/15 A12
A13 F45 5A
5 7 12 +15/1
X4/94 AUX 5
R20/2 0.5 V
560Ω CAN H
3 P8/1 3 4 1 2 3
4.7 V 470Ω X10/12 6 CAN L
1 P8 ICU P8 2
CAN +
2 7 X14/14 X10/14 1
CAN -
X15 5 4 7 4
R20/3 0.5 V 560Ω
6 3
4.7 V
470Ω
(7)
A X3/10 B
4 A14 X20/1 X23/1
(8) F93 5A
5 +30 8 Q
R20/4 0.5 V 560Ω 120 Ω
3
470Ω
4.7 V A12 Central print R20/5 Potentiometer AUX5 X10/14 10-pin plug connection
1 A13 Roof print S2/7/3 Switch, hydraulic master X11 16-pin plug connection
2 A14 Engine print S34 Switch AUX5 X12 4-pin plug connection
X12 A27 CAN module ---> DBD..... S35 Joystick pushbutton X14/14 14-pin plug connection
R20/5 0.5 V 560Ω A28 Plug module ---> DBD..... S60/6 AUX blue pushbutton X14/15 14-pin plug connection
4 A30 Print ARU DBD..... ---> S60/8 Shift pushbutton X15 6-pin plug connection
4.7 V
1 A29 Joystick (float position) X16 6-pin plug connection
A31 Multi controller X1 14-pin plug connection X18/4 18-pin plug connection
2 A60 ECCU2 X3/10 3-pin plug connection X19 2-pin plug connection
X6 0Ω B30 Joystick X4 4-pin plug connection X20/1 20-pin plug connection
longitudinal direction AUX1 X4/83 4-pin plug connection X21 14-pin plug connection
8
5V
6k2 B31 Joystick X4/90 4-pin plug connection X23/1 23-pin plug connection
2 transverse direction AUX2 X4/91 4-pin plug connection X24/2 24-pin plug connection
S34 1k2
B52 Selector lever AUX4 X4/92 4-pin plug connection YA1 44-pin plug connection
3
6k2 CN1a 26-pin plug connection X4/93 4-pin plug connection ---> DBD.....
2
7 CN3a 26-pin plug connection X4/94 4-pin plug connection YB1 44-pin plug connection
0
15/1

1
4 0Ω
5V GND 15/1 GND P8 ICU X5 2-pin plug connection ---> DBD.....
2 P8 10-pin plug connection X5/1 Plug connection (7) Ground point, roof hood, left
4 P8/1 4-pin plug connection X6 8-pin plug connection (8) Ground point, roof hood,
8 *YA1 35 41 32 30 28 26 24 27 31 29 37 9 19 23 34 6 8 39 40 33 3 1 4 2 5 7 R20/1 Potentiometer AUX1 X7 4-pin plug connection right
1 R20/2 Potentiometer AUX2 X10/9 10-pin plug connection (16) Ground, starter
5 *YB1 35 41 32 30 28 26 24 27 31 29 37 9 19 23 34 6 8 39 40 33 3 1 4 2 5 7
7 R20/3 Potentiometer AUX3 X10/11 10-pin plug connection
* A27 CAN MODULE R20/4 Potentiometer AUX4 X10/12 10-pin plug connection

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ARU up to DBD094270 4011-81

*) see Note page 8 FUNCTIONAL SCHEMATIC DIAGRAM FOR EEM2

A12 F19 5A

F20 5A
X20/1 F97 10A
+15/1 7 +15/2
ARMREST F16 5A
F94 25A
+15/2 X1/14
(16) 31
*A28 PLUG MODULE X1/10 F92 10A
+30
X1 X18/4
*A30 PRINT ARU X24/2 17 18 2 X5/1
8 10
X3 7 13
B28 5V X70 21 48 70 46 69
1 9 9 (11)
CAN H A14
CAN + 18 A2 EEM2 A2 _GND
X7 15 CAN L
0.4V to 4.7V CAN - 42
X 2 2 16 Supply
CAN H
3 17
GND 4 CAN L
4 18
X1/21
P8/1 4 3 1 2 Pre-glowing and
+15

P8 ICU P8/2 fuel delivery pump X70 X20/1 A50/1 E10/1

*YA1 39 40 25 8 6 33 4 2 3 1 5 7
3 3 12V 4 (11)
K8/2
4 50 12V 5 SSR1
X1/12 30 87
*YB1 39 40 25 8 6 33 4 2 3 1 5 7 +30

1 2
X20/1 (11)
12V
CN3 17
* A27 CAN MODULE A1 ADIC 12V
26 16
M13 (11)
25 Emergency signal
X70
3 M 1
36 0.8 to 4.4 V
A2/2 PCU 2
X70 X9/7 (11)
12V
R8 X23/2 1 7
GND M13 _GND
4 U 23 6
CAN H
PCU activation 20 2 2.5 V
CAN L
44 1 2.5 V
S6
43 5 Emergency shut-down
130 Hz at 900 rpm
B21 X1/3 p 19 8 DZG
335 Hz at 2300 rpm
1 X70
p 34 GND A1 ADIC X1 14-pin plug connection
A2 EEM2 X1/3 1-pin plug connection
X3/20 55 GND A2/2 PCU X1/10 Plug connection
GND
n 1 62 A12 Central print X1/12 Plug connection
B20 2 39 510 Hz at 900 rpm
1300 Hz at 2300 rpm
A14 Engine print X1/14 Plug connection
f 12V A27 CAN module ---> DBD..... X1/21 Plug connection
3 45 A28 Plug module ---> DBD..... X2/22 2-pin plug connection
Switches and A30 Print ARU DBD..... ---> X3 4-pin plug connection
sensors A50/1 Power module X3/12 3-pin plug connection
t X2/22 B20 Engine speed sensor X3/13 3-pin plug connection
GND
B22 1 33 B21 Test switch, fuel delivery pressure X3/20 3-pin plug connection
R 2 PTC 1kΩ to 4.6 kΩ B22 Engine temperature sensor X4/71 4-pin plug connection
9
B23 „Water in fuel“ sensor X5/1 Plug connection
X3/13 X3/12 B28 Manual throttle X7 4-pin plug connection
12V B29 Sensor for charger pressure, X9/7 9-pin plug connection
R A 1 25
0.7 V at water in fuel charged air temperature X18/4 18-pin plug connection
B23 B 2 31 9 V no water in fuel CN3 26-pin plug connection X20/1 20-pin plug connection
U C 3
GND
22 E10/1 Heating flange X23/2 23-pin plug connection
K8/2 Relay, heating flange X24/2 24-pin plug connection
X4/71 M13 Fuel delivery pump X70 70-pin plug connection
GND
p,t 1 59 P8 ICU YA1 44-pin plug connection ---> DBD.....
NTC 32 kΩ to 102 Ω P8/1 4-pin plug connection
B29 2 12 YB1 44-pin plug connection ---> DBD.....
P8/2 4-pin plug connection (11) Ground point, engine device carrier
U,R 3 5V
11 R8 Potentiometer, accelerator pedal (16) Ground point, starter
4 35 1 V to approx. 2 V S6 Switch, engine oil pressure

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BLANK PAGE

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ARU up to DBD094270 4011-83

*) see Note page 8

FUNCTIONAL SCHEMATIC DIAGRAM FOR FMGR - SGR
X24/2
ARMREST (16) F19 5A
17 +15/1 F51 10A F18 5A
F20 5A +15/1 +15/1
*A28 PLUG MODULE 18 F14 7.5A A12 F9 10A
F16 5A GND +30 +30 A24 HYDROSTAT
X21 X11 *A30 PRINT ARU X1 X18/4 2 +15/2
3R7
A31 2 9 8 10
X5/1 X24/2 1 6 X24/2 21 23 M
1 1 7 13
S60/1 9 9
13 3 (16) (16) 3R7
X7 15 A4/3 10 14 13 A4/4 X16/21 13 12 3
CAN - CAN H
S60/2 2 16 1 A4 FMGR 17 1 A21 SGR
CAN H CAN L X6/9 E F L M H K B
11 11 3 17 3 18 2
CAN L Supply Supply
4 18 2

GND
11 V
S60/3
10 12 S4/4
X6/3 X24/3 A4/2 1 12 2 11 9 10 3
S60/4

0 V or 5 V
3 10 8 NEUTRAL LIMP HOME circuit
9 4 X16/21
2 11 7 DEAD MAN GND
GSV2 10
S60/5 4 12 6 12 V
Shuttle lever 14 Select 0 V** for FORWARDS
12 5 1 2 2 12 V
8 Select 0 V** for REVERSE
5 1 1 7 11 FORWARDS
*YA1 21 17 15 13 11 8 6 4 2 3 1 33 5 7 A23 ELECTRONICS
6 3 3 8 10 REVERSE **) Only if the
X4/59/b (A) and X4/59/c (B) A23 8 5 7 6

X4/59/b
X4/59/a
*YB1 21 17 15 13 11 8 6 4 2 3 1 33 5 7 plug connection is linked.
A21/4
* A27 CAN MODULE 11 X6/1

CAN H

CAN +
CAN L
12 4

CAN -
X24/3
2 19 A21/5 1
A12 X14/15 X10/11 A13 X10/12 P8 P8 ICU P8/1 1 21 3 3
F45 5A
+15/1 12 7 6 7 4 3 20 9 2
5 3 X4/59/c
3 2 A24 Hydrostat X5/1 Plug connection
Brake
X14/14 4 1 A27 CAN module ---> DBD..... X6/1 4-pin plug connection
X4/14 X24/3 A4/2 A28 Plug module ---> DBD..... X6/3 6-pin plug connection
P8/2 3 4 1 GSV2
6 A30 Print ARU DBD..... ---> X6/9 7-pin plug connection
A14 X20/1 X23/1 X10/14 12
F93 5A (7) S25 3.9 Ω A31 Multi controller X7 4-pin plug connection
+30 8 Q 7 (8) 3 4 14 3 V B17 Angle of rotation sensor, clutch X10/11 10-pin plug connection
S5 2 5 13 3 V CN3 26-pin plug connection X10/12 10-pin plug connection
P8 ICU X10/14 10-pin plug connection
P8 10-pin plug connection X11 16-pin plug connection
CN3 X24/3 A4/2 Clutch P8/1 4-pin plug connection X14/14 14-pin plug connection
A1 ADIC CAN L GSV2 P8/2 4-pin plug connection X14/15 14-pin plug connection
25 1 12 6
3.9 Ω R8 Potentiometer, accelerator pedal X16/21 16-pin plug connection
CAN H S46
26 A4/1 S4/4 Shuttle lever X18/4 18-pin plug connection
2 24 15 3 V S5 Switch for brake light X20/1 20-pin plug connection
S25 Switch for steering brake X21 14-pin plug connection
A4/4 S46 Switch, clutch X23/1 23-pin plug connection
A1 ADIC GND
1 13 4 S60/1 F/R button X23/2 23-pin plug connection
CAN H

A2 EEM2
CAN L

B17 5.6V S60/2 Cruise control button X24/2 24-pin plug connection
A4 FMGR 2 14 11
S60/3 Speed button + X24/3 24-pin plug connection
A4/1 18-pin plug connection U 3 15 12 1.1 to 4 V S60/4 Speed button - X70 70-pin plug connection
A4/2 18-pin plug connection S60/5 HTS button YA1 44-pin plug connection
A4/3 15-pin plug connection X1 14-pin plug connection ---> DBD.....
A4/4 18-pin plug connection X4/70 A4/4 Accelerator pedal X4/14 4-pin plug connection YB1 44-pin plug connection
A12 Central print GND X4/59/a 3-pin plug connection ---> DBD.....
1 1
A13 Roof print
X70 18 42 3 X4/59/b 3-pin plug connection (7) Ground point, roof hood, left
A14 Engine print R8 6 4.4 to 0.8 V X4/59/c 3-pin plug connection (8) Ground point, roof hood, right
A21 SGR transmission controller
A2 EEM2 5.8V
2 10 X4/70 4-pin plug connection (16) Ground point, starter
A21/4 12-pin plug connection
A21/5 12-pin plug connection 4 3 0.8 to 4.4 V
A23 Electronics X70 X23/2
A23 12-pin plug connection 36 U

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 4011-85

FAULTCODES ARU FROM DBD094271

ARU - 1 Processor fault (register check) ............................................................................................................. 87
ARU - 2 Processor fault (flash memory) ............................................................................................................. 87
ARU - 5 Processor fault (data memory) .............................................................................................................. 88
ARU - 10 Acknowledgement message from AUX1 was not received correctly after reprogramming from 0 to 1 88
ARU - 11 Acknowledgement message from AUX2 was not received correctly after reprogramming from 0 to 2 89
ARU - 12 Acknowledgement message from AUX3 was not received correctly after reprogramming from 0 to 3 90
ARU - 13 Acknowledgement message from AUX4 was not received correctly after reprogramming from 0 to 4 91
ARU - 14 Acknowledgement message from AUX5 was not received correctly after reprogramming from 0 to 5 92
ARU - 20 Supply voltage too low (< 8V) ............................................................................................................. 93
ARU - 21 Supply voltage too high (>18V) ........................................................................................................... 94
ARU - 30 Signal from AUX stick with latch (AUX1) below valid range ................................................................ 95
ARU - 31 Signal from AUX stick with latch (AUX1) above valid range ............................................................... 96
ARU - 32 Signal from AUX stick without latch (AUX2) below valid range ........................................................... 97
ARU - 33 Signal from AUX stick without latch (AUX2) above valid range .......................................................... 98
ARU - 34 Signal from AUX stick (AUX3) below valid range ................................................................................ 99
ARU - 35 Signal from AUX stick (AUX3) above valid range ............................................................................. 100
ARU - 36 Signal from throttle lever below valid range ...................................................................................... 101
ARU - 37 Signal from throttle lever above valid range ...................................................................................... 102
ARU - 38 Signal voltage from Resume Cruise Control button below valid range ............................................. 103
ARU - 39 Signal voltage from Resume Cruise Control button above valid range ............................................. 104
ARU - 40 Signal voltage from + button below valid range ................................................................................ 105
ARU - 41 Signal voltage from + button above valid range ................................................................................ 106
ARU - 50 Signal from oil flow potentiometer 1 (AUX1) outside valid range ...................................................... 107
ARU - 52 Signal from oil flow potentiometer 2 (AUX2) outside valid range ...................................................... 108
ARU - 54 Signal from oil flow potentiometer 3 (AUX3) outside valid range ...................................................... 109
ARU - 56 Signal from oil flow potentiometer 4 (AUX4) outside valid range ...................................................... 111
ARU - 58 Signal from oil flow potentiometer 5 (AUX5) outside valid range ...................................................... 112
ARU - 71 CAN Bus OFF up to DBD100000 ...................................................................................................... 114
ARU - 71 CAN Bus OFF from DBD100001 ....................................................................................................... 116
COMPONENTS SUMMARY ............................................................................................................................. 118
FUNCTIONAL SCHEMATIC DIAGRAM FOR REMOTE CONTROL VALVES UP TO DBD100000 ................ 123
FUNCTIONAL SCHEMATIC DIAGRAM FOR REMOTE CONTROL VALVES FROM DBD100001 ................ 125
FUNCTIONAL SCHEMATIC DIAGRAM FOR EEM2 UP TO DBD100000 ....................................................... 127
FUNCTIONAL SCHEMATIC DIAGRAM FOR EEM3 FROM DBD100001 ........................................................ 129
FUNCTIONAL SCHEMATIC DIAGRAM FOR FMGR - SGR UP TO DBD100000 ........................................... 131
FUNCTIONAL SCHEMATIC DIAGRAM FOR FMGR - SGR FROM DBD100001 ............................................ 133

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 4011-87

ARU - 1 Processor fault (register check)

Cause:
The processor's register appears to be defective.
The fault is stored and indicated by a warning triangle on the display.
Remedy:
Turn the ignition switch to the OFF position and then back to ON. The Print ARU must be replaced if the fault is acti-
vated again.
1. Remove the armrest:
Turn the ignition switch to the OFF position and remove the armrest.
Remove the lower armrestcover.
2. Replace the Print ARU:
Mark the connection and disconnect. Replace the Print ARU. Tight the screws smoothly.
Reconnect the connection accurate to right place.
3. Turn the ignition switch to the ON position and cancel the fault. Turn the ignition switch to the OFF position. After
waiting for at least 5 secs. turn the ignition switch to the ON position and check whether the fault is activated
again.
4. Attach the lower armrest cover. Fit the armrest.

ARU - 2 Processor fault (flash memory)

Cause:
Program memory fault: The program or memory could be defective.
The fault is stored and indicated by a warning triangle on the display.
Remedy:
Turn the ignition switch to the OFF position. Start the engine. (the number on the fault counter must have increased
by 1 if it is not already 13). If the same behaviour occurs again, then the Print ARU in the armrest must be replaced.
1. Remove the armrest:
Turn the ignition switch to the OFF position and remove the armrest.
Remove the lower armrest cover.
2. Replace the Print ARU :
Mark the connection and disconnect. Replace the Print ARU. Tight the screws smoothly.
Reconnect the connection accurate to right place.
3. Turn the ignition switch to the ON position and cancel the fault. Turn the ignition switch to the OFF position. After
waiting for at least 5 secs. turn the ignition switch to the ON position and check whether the fault is activated
again.
4. Attach the lower armrest cover. Fit the armrest.

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ARU - 5 Processor fault (data memory)

Cause:
The processor's data memory appears to be defective.
The fault is stored and indicated by a warning triangle on the display.
Remedy:
Turn the ignition switch to the OFF position. Start the engine. (the number on the fault counter must have increased
by 1 if it is not already 13). If the same behaviour occurs again, then the Print ARU in the armrest must be replaced.
1. Remove the armrest:
Turn the ignition switch to the OFF position and remove the armrest.
Remove the lower armrestcover.
2. Replace the Print ARU :
Mark the connection and disconnect. Replace the Print ARU. Tight the screws smoothly.
Reconnect the connection accurate to right place.
3. Turn the ignition switch to the ON position and cancel the fault. Turn the ignition switch to the OFF position. After
waiting for at least 5 secs. turn the ignition switch to the ON position and check whether the fault is activated
again.
4. Attach the lower armrest cover. Fit the armrest.

ARU - 10 Acknowledgement message from AUX1 was not received

correctly after reprogramming from 0 to 1
Cause:
The fault is stored and indicated by a warning triangle on the display.

Every AUX is assigned with a number (1 to 5) in the armrest.

The assignment (between 1 and 5) is included in the address of every message that is transmitted to all bus users
via the CAN BUS and thus to all AUX's as well. If an AUX is replaced by a "new" one, then this is normally assigned
with "0". After assembly, once the plug-in connection has been re-established and the ignition switch is turned to the
ON position, the number of the "previously installed" AUX is automatically assigned to the "newly installed" AUX (in
this case, No.1). The AUX then automatically sends an acknowledgement message (reply parameter) to the data bus.

If the acknowledgement message is not received correctly at the Print ARU in the armrest, two further attempts are
automatically made before the fault is activated and stored.
Remedy:
1. Use the Service Tool menu function "CONFIGURATION OF THE AUXILIARY VALVES".

a) Check whether the "newly installed" AUX has sent the acknowledgement message to the data bus: If the as-
signed number of the "previously installed" AUX appears in the left-hand column, then the Service Tool has re-
ceived the acknowledgement message.
b) Check the number of AUX's at the data bus. The number of AUX's connected to the data bus (and installed in
the tractor) is indicated in the left-hand column of the Service Tool ("EXISTING NUMBER OF AUXILIARY VAL-
VES").
2. If the "newly installed" AUX is connected to the CAN bus, but the number of AUX's is not displayed in the left-
hand column on the Service Tool, then the data bus cabling between the previously installed AUX and the Print
ARU in the armrest must be checked (see fault code ARU 71 and CAN BUS scheme).
3. If the fault is activated again even though the cabling is ok, then the following steps must be performed:
a) Replace the "newly installed" AUX with another one (connect it to the CAN BUS) and check repeatedly with
the Service Tool to see whether the assigned number of the "previously installed" AUX is displayed. If the number
is still not displayed, the Print ARU in the armrest could be defective.
b) Replace the Print ARU: (see fault code ARU 1, steps 1 to 4).
c) Repeat the check using the Service Tool.

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ARU - 11 Acknowledgement message from AUX2 was not received

correctly after reprogramming from 0 to 2
Cause:
The fault is stored and indicated by a warning triangle on the display.

Every AUX is assigned with a number (1 to 5) in the armrest.

The assignment (between 1 and 5) is included in the address of every message that is transmitted to all bus users
via the CAN BUS and thus to all AUX's as well. If an AUX is replaced by a "new" one, then this is normally assigned
with "0". After assembly, once the plug-in connection has been re-established and the ignition switch is turned to the
ON position, the number of the "previously installed" AUX is automatically assigned to the "newly installed" AUX (in
this case, No. 2). The AUX then automatically sends an acknowledgement message (reply parameter) to the data
bus.

If the acknowledgement message is not received correctly at the Print ARU in the armrest, two further attempts are
automatically made before the fault is activated and stored.
Remedy:
1. Use the Service Tool menu function "CONFIGURATION OF THE AUXILIARY VALVES".

a) Check whether the "newly installed" AUX has sent the acknowledgement message to the data bus: If the as-
signed number of the "previously installed" AUX appears in the left-hand column, then the Service Tool has re-
ceived the acknowledgement message.
b) Check the number of AUX's at the data bus. The number of AUX's connected to the data bus (and installed in
the tractor) is indicated in the left-hand column of the Service Tool ("EXISTING NUMBER OF AUXILIARY VAL-
VES").
2. If the "newly installed" AUX is connected to the CAN bus, but the number of AUX's is not displayed in the left-
hand column on the Service Tool, then the data bus cabling between the previously installed AUX and the Print
ARU in the armrest must be checked (see fault code ARU 71 and CAN BUS).
3. If the fault is activated again even though the cabling is ok, then the following steps must be performed:
a) Replace the "newly installed" AUX with another one (connect it to the CAN BUS) and check repeatedly with
the Service Tool to see whether the assigned number of the "previously installed" AUX is displayed. If the number
is still not displayed, the Print ARU in the armrest could be defective.
b) Replace the Print ARU: (see fault code ARU 1, steps 1 to 4).
c) Repeat the check using the Service Tool.

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ARU - 12 Acknowledgement message from AUX3 was not received

correctly after reprogramming from 0 to 3
Cause:
The fault is stored and indicated by a warning triangle on the display.

Every AUX is assigned with a number (1 to 5) in the armrest.

The assignment (between 1 and 5) is included in the address of every message that is transmitted to all bus users
via the CAN BUS and thus to all AUX's as well. If an AUX is replaced by a "new" one, then this is normally assigned
with "0". After assembly, once the plug-in connection has been re-established and the ignition switch is turned to the
ON position, the number of the "previously installed" AUX is automatically assigned to the "newly installed" AUX (in
this case, No. 3). The AUX then automatically sends an acknowledgement message (reply parameter) to the data
bus.

If the acknowledgement message is not received correctly at the Print ARU in the armrest, two further attempts are
automatically made before the fault is activated and stored.
Remedy:
1. Use the Service Tool menu function "CONFIGURATION OF THE AUXILIARY VALVES".

a) Check whether the "newly installed" AUX has sent the acknowledgement message to the data bus: If the as-
signed number of the "previously installed" AUX appears in the left-hand column, then the Service Tool has re-
ceived the acknowledgement message.
b) Check the number of AUX's at the data bus. The number of AUX's connected to the data bus (and installed in
the tractor) is indicated in the left-hand column of the Service Tool ("EXISTING NUMBER OF AUXILIARY
VALVES").
2. If the "newly installed" AUX is connected to the CAN bus, but the number of AUX's is not displayed in the left-
hand column on the Service Tool, then the data bus cabling between the previously installed AUX and the Print
ARU in the armrest must be checked (see fault code ARU 71 and CAN BUS).
3. If the fault is activated again even though the cabling is ok, then the following steps must be performed:
a) Replace the "newly installed" AUX with another one (connect it to the CAN BUS) and check repeatedly with
the Service Tool to see whether the assigned number of the "previously installed" AUX is displayed. If the number
is still not displayed, the Print ARU in the armrest could be defective.
b) Replace the Print ARU: (see fault code ARU 1, steps 1 to 4).
c) Repeat the check using the Service Tool.

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ARU - 13 Acknowledgement message from AUX4 was not received

correctly after reprogramming from 0 to 4
Cause:
The fault is stored and indicated by a warning triangle on the display.

Every AUX is assigned with a number (1 to 5) in the armrest.

The assignment (between 1 and 5) is included in the address of every message that is transmitted to all bus users
via the CAN BUS and thus to all AUX's as well. If an AUX is replaced by a "new" one, then this is normally assigned
with "0". After assembly, once the plug-in connection has been re-established and the ignition switch is turned to the
ON position, the number of the "previously installed" AUX is automatically assigned to the "newly installed" AUX (in
this case, No. 4). The AUX then automatically sends an acknowledgement message (reply parameter) to the data
bus.

If the acknowledgement message is not received correctly at the Print ARU in the armrest, two further attempts are
automatically made before the fault is activated and stored.
Remedy:
1. Use the Service Tool menu function "CONFIGURATION OF THE AUXILIARY VALVES".

a) Check whether the "newly installed" AUX has sent the acknowledgement message to the data bus: If the as-
signed number of the "previously installed" AUX appears in the left-hand column, then the Service Tool has re-
ceived the acknowledgement message.
b) Check the number of AUX's at the data bus. The number of AUX's connected to the data bus (and installed in
the tractor) is indicated in the left-hand column of the Service Tool ("EXISTING NUMBER OF AUXILIARY
VALVES").
2. If the "newly installed" AUX is connected to the CAN bus, but the number of AUX's is not displayed in the left-
hand column on the Service Tool, then the data bus cabling between the previously installed AUX and the Print
ARU in the armrest must be checked (see fault code ARU 71 and CAN BUS).
3. If the fault is activated again even though the cabling is ok, then the following steps must be performed:
a) Replace the "newly installed" AUX with another one (connect it to the CAN BUS) and check repeatedly with
the Service Tool to see whether the assigned number of the "previously installed" AUX is displayed. If the number
is still not displayed, the Print ARU in the armrest could be defective.
b) Replace the Print ARU: (see fault code ARU 1, steps 1 to 4).
c) Repeat the check using the Service Tool.

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ARU - 14 Acknowledgement message from AUX5 was not received

correctly after reprogramming from 0 to 5
Cause:
The fault is stored and indicated by a warning triangle on the display.

Every AUX is assigned with a number (1 to 5) in the armrest.

The assignment (between 1 and 5) is included in the address of every message that is transmitted to all bus users
via the CAN BUS and thus to all AUX's as well. If an AUX is replaced by a "new" one, then this is normally assigned
with "0". After assembly, once the plug-in connection has been re-established and the ignition switch is turned to the
ON position, the number of the "previously installed" AUX is automatically assigned to the "newly installed" AUX (in
this case, No. 5). The AUX then automatically sends an acknowledgement message (reply parameter) to the data
bus.

If the acknowledgement message is not received correctly at the Print ARU in the armrest, two further attempts are
automatically made before the fault is activated and stored.
Remedy:
1. Use the Service Tool menu function "CONFIGURATION OF THE AUXILIARY VALVES".

a) Check whether the "newly installed" AUX has sent the acknowledgement message to the data bus: If the as-
signed number of the "previously installed" AUX appears in the left-hand column, then the Service Tool has re-
ceived the acknowledgement message.
b) Check the number of AUX's at the data bus. The number of AUX's connected to the data bus (and installed in
the tractor) is indicated in the left-hand column of the Service Tool ("EXISTING NUMBER OF AUXILIARY VAL-
VES").
2. If the "newly installed" AUX is connected to the CAN bus, but the number of AUX's is not displayed in the left-
hand column on the Service Tool, then the data bus cabling between the previously installed AUX and the Print
ARU in the armrest must be checked (see fault code ARU 71 and CAN BUS).
3. If the fault is activated again even though the cabling is ok, then the following steps must be performed:
a) Replace the "newly installed" AUX with another one (connect it to the CAN BUS) and check repeatedly with
the Service Tool to see whether the assigned number of the "previously installed" AUX is displayed. If the number
is still not displayed, the Print ARU in the armrest could be defective.
b) Replace the Print ARU: (see fault code ARU 1, steps 1 to 4).
e) Repeat the check using the Service Tool.

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ARU - 20 Supply voltage too low (< 8V)

Cause:
The supply voltage of the Print ARU is < 8V (12V nominal).
The fault is stored and indicated by a warning triangle on the display.

Possible causes:
1. Contact resistance at electrical connections too high:
a) Plug-in contacts, screwed / crimped connections oxidized.
b) Contacts loose, bent or pushed back (not engaged) in the plug housing.
c) The Print ARU is defective.
2. Voltage drop too high during the starting procedure:
a) Battery charge is insufficient or the battery is defective.
b) Print ARU in the armrest is defective (buffer capacity too small).
Remedy:
General:
Once the ignition switch is turned to the ON position, the Print ARU is supplied with 12V (nominal) for fuse F20, 5A
(15/1), on central print A12.

The voltage should be 12.5 to 14 V when the engine is running and the charging indicator has gone out.

In order to ensure a reliable supply to the Print ARU under all operating conditions, the following safety components
are ordered:
Safety diode V1/1, overload protection V1/2, capacities C1 and C2 as a buffer against short dips in the supply voltage
(caused by operating loads outside the armrest).

For voltage measurements, the ignition switch must be turned to the ON position.
1. Cancel the fault. Turn the ignition switch to the ON position.
a) If fault ARU 20 is activated again, go to step 2.
b) If fault ARU 20 is not activated, start the engine. If fault ARU 20 is activated again, go to step 2.
2. Check the supply voltage (12V nominal):

Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover.

a) Check the voltage between PIN9 (12V) and PIN8 (GND) on plug X30/1 of the Print ARU (at least 12V). If there
is no voltage, go to step b.
NOTE: When checking the voltage at plug X30/1, load the supply with a 12V 21W bulb (during operation there is an
additional load due to the switching of the front loader switch.
If a voltage of 12V is available, go to step c.

b) Check the supply voltage at plug X18/4:

Turn the ignition switch to the OFF position. Remove the lower right-hand covering in the cab.
Plug X18/4 PIN9 (at least 12V) to PIN10 (GND). If the voltage is available, rectify the fault in the cabling between
plug X18/4 and plug X30/1 on the Print ARU.
If the voltage is not available, rectify the fault in the cabling between fuse F20 and plug X18/4 with the help of the
circuit diagram.

c) Cancel the fault. Then turn the ignition switch to the OFF position. After waiting for at least 5 secs., start the
engine. If fault ARU 20 is activated again, then the Print ARU must be replaced
(see fault code ARU 1, steps 1 to 4).

d) Refit the lower armrest cover. Fit the armrest. Start the engine and check that fault ARU 20 is no longer acti-
vated.

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ARU - 21 Supply voltage too high (>18V)

Cause:
The supply voltage is > 18VDC.
The fault is stored and indicated by a warning triangle on the display.

Possible causes:
1. The alternator voltage regulator is defective.
2. Ground connection between the alternator / battery and Print ARU faulty.
3. Print ARU defective.
Remedy:
With the engine running (charging indicator lamp has gone out), check the charge voltage of the alternator and the
battery voltage. The charge voltage should be 13.8 to 14.5 V at various engine speeds. If the charge voltage is much
higher, go to step 2.
1. If the charge voltage is ok, check the ground connection from the generator via the battery to the Print ARU, plug
X30/1, PIN4 (12V) to PIN8 (GND); repair if necessary. With the engine running (charging indicator lamp has gone
out), check the supply voltage at the Print ARU, plug X30/1, PIN9 (12V) to PIN8 (GND) (12.5 to 14.5 V). If the
cabling and supply voltage at the Print ARU are ok, but fault 21 is activated again after starting the engine once
again, then the Print ARU must be replaced (see fault code ARU 1, steps 1 to 4).
2. If the charge voltage is not within the specified value limits, then the alternator voltage regulator must be replaced.
Then start the engine. When the charging indicator lamp has gone out, check the charge voltage at various engine
speeds and check whether fault 21 is still activated.

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ARU - 30 Signal from AUX stick with latch (AUX1) below valid range
Cause:
The signal voltage from the AUX stick B30 is < 0.2V.
The fault is stored and indicated by a warning triangle on the display.

The signal voltage must lie within a certain voltage range (0.2 to 4.8V) over the entire control range.

Possible causes:
1. Short-circuit between the signal line and ground (GND).
2. Contact fault or interruption in the signal line from the AUX stick via the Print ARU (resistance too high).
3. Contact fault in the supply line (5V) from the Print ARU up to the AUX stick (resistance too high), thus voltage at
AUX stick < 5V.
4. AUX stick defective (mechanical or electrical fault).
5. Print ARU defective (e.g. load resistance for signal < 20 kohms).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 30 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"AUX1 RAISE / LOWER OIL FLOW SETPOINT" to check the functionality of the AUX stick.
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Carry out the following voltage measurements at the Print ARU , plug X30/5:
PIN1 (5V) to PIN3 (GND): Supply voltage approx. 5.0V (plug X30/5 disconnected; the AUX stick supply is thus
not on-load).
The AUX stick has a maximum power consumption of 10 mA.
Supply voltage approx. 5.0V (plug X30/5 connected).
PIN2 (signal) to PIN3 (GND): The signal voltage must change from 0.2 to 4.8V when the AUX stick is moved from
limit to limit (plug X30/5 connected).
Signal voltage between 2.33 and 2.67V (2.5V nominal), when the AUX stick B30 is in the Neutral position (plug
X30/5 connected).
If the supply voltage and the signal voltage correspond with the setpoints, then the AUX stick and the cabling bet-
ween the AUX stick and plug X30/5 on the plug module are ok. Go to step 4.
If the signal voltage at plug X30/5 PIN2 is < 0.2V, go to step 3.
3. Check the plug-in contacts and lines to the AUX stick. Detach PIN2 (signal) from the plug housing (it is thus not
on-load). Check the AUX stick signal voltage from detached PIN2 to PIN3 (GND). If the signal voltage is still
< 0.2V in this state, then the AUX stick must be replaced.
If this section of the signal line is ok and the signal voltage at plug X30/5 is ok with PIN2 detached, set in PIN2
again.
4. Attach the lower armrest cover and fit the armrest.

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ARU - 31 Signal from AUX stick with latch (AUX1) above valid range
Cause:
The signal voltage from the AUX stick B30 is > 4.8 V.
The fault is stored and indicated by a warning triangle on the display.

The signal voltage must lie within a certain voltage range (0.2 to 4.8 V) over the entire control range.

Possible causes:
1. Short-circuit between the signal line and supply voltage (5V).
2. Contact fault or interruption in the ground line (GND) from the Print ARU up to the AUX stick (resistance too high).
3. AUX stick defective (mechanical or electrical fault).
4. Supply voltage < 5V > 12V (Print ARU defective).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 31 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"AUX1 RAISE / LOWER OIL FLOW SETPOINT" to check the functionality of the AUX stick.
1. Turn the ignition switch to the OFF position. Remove the armrest and the lower cover.
2. Check the supply voltage (setpoint value approx. 5.0V):
At Print ARU , plug X30/5 PIN1 (5V) to PIN3 (GND).
3. Check the signal voltage (setpoint value from 0.2 to 4.8V; move the AUX stick when doing so). Signal voltage
between 2.33 and 2.67V (2.5V nominal) when the AUX stick B30 is in the Neutral position:
At Print ARU, plug X30/5 PIN2 (signal) to PIN3 (GND for "hall elements" such as AUX sticks, etc.).
If the signal voltage is > 4.8V, go to step 5.
If the supply voltage and the signal voltage correspond with the setpoints, then the Print ARU is defective. Repla-
ce the Print ARU (see fault code ARU 1, steps 1 and 2).
4. Supply voltage > 5V, <12V):
Turn the ignition switch to the OFF position. Check the ground line (GND) at plug 30/5. Rectify any contact faults
that are found or replace the units.
If the ground line is ok, then the Print ARU must be replaced (see fault code ARU 1, steps 1 and 2).
5. Disconnect plug X30/5 at the Print ARU. Cancel fault 31. Turn the ignition switch to the ON position.
If fault 31 is no longer activated, check plug X30/5 and the cabling to the AUX stick.
If the check does not reveal a fault, then the AUX stick must be replaced.
6. Attach the lower armrest cover and fit the armrest.

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ARU - 32 Signal from AUX stick without latch (AUX2) below

valid range
Cause:
The signal voltage from the AUX stick B31 is < 0.2V.
The fault is stored and indicated by a warning triangle on the display.

The signal voltage must lie within a certain voltage range (0.2 to 4.8V) over the entire control range.

Possible causes:
1. Short-circuit between the signal line and ground (GND).
2. Contact fault or interruption in the signal line from the AUX stick via the Print ARU (resistance too high).
3. Contact fault in the supply line (5V) from the Print ARU up to the AUX stick (resistance too high), thus voltage at
AUX stick < 5V.
4. AUX stick defective (mechanical or electrical fault).
5. Print ARU defective (e.g. load resistance for signal < 20 kohms).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 32 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"AUX2 RAISE / LOWER OIL FLOW SETPOINT" to check the functionality of the AUX stick.
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Carry out the following voltage measurements at Print ARU , plug X30/5:
PIN5 (5V) to PIN7 (GND): Supply voltage approx. 5.0V (plug X30/5 disconnected; the AUX stick supply is thus
not on-load).
The AUX stick has a maximum power consumption of 10 mA.
Supply voltage approx. 5.0V (plug X30/5 connected).
PIN6 (signal) to PIN7 (GND): The signal voltage must change from 0.2 to 4.8V when the AUX stick is moved from
limit to limit (plug X30/5 connected).
Signal voltage between 2.33 and 2.67V (2.5V nominal), when the AUX stick B31 is in the Neutral position (plug
X30/5 connected).
If the supply voltage and the signal voltage correspond with the setpoints, then the AUX stick and the cabling bet-
ween the AUX stick and plug X30/5 on the Print ARU are ok. Go to step 4.
If the signal voltage at plug X30/5 PIN6 is < 0.2V, go to step 3.
3. Check the plug-in contacts and lines to the AUX stick. Detach PIN6 (signal) from the plug housing (it is thus not
on-load). Check the AUX stick signal voltage from detached PIN6 to PIN7 (GND). If the signal voltage is still
< 0.2V in this state, then the AUX stick must be replaced.
If this section of the signal line is ok and the signal voltage at plug X30/5 is ok with PIN6 detached, set in PIN6
again.
4. Attach the lower armrest cover and fit the armrest.

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ARU - 33 Signal from AUX stick without latch (AUX2) above

valid range
Cause:
The signal voltage from the AUX stick B31 is > 4.8 V.
The fault is stored and indicated by a warning triangle on the display.

The signal voltage must lie within a certain voltage range (0.2 to 4.8V) over the entire control range.

Possible causes:
1. Short-circuit between the signal line and supply voltage (5V).
2. Contact fault or interruption in the ground line (GND) from the Print ARU up to the AUX stick (resistance too high).
3. AUX stick defective (mechanical or electrical fault).
4. Supply voltage < 5V > 12V (Print ARU defective).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 33 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"AUX2 RAISE / LOWER OIL FLOW SETPOINT" to check the functionality of the AUX stick.
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover.
2. Check the supply voltage (setpoint value approx. 5.0V):
At the Print ARU, plug X30/5 PIN5 (5V) to PIN7 (GND).
3. Check the signal voltage (setpoint value from 0.2 to 4.8V; move the AUX stick when doing so). Signal voltage
between 2.33 and 2.67V (2.5V nominal) when the AUX stick B31 is in the Neutral position:
At the Print ARU, plug X30/5 PIN6 (signal) to PIN7 (GND for "hall elements" such as AUX sticks, etc.).
If the signal voltage is > 4.8V, go to step 5.
If the supply voltage and the signal voltage correspond with the setpoints, then the Print ARU is defective. Repla-
ce the Print ARU (see fault code ARU 1, steps 1 and 2).
4. Supply voltage > 5V, <12V):
Turn the ignition switch to the OFF position. Check the ground line (GND) at plug X30/5. Rectify any contact faults
that are found or replace the units.
If the ground line is ok, then the Print ARU must be replaced (see fault code ARU 1, steps 1 and 2).
5. Disconnect plug X30/5 at the Print ARU. Cancel fault 33. Turn the ignition switch to the ON position.
If fault 33 is no longer activated, check plug X30/5 and the cabling to the AUX stick.
If the check does not reveal a fault, then the AUX stick must be replaced.
6. Attach the lower armrest cover and fit the armrest.

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 4011-99

ARU - 34 Signal from AUX stick (AUX3) below valid range

Cause:
The signal voltage from the AUX stick B52 is < 0.2V.
The fault is stored and indicated by a warning triangle on the display.

The signal voltage must lie within a certain voltage range (0.2 to 4.8V) over the entire control range.

Possible causes:
1. Short-circuit between the signal line and ground (GND).
2. Contact fault or interruption in the signal line from the AUX stick via the Print ARU (resistance too high).
3. Contact fault in the supply line (5V) from the Print ARU up to the AUX stick (resistance too high), thus voltage at
AUX stick < 5V.
4. AUX stick defective (mechanical or electrical fault).
5. Print ARU defective (e.g. load resistance for signal < 20 kohms).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 34 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"AUX3 RAISE / LOWER OIL FLOW SETPOINT" to check the functionality of the AUX stick.
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Carry out the following voltage measurements at the Print ARU, plug X30/4:
PIN1 (5V) to PIN4 (GND): Supply voltage approx. 5.0V (plug X30/4 disconnected; the AUX stick supply is thus
not on-load).
The AUX stick has a maximum power consumption of 10 mA.
Supply voltage approx. 5.0V (plug X30/4 connected).
PIN2 (signal) to PIN4 (GND): The signal voltage must change from 0.2 to 4.8V when the AUX stick is moved from
limit to limit (plug X30/4 connected).
Signal voltage between 2.33 and 2.67V (2.5V nominal), when the AUX stick B52 is in the Neutral position (plug
X30/4 connected).
If the supply voltage and the signal voltage correspond with the setpoints, then the AUX stick and the cabling bet-
ween the AUX stick and plug X30/4 on the Print ARU are ok. Go to step 4.
If the signal voltage at plug X30/4 PIN2 is < 0.2V, go to step 3.
3. Check the plug-in contacts and lines to the AUX stick. Detach PIN2 (signal) from the plug housing (it is thus not
on-load). Check the AUX stick signal voltage from detached PIN2 to PIN4 (GND). If the signal voltage is still
< 0.2V in this state, then the AUX stick must be replaced.
If this section of the signal line is ok and the signal voltage at plug X30/4 is ok with PIN2 detached, set in PIN2
again.
4. Attach the lower armrest cover and fit the armrest.

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4011-100

ARU - 35 Signal from AUX stick (AUX3) above valid range

Cause:
The signal voltage from the AUX stick B52 is > 4.8 V.
The fault is stored and indicated by a warning triangle on the display.

The signal voltage must lie within a certain voltage range (0.2 to 4.8V) over the entire control range.

Possible causes:
1. Short-circuit between the signal line and supply voltage (5V).
2. Contact fault or interruption in the ground line (GND) from the Print ARU up to the AUX stick (resistance too high).
3. AUX stick defective (mechanical or electrical fault).
4. Supply voltage < 5V > 12V (Print ARU defective).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 35 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"AUX3 RAISE / LOWER OIL FLOW SETPOINT" to check the functionality of the AUX stick.
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover.
2. Check the supply voltage (setpoint value approx. 5.0V):
At the Print ARU, plug X30/4 PIN1 (5V) to PIN4 (GND).
3. Check the signal voltage (setpoint value from 0.2 to 4.8V; move the AUX stick when doing so). Signal voltage
between 2.33 and 2.67V (2.5V nominal) when the AUX stick B52 is in the Neutral position:
At thePrint ARU, plug X30/4 PIN2 (signal) to PIN4 (GND for "hall elements" such as AUX sticks, etc.).
If the signal voltage is > 4.8V, go to step 5.
If the supply voltage and the signal voltage correspond with the setpoints, then the Print ARU is defective.
Replace the Print ARU (see fault code ARU 1, steps 1 and 2).
4. Supply voltage > 5V, <12V):
Turn the ignition switch to the OFF position. Check the ground line (GND) at plug X30/4. Rectify any contact faults
that are found or replace the units.
If the ground line is ok, then the Print ARU must be replaced (see fault code ARU 1, steps 1 and 2).
5. Disconnect plug X30/4 at the Print ARU. Cancel fault 35. Turn the ignition switch to the ON position.
If fault 35 is no longer activated, check plug X30/4 and the cabling to the AUX stick.
If the check does not reveal a fault, then the AUX stick must be replaced.
6. Attach the lower armrest cover and fit the armrest.

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 4011-101

ARU - 36 Signal from throttle lever below valid range

Cause:
The signal voltage from the throttle lever B28 is < 0.2V.
The fault is stored and indicated by a warning triangle on the display.

The signal voltage must lie within a certain voltage range (0.2 to 4.8V) over the entire control range.

Possible causes:
1. Short-circuit between the signal line and ground (GND).
2. Contact fault or interruption in the signal line from the throttle lever via the Print ARU (resistance too high).
3. Contact fault in the supply line (5V) from the Print ARU up to the throttle lever (resistance too high), thus voltage
at the throttle lever < 5V.
4. Throttle lever defective (mechanical or electrical fault).
5. Print ARU defective (e.g. load resistance for signal < 4.5k ohms).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 36 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"THROTTLE LEVER" to check the functionality of the throttle lever.
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Carry out the following voltage measurements at the Print ARU, plug X30/3:
PIN1 (5V) to PIN4 (GND): Supply voltage approx. 5.0V (plug X30/3 disconnected; the throttle lever supply is thus
not on-load).
The throttle lever has a maximum power consumption of 15 mA.
Supply voltage approx. 5.0V (plug X30/3 connected).
PIN2 (signal) to PIN4 (GND): The signal voltage must not be < 0.2V and > 4.8V when the throttle lever is moved
from limit to limit (plug X30/3 connected).
If the supply voltage and the signal voltage correspond with the setpoints, then the throttle lever and the cabling
between the throttle lever and plug X30/3 on the Print ARU is ok. Go to step 4.
If the signal voltage at plug X30/3 PIN2 is < 0.2V, go to step 3.
3. Check the plug-in contacts and lines to the throttle lever. Detach PIN2 (signal) from the plug housing (it is thus
not on-load). Check the throttle lever signal voltage from detached PIN2 to PIN4 (GND). If the signal voltage is
still < 0.2V in this state, then the throttle lever must be replaced.
If this section of the signal line is ok and the signal voltage at plug X30/3 is ok with PIN2 detached, set in PIN2
again.
4. Attach the lower armrest cover and fit the armrest.

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4011-102

ARU - 37 Signal from throttle lever above valid range

Cause:
The signal voltage from the throttle lever B28 is > 4.8V.
The fault is stored and indicated by a warning triangle on the display.

The signal voltage must lie within a certain voltage range (0.2 to 4.8V) over the entire control range.

Possible causes:
1. Short-circuit between the signal line and supply voltage (5V).
2. Contact fault or interruption in the ground line (GND) from the Print ARU to the throttle lever (resistance too high).
3. Throttle lever defective (mechanical or electrical fault).
4. Supply voltage < 5V > 12V (Print ARU defective).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again. If fault 37 is activated again, carry out troubles-
hooting as follows:
Use the Service Tool monitor:
"THROTTLE LEVER" to check the functionality of the throttle lever.
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover.
2. Check the supply voltage (setpoint value approx. 5.0V):
At the Print ARU, plug X30/3 PIN1 (5V) to PIN4 (GND).
3. Check the signal voltage (setpoint value from 0.2 to 4.8V; move the throttle lever B28 from limit to limit when doing
so):
At the Print ARU, plug X30/3 PIN2 (signal) to PIN4 (GND for "hall elements" such as AUX sticks, etc.).
If the signal voltage is > 4.8V, go to step 5.
If the supply voltage and the signal voltage correspond with the setpoints, then the Print ARU is defective.
Replace the Print ARU (see fault code ARU 1, steps 1 and 2).
4. Supply voltage > 5V, <12V):
Turn the ignition switch to the OFF position. Check the ground line (GND) at plug X30/3. Rectify any contact faults
that are found or replace the units.
If the ground line is ok, then the Print ARU must be replaced (see fault code ARU 1, steps 1 and 2).
5. Disconnect plug X30/3 at the Print ARU. Cancel fault 37. Turn the ignition switch to the ON position.
If fault 37 is no longer activated, check plug X30/3 and the cabling to the throttle lever.
If the check does not reveal a fault, then the throttle lever must be replaced.
6. Attach the lower armrest cover and fit the armrest.

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 4011-103

ARU - 38 Signal voltage from Resume Cruise Control button below

valid range
Cause:
The signal voltage from the Resume Cruise Control button S60/2 is < 0.2V.
The fault is stored and indicated by a warning triangle on the display.

The signal voltage must lie within a certain voltage range:

Cruise Control button not depressed: 0.2 - 2.3V (actual approx. 1V).
Cruise Control button depressed: 2.4 - 4.8V (actual approx. 4V).
The Print ARU supplies a supply voltage of 5V for the pushbutton function on the multi-controller.
Possible causes:
1. Multi-controller defective
2. Plug module defective
Remedy:
Start the engine again and check whether the fault is activated again.
Use the Service Tool monitor:
"RESUME CRUISE CONTROL BUTTON" to check the pushbutton function.
If fault 38 is activated again, continue troubleshooting as follows:
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Check the supply voltage (5V):
Plug X30/11 on the Print ARU, PIN1 (5V) to PIN9 (GND) and plug X21 on the print of the multi-controller II, PIN1
(5V) to PIN2 (GND).
If a voltage of 5V is available at plug X30/11, but not up to plug X21, then there is an interruption in between or a
poor line connection. Check the individual plugs and sections; replace faulty units. Go to step 3 when there is a
supply voltage of 5V at plug X21.
3. Check the signal voltage (from the keyboard up to the Print ARU):
Plug X21 on the print of the multi-controller II, PIN11 to PIN2 (GND).
Plug X30/11 on the plug module, PIN11 to PIN9 (GND).
Button not depressed 0.2V - 2.3V; button depressed 2.4 - 4.8V. If the signal voltage is < 0.2V, go to step 4.
If the supply voltage and the signal voltage are in the specified range, then the Print ARU must be replaced (see
fault code ARU 1, steps 1 and 2).
If the signal voltage at plug X30/11 PIN11 isn't ok (< 0,2V), got to step 4.
4. Disconnect plug X30/11 and measure the resistance at the plug connection to multi-controller II (from PIN11 to
PIN1).
Button not depressed: approx. 8.2 kohms. Button depressed approx. 480 ohms.
If the setpoint values are attained, the button's resistor circuit is ok.
If the setpoint values are not attained, go to step 5.
5. Unscrew the screw on the grip housing on the multi-controller II. Carefully detach the keyboard from the grip hou-
sing. Disconnect plug X21 at the keyboard (14-pole) and measure the resistance at the connection on the key-
board (from PIN1 to PIN11):
a) Button not depressed, approx. 8.2 kohms.
b) Button depressed, approx. 480 ohms.
If the setpoint values are not attained, the fault is in the keyboard. Replace the keyboard. If the setpoint values
are attained, the fault in the line between plug X30/11 and plug X21 must be rectified or the line replaced.
If the resistance setpoint values are now attained at plug X30/11, reconnect the plug.
Turn the ignition switch to the ON position. Cancel fault 38 and check whether the fault is activated again.
6. Attach the lower armrest cover and fit the armrest.

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4011-104

ARU - 39 Signal voltage from Resume Cruise Control button above

valid range
Cause:
The signal voltage from the Resume Cruise Control button S60/2 is > 4.8V.
The fault is stored and indicated by a warning triangle on the display.

The signal voltage must lie within a certain voltage range:

Cruise Control button not depressed: 0.2 - 2.3V (actual approx. 1V).
Cruise Control button depressed: 2.4 - 4.8V (actual approx. 4V).
Possible causes:
1. Signal voltage too high due to a short-circuit to another signal in the armrest or to the 5V or 12V supply.
2. Fault in the resistor circuit on the print of the multi-controller II. Supply voltage to the keyboard too high (> 5V)
due to:
3. Faulty ground supply (GND) to the Print ARU.
4. Print ARU defective.
Remedy:
Start the engine again and check whether the fault is activated again.
Use the Service Tool monitor:
"RESUME CRUISE CONTROL BUTTON" to check the pushbutton function.
If fault 39 is activated again, continue troubleshooting as follows:
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Check the supply voltage (5V):
Plug X30/11 on the Print ARU, PIN1 (5V) to PIN9 (GND).
If the supply voltage of 5V is exceeded, then the Print ARU must be replaced
(see fault code ARU 1, steps 1 and 2).
If the supply voltage of 5V is not exceeded, go to step 3.
3. Check the signal voltage (from pushbutton function to Print ARU) at the following points:
Plug X30/11 on Print ARU, PIN11 to PIN9 (GND).
Button not depressed: 0.2 - 2.3V, button depressed: 2.4 - 4.8V. If the signal voltage at plug X30/11 is ok, the
ground line (GND) and plug-in connections from plug X18/4 to plug X30/11 on the Print ARU still have to be chek-
ked.
If the ground line is ok and the signal voltage too high, go to step 4.
4. Turn the ignition switch to the OFF position and disconnect plug X30/11 at the Print ARU.
Measure the resistance at the plug connection to the multi-controller II (from PIN11 to PIN1). Button not depres-
sed: approx. 8.2 kohms, button depressed: approx. 480 ohms.
If the setpoint values are attained, the button's resistor circuit is ok.
The next step is to check whether the signal line to plug X30/11 has a short-circuit to another signal line or to a
supply (+).
If the setpoint values are not attained (e.g. the resistance is much lower), continue troubleshooting as follows:
Unscrew the screw on the grip housing on the multi-controller II and carefully detach the pushbutton function unit
from the grip housing. Disconnect plug X21 (14-pole) at the keyboard and measure the resistance from PIN1 to
PIN11 on the keyboard:
a) Button not depressed: approx. 8.2 kohms,
b) Button depressed: approx. 480 ohms.
If the setpoint values are not attained, the fault is in the keyboard. Replace it. If the setpoint values are attained,
the fault in the line between plug X30/11 and plug X21 must be rectified or the line replaced.
5. Cancel the fault, start the engine again and check whether the fault is activated again.
6. Attach the lower armrest cover and fit the armrest.

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 4011-105

ARU - 40 Signal voltage from + button below valid range

Cause:
The signal voltage from the "+" button S60/3 is < 0.2V.

The fault is stored and indicated by a warning triangle on the display.

The signal voltage must lie within a certain voltage range:
Button "+" not depressed: 0.2 -2.3V (actual approx. 1V).
Button"+" depressed: 2.4 - 4.8V (actual approx. 4V).
The Print ARU supplies a supply voltage of 5V for the pushbutton function on the multi-controller II
Possible causes:
1. Multi-controller II defective
2. Print ARU defective
Remedy:
Start the engine again and check whether the fault is activated again.
Use the Service Tool monitor:
"MULTI-CONTROLLER II + BUTTON" to check the pushbutton function.
If fault 38 is activated again, carry out troubleshooting as follows:
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Check the supply voltage (5V):
Plug X30/11 on the Print ARU, PIN1 (5V) to PIN9 (GND) and plug X21 on the multi-controller II keyboard, PIN1
(5V) to PIN2 (GND). If a voltage of 5V is available at plug X30/11, but not up to plug X21, then there is an inter-
ruption in between or a poor line connection. Check the individual plugs and sections; replace faulty units. Go to
step 3 when there is a supply voltage of 5V at plug X21.
3. Check the signal voltage (from the keyboard up to the Print ARU):
Plug X21 on the multi-controller II keyboard, PIN10 to PIN2 (GND).
Plug X30/11 on the Print ARU, PIN12 to PIN9 (GND).
Button not depressed 0.2 - 2.3V; button depressed 2.4 - 4.8V. If the signal voltage is < 0.2V, go to step 4.
If the supply voltage and the signal voltage are in the specified range, then the Print ARU must be replaced (see
fault code ARU 1, steps 1 and 2).

If the signal voltage at plug X30/11 PIN12 is not ok (< 0.2V). Go to step 4.
4. Disconnect plug X30/11. Measure the resistance at the plug connection to the multi-controller II (from PIN12 to
PIN1).
a) Button not depressed: Setpoint value approx. 8.2 kohms,
b) Button depressed: Setpoint value approx. 480 ohms.
If the setpoint values are attained, the button's resistor circuit is ok.
If the setpoint values are not attained, go to step 5.
5. Unscrew the screw on the grip housing on the multi-controller II. Carefully detach the keyboard from the grip hou-
sing. Disconnect plug X21 at the keyboard (14-pole) and measure the resistance at the plug connection on the
keyboard (from PIN1 to PIN10):
a) Button not depressed, approx. 8.2 kohms.
b) Button depressed, approx. 480 ohms.
If the setpoint values are not attained, the fault is in the keyboard. Replace the keyboard. If the setpoint values
are attained, the fault in the line between plug X30/11 and plug X21 must be rectified or the line replaced.
If the resistance setpoint values are now attained at plug X30/11, reconnect the plug.
Turn the ignition switch to the ON position. Cancel fault 40 and check whether the fault is activated again.
6. Attach the lower armrest cover and fit the armrest.

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4011-106

ARU - 41 Signal voltage from + button above valid range

Cause:
The signal voltage from the "+" button S60/3 is > 4.8V.
The fault is stored and indicated by a warning triangle on the display.

The signal voltage must lie within a certain voltage range:

Button "+" not depressed: 0.2 - 2.3V (actual approx. 1V).
Button "+" depressed: 2.4 - 4.8V (actual approx. 4V).

Possible causes:
1. Signal voltage too high due to a short-circuit to another signal in the armrest or to the 5V or 12V supply.
2. Fault in the resistor circuit of the multi-controller II pushbutton function. Supply voltage to the keyboard too high
(> 5V) due to:
3. Faulty ground supply (GND) to the Print ARU.
4. Print ARU defective.
Remedy:
Start the engine again and check whether the fault is activated again.
Use the Service Tool monitor:
"MULTI-CONTROLLER II + BUTTON" to check the pushbutton function.
If fault 41 is activated again, continue troubleshooting as follows:
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Check the supply voltage (5V):
Plug X30/11 on the Print ARU, PIN1 (5V) to PIN9 (GND).
If the supply voltage of 5V is exceeded, then the Print ARU must be replaced
(see fault code ARU 1, steps 1 and 2).
If the supply voltage of 5V is not exceeded, go to step 3.
3. Check the signal voltage (from pushbutton function to Print ARU) at the following points:
Plug X30/11 on Print ARU, PIN12 to PIN9 (GND).
Button not depressed: 0.2 - 2.3V, button depressed: 2.4 - 4.8V. If the signal voltage at plug X30/11 is ok, the
ground line (GND) and plug-in connections from plug X18/4 to plug X30/11 on the Print ARU still have to
be checked.
If the ground line is ok and the signal voltage too high, go to step 4.
4. Turn the ignition switch to the OFF position and disconnect plug X30/11 at the Print ARU.
Measure the resistance at the plug connection to the multi-controller II from (PIN12 to PIN1). Button not depres-
sed: approx. 8.2 kohms, button depressed: approx. 480 ohms.
If the setpoint values are attained, the button's resistor circuit is ok.
The next step is to check whether the signal line at plug X30/11 has a short-circuit to another signal line or to a
supply (+).
If the setpoint values are not attained (e.g. the resistance is much lower), continue troubleshooting as follows:
Unscrew the screw on the grip housing on the multi-controller II and carefully detach the pushbutton function unit
from the grip housing. Disconnect plug X21 (14-pole) at the keyboard and measure the resistance from PIN1 to
PIN10 on the keyboard:
a) Button not depressed: approx. 8.2 kohms,
b) Button depressed: approx. 480 ohms.
If the setpoint values are not attained, the fault is in the keyboard. Replace it. If the setpoint values are attained,
the fault in the line between plug X30/11 and plug X21 must be rectified or the line replaced.
5. Cancel the fault, start the engine again and check whether the fault is activated again.
6. Attach the lower armrest cover and fit the armrest.

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 4011-107

ARU - 50 Signal from oil flow potentiometer 1 (AUX1) outside

valid range
Cause:
The signal voltage is < 0.43 or > 4.70V.
The fault is stored and indicated by a warning triangle on the display.

The signal voltage must lie within a certain range (> 0.43 and < 4.70V).

Possible causes:
1. Contact fault in the signal line between potentiometer R20/1 and the Print ARU in the armrest.
2. Short-circuit in the signal line to supply (5V) between the potentiometer R20/1 and Print ARU.
3. Contact fault in the supply line (5V) between the Print ARU and potentiometer R20/1.
4. Contact fault in the GND potentiometer line between the Print ARU and potentiometer R20/1.
5. The potentiometer R20/1 is defective.
6. Print ARU is defective (e.g. resistors R28/7 or R28/8 have an interruption).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again and check whether fault 50 is activated again.
Use the Service Tool monitor:
"AUX1 FLOW COMMAND SETPOINT" (signal value in %)
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Check the supply voltage for the operating controls (5V) at the Print ARU :
Plug X30/11 PIN1 (5V) to PIN9 (GND).
Setpoint value approx. 5V. If a voltage of 5V is not available, check the supply voltage at plug X30/1 PIN9 (12 V)
to PIN8 (GND) on the Print ARU.
Check the plug-in contacts and lines of the individual sections (Print ARU).
If the supply voltage deviates substantially from 5V at plug X30/11, then the Print ARU must be replaced (see fault
code ARU 1, steps 1 and 2).
If the supply voltage of 5V is available at plug X30/11, go to step 3.
3. Check the supply voltage for potentiometer R20/1 at the Print ARU (after resistor R28/7). When doing so, plug
X30/16 (potentiometer R20/1) must be connected to the plug module.
Plug X30/16 PIN4 to plug X30/11 PIN9 (GND): Setpoint value 4.55-4.70V.
Check the supply (GND) for potentiometer R20/1 at the Print ARU (after resistor R28/8):
Plug X30/16 PIN6 to plug X30/11 PIN9 (GND): Setpoint value 0.43-0.48V.
If the setpoint values are attained at plug X30/16, go to step 4
If the supply voltage is 5V at plug X30/11, but the voltages deviate substantially from the setpoint values at plug
X30/16, go to step 5.
4. Check the signal voltage at the Print ARU:
Plug X30/16 PIN5 to plug X30/11 PIN9 (GND):
Setpoint value 0.43 to 4.70V (depending on the position of the potentiometer).
If the signal voltage is in the specified range, then the Print ARU must be replaced
(see fault code ARU 1, steps 1 and 2).
If the signal voltage is below or above the specified range, refer to the checks in steps 5, 6 and 7.
5. Check the resistance at the two assigned series resistors on the Print ARU :
Turn the ignition switch to the OFF position and disconnect plug X30/16 at the Print ARU.
Plug X30/11 PIN1 to plug X30/16 PIN4, setpoint value 470 ohms.
Plug X30/16 PIN6 to plug X30/11 PIN34, setpoint value 560 ohms.
If a resistance value deviates substantially from the setpoint value, then the Print ARU must be replaced.
If the signal voltage does not reach the setpoint values (see step 4) or if the signal voltage is a constant 5V or 0V
even though the resistance values at the Print ARU are in the specified range, go to step 6.

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6. Check the resistance of potentiometer R20/1 (plug X30/16 disconnected):
Plug X30/16 PIN4 to PIN6, setpoint value 5 kohms ± 5% (any potentiometer position).
Plug X30/16 PIN4 to PIN5, setpoint value 0 ohms to 5 kohms ± 5%
(depending on the position of the potentiometer).
Plug X30/16 PIN5 to PIN6, setpoint value 0 ohms to 5 kohms ± 5%
(depending on the position of the potentiometer).
If the resistance deviates from the setpoint value, the resistance must be checked directly at the potentiometer
R20/1. Do do so, remove the Print ARU and disconnect the tab connections at potentiometer R20/1. If the setpoint
value is attained at the potentiometer R20/1, then the individual lines between the potentiometer and plug
X30/16 must be checked. (Resistance < 1 ohm). Resistance between the individual lines: infinite. Repair or re-
place faulty lines.
Replace faulty potentiometer R20/1 as required.
7. If the signal voltage at plug X30/16 is outside the setpoint value even though the supply voltage (5V) at plug
X30/11 and the resistance values are ok, then the Print ARU must be replaced. Furthermore, there must be no
connection to another line.
8. Cancel the fault and check whether fault 50 is activated again. Attach the lower armrest cover and fit the armrest.

ARU - 52 Signal from oil flow potentiometer 2 (AUX2) outside

valid range
Cause:
The signal voltage is < 0.43 or > 4.70V.
The fault is stored and indicated by a warning triangle on the display.

The signal voltage must lie within a certain range (> 0.43 and < 4.70V).

Possible causes:
1. Contact fault in the signal line between potentiometer R20/2 and the Print ARU in the armrest.
2. Short-circuit in the signal line to supply (5V) between the potentiometer R20/2 and Print ARU.
3. Contact fault in the supply line (5V) between the Print ARU and potentiometer R20/2.
4. Contact fault in the GND potentiometer line between the Print ARU and potentiometer R20/2.
5. Potentiometer R20/2 is defective.
6. Print ARU is defective (e.g. resistors R28/5 or R28/6 have an interruption).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again and check whether fault 52 is activated again.
Use the Service Tool monitor:
"AUX2 FLOW COMMAND SETPOINT" (signal value in %)
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Check the supply voltage for the operating controls (5V) at the Print ARU:
Plug X30/11 PIN1 (5V) to PIN9 (GND.
Setpoint value approx. 5V. If a voltage of 5V is not available, check the supply voltage at plug X30/1 PIN9 (12V)
to PIN8 (GND) on the Print ARU.
Check the plug-in contacts and lines of the individual sections (Print ARU).
If the supply voltage already deviates substantially from 5V at plug 30/11, then the Print ARU must be replaced
(see fault code ARU 1, steps 1 and 2).
If the supply voltage of 5V is available at plug X30/11, go to step 3.
3. Check the supply voltage for potentiometer R20/2 at the Print ARU (after resistor R28/5). When doing so, plug
X30/16 (potentiometer R20/2) must be connected to the Print ARU.
Plug X30/16 PIN1 to plug X30/11 PIN9 (GND): Setpoint value 4.55-4.70V.
Check the supply (GND) for potentiometer R20/2 at the Print ARU (after resistor R28/6).
Plug X30/16 PIN3 to plug X30/11 PIN9 (GND): Setpoint value 0.43-0.48V.
If the setpoint values are attained at plug X30/16, go to step 4
If the supply voltage is 5V at plug X30/11, but the voltages deviate substantially from the setpoint values at plug
X30/16, go to step 5.

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4. Check the signal voltage at the Print ARU:
Plug X30/11 PIN2 to plug X30/11 PIN9 (GND for potentiometer R20/2):
Setpoint value 0.43 to 4.70V (depending on the position of the potentiometer).
If the signal voltage is in the specified range, then the Print ARU must be replaced
(see fault code ARU 1, steps 1 and 2).
If the signal voltage is below or above the specified range, refer to the checks in steps 5, 6 and 7.
5. Check the resistance at the two assigned series resistors on the Print ARU:
Turn the ignition switch to the OFF position and disconnect plug X30/16 at the Print ARU.
Plug X30/11 PIN1 to plug X30/16 PIN1, setpoint value 470 ohms.
Plug X30/16 PIN3 to plug X30/11 PIN9, setpoint value 560 ohms.
If a resistance value deviates substantially from the setpoint value, then the Print ARU must be replaced.
If the signal voltage does not reach the setpoint values (see step 4) or if the signal voltage is a constant 5V or 0V
even though the resistance values at the Print ARU are in the specified range, go to step 6.
6. Check the resistance of potentiometer R20/2 (plug X30/16 disconnected):
Plug X30/16 PIN1 to PIN3, setpoint value 5 kohms ± 5% (any potentiometer position).
Plug X30/16 PIN1to PIN2, setpoint value 0 ohms to 5 kohms ± 5%
(depending on the position of the potentiometer).
Plug X30/16 PIN2to PIN3, setpoint value 0 ohms to 5 kohms ± 5%
(depending on the position of the potentiometer).
If the resistance deviates from the setpoint value, the resistance must be checked directly at potentiometer
R20/2 . Do do so, remove the Print ARU and disconnect the tab connections at potentiometer R20/2. If the set-
point value is attained at the potentiometer, then the individual lines between the potentiometer R20/2 and plug
X30/16 must be checked. (Resistance < 1 ohm). Resistance between the individual lines: infinite. Repair or re-
place faulty lines. Replace faulty potentiometer R20/2 as required.
7. If the signal voltage at plug X30/16 is outside the setpoint value even though the supply voltage (5V) at plug
X30/11 and the resistance values are ok, then the Print ARU must be replaced.
Furthermore, there must be no connection to another line.
8. Cancel the fault and check whether fault 52 is activated again. Attach the lower armrest cover and fit the armrest.

ARU - 54 Signal from oil flow potentiometer 3 (AUX3) outside

valid range
Cause:
The signal voltage is < 0.43 or > 4.70V.
The fault is stored and indicated by a warning triangle on the display.
The signal voltage must lie within a certain range (> 0.43 and < 4.70V).

Possible causes:
1. Contact fault in the signal line between potentiometer R20/3 and the Print ARU in the armrest.
2. Short-circuit in the signal line to supply (5V) between the potentiometer R20/3 and Print ARU.
3. Contact fault in the supply line (5V) between the Print ARU and potentiometer R20/3.
4. Contact fault in the GND potentiometer line between the Print ARU and potentiometer R20/3.
5. Potentiometer R20/3is defective.
6. Print ARU is defective (e.g. resistors R28/3 or R28/4 have an interruption).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again and check whether fault 54 is activated again.
Use the Service Tool monitor:
"AUX3 FLOW COMMAND SETPOINT" (signal value in %)
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Check the supply voltage for the operating controls (5V) at the Print ARU:
Plug X30/11 PIN1 (5V) to PIN9 (GND)
Setpoint value approx. 5V. If a voltage of 5V is not available, check the supply voltage at plug X30/1 PIN9 (12V)
to PIN8 (GND) on the Print ARU.
Check the plug-in contacts and lines of the individual sections (Print ARU).
If the supply voltage deviates substantially from 5V at plug X30/11, then the Print ARU must be replaced (see fault
code ARU 1, steps 1 and 2).
If the supply voltage of 5V is available at plug X30/11, go to step 3.

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3. Check the supply voltage for potentiometer R20/3 at the Print ARU (after resistor R28/3). When doing so, plug
X30/15 (potentiometer R20/3) must be connected to the Print ARU.
Plug X30/15 PIN4 to plug X30/11 PIN9 (GND): Setpoint value 4.55-4.70V.
Check the supply (GND) for potentiometer R20/3 at the Print ARU (after resistor R28/4):
Plug X30/15 PIN6 to plug X30/11 PIN9 (GND): Setpoint value 0.43-0.48V.
If the setpoint values are attained at plug X30/15, go to step 4
If the supply voltage is 5V at plug X30/11, but the voltages deviate substantially from the setpoint values at plug
X30/15, go to step 5.
4. Check the signal voltage at the Print ARU:
Plug X30/15 PIN5 to plug X30/11 PIN9 (GND for potentiometer):
Setpoint value 0.43 to 4.70V (depending on the position of the potentiometer).
If the signal voltage is in the specified range, then the Print ARU must be replaced
(see fault code ARU 1, steps 1 and 2).
If the signal voltage is below or above the specified range, refer to the checks in steps 5, 6 and 7.
5. Check the resistance at the two assigned series resistors on the Print ARU:
Turn the ignition switch to the OFF position and disconnect plug X30/15 at the Print ARU.
Plug X30/11 PIN1 to plug X30/15 PIN4, setpoint value 470 ohms.
Plug X30/15 PIN6 to plug X30/11 PIN9, setpoint value 560 ohms.
If a resistance value deviates substantially from the setpoint value, then the Print ARU must be replaced.
If the signal voltage does not reach the setpoint values (see step 4) or if the signal voltage is a constant 5V or 0V
even though the resistance values at the Print ARU are in the specified range, go to step 6.
6. Check the resistance of potentiometer R20/3 (plug X30/15 disconnected):
Plug X30/15 PIN4 to PIN6, setpoint value 5 kohms ± 5% (any potentiometer position).
Plug X30/15 PIN4 to PIN5, setpoint value 0 ohms to 5 kohms ± 5%
(depending on the position of the potentiometer).
Plug X30/15 PIN5 to PIN6, setpoint value 0 ohms to 5 kohms ± 5%
(depending on the position of the potentiometer).
If the resistance deviates from the setpoint value, the resistance must be checked directly at potentiometer
R20/3. Do do so, remove the Print ARU and disconnect the tab connections at potentiometer R20/3. If the setpoint
value is attained at the potentiometer R20/3, then the individual lines between potentiometer and plug
X30/15 must be checked. (Resistance < 1 ohm). Resistance between the individual lines: infinite. Repair or re-
place faulty lines.
Replace faulty potentiometer R20/3 as required.
7. If the signal voltage at plug X30/15 is outside the setpoint value even though the supply voltage (5V) at plug
X30/11 and the resistance values are ok, then the Print ARU must be replaced. Furthermore, there must be no
connection to another line.
8. Cancel the fault and check whether fault 54 is activated again. Attach the lower armrest cover and fit the armrest.

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ARU - 56 Signal from oil flow potentiometer 4 (AUX4) outside

valid range
Cause:
The signal voltage is < 0.43 or > 4.70V.
The fault is stored and indicated by a warning triangle on the display.

The signal voltage must lie within a certain range (> 0.43 and < 4.70V).

Possible causes:
1. Contact fault in the signal line between potentiometer R20/4 and the Print ARU in the armrest.
2. Short-circuit in the signal line to supply (5V) between the potentiometer R20/4 and Print ARU.
3. Contact fault in the supply line (5V) between the Print ARU and potentiometer R20/4.
4. Contact fault in the GND potentiometer line between the Print ARU and potentiometer R20/4.
5. Potentiometer R20/4 is defective.
6. Print ARU is defective (e.g. resistors R28/1 or R28/2 have an interruption).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again and check whether fault 56 is activated again.
Use the Service Tool monitor:
"AUX4 FLOW COMMAND SETPOINT" (signal value in %)
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Check the supply voltage for the operating controls (5V) at the Print ARU:
Plug X30/11 PIN1 (5V) to PIN9 (GND). Setpoint value approx. 5V. If a voltage of 5V is not available, check the
supply voltage at plug X30/1 PIN9 (12V) to PIN8 (GND) at the Print ARU.
Check the plug-in contacts and lines of the individual sections (Print ARU).
If the supply voltage already deviates substantially from 5V at plug X30/11, then the Print ARU must be replaced
(see fault code ARU 1, steps 1 and 2).
If the supply voltage of 5V is available at plug X30/11, go to step 3.
3. Check the supply voltage for potentiometer R20/4 at the Print ARU (after resistor R28/1). When doing so, plug
X30/15 (potentiometer R20/4) must be connected to the Print ARU.
Plug X30/15 PIN1 to plug X30/11 PIN9 (GND): Setpoint value 4.55-4.70V.
Check the supply (GND) for potentiometer R20/4 at the Print ARU (after resistor R28/2):
Plug X30/15 PIN3 to plug X30/11 PIN9 (GND): Setpoint value 0.43-0.48V.
If the setpoint values are attained at plug X30/15, go to step 4
If the supply voltage is 5V at plug X30/11, but the voltages deviate substantially from the setpoint values at plug
X30/15, go to step 5.
4. Check the signal voltage at the Print ARU:
Plug X30/15 PIN2 to plug X30/11 PIN9 (GND for potentiometer):
Setpoint value 0.43 to 4.70V (depending on the position of the potentiometer).
If the signal voltage is in the specified range, then the Print ARU must be replaced (see fault code ARU 1,
steps 1 and 2).
If the signal voltage is below or above the specified range, refer to the checks in steps 5, 6 and 7.
5. Check the resistance at the two assigned series resistors on the Print ARU:
Turn the ignition switch to the OFF position and disconnect plug X30/15 at the Print ARU.
Plug X30/11 PIN1 to plug X30/15 PIN1, setpoint value 470 ohms.
Plug X30/15 PIN3 to plug X30/11 PIN9, setpoint value 560 ohms.
If a resistance value deviates substantially from the setpoint value, then the Print ARU must be replaced.
If the signal voltage does not reach the setpoint values (see step 4) or if the signal voltage is a constant 5V or 0V
even though the resistance values at thePrint ARU are in the specified range, go to step 6.

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6. Check the resistance of potentiometer R20/4 (plug X30/15 disconnected):
Plug X30/15 PIN1 to PIN3, setpoint value 5 kohms ± 5% (any potentiometer position).
Plug X30/15 PIN1 to PIN2, setpoint value 0 ohms to 5 kohms ± 5%
(depending on the position of the potentiometer).
Plug X30/15 PIN2 to PIN3, setpoint value 0 ohms to 5 kohms ± 5%
(depending on the position of the potentiometer).
If the resistance deviates from the setpoint value, the resistance must be checked directly at potentiometer
R20/4. Do do so, remove the Print ARU and disconnect the tab connections at the potentiometer R20/4. If the
setpoint value is attained at the potentiometer R20/4, then the individual lines between the potentiometer and plug
X30/15 must be checked. (Resistance < 1 ohm). Resistance between the individual lines: infinite. Repair or re-
place faulty lines.
Replace faulty potentiometer R20/4 as required.
7. If the signal voltage at plug X30/15 is outside the setpoint value even though the supply voltage (5V) at plug
X30/11 and the resistance values are ok, then the Print ARU must be replaced. Furthermore, there must be no
connection to another line.
8. Cancel the fault and check whether fault 56 is activated again. Attach the lower armrest cover and fit the armrest.

ARU - 58 Signal from oil flow potentiometer 5 (AUX5) outside

valid range
Cause:
The signal voltage is < 0.43 or > 4.70V.
The fault is stored and indicated by a warning triangle on the display.

The signal voltage must lie within a certain range (> 0.43 and < 4.70V).

Possible causes:
1. Contact fault in the signal line between the potentiometer R20/5 and the Print ARU in the armrest.
2. Short-circuit in the signal line to supply (5V) between the potentiometer R20/5 and Print ARU.
3. Contact fault in the supply line (5V) between the Print ARU and potentiometer R20/5.
4. Contact fault in the GND potentiometer line between the Print ARU and potentiometer R20/5.
5. Potentiometer R20/5 is defective.
6. Print ARU is defective (e.g. resistors R28/9 or R28/10 have an interruption).
Remedy:
Turn the ignition switch to the OFF position. Start the engine again and check whether fault 58 is activated again.
Use the Service Tool monitor:
"AUX5 FLOW COMMAND SETPOINT" (signal value in %)
1. Turn the ignition switch to the OFF position. Remove the armrest and take off the lower cover. Turn the ignition
switch to the ON position.
2. Check the supply voltage for the operating controls (5V) at the Print ARU:
Plug X30/11 PIN1 (5V) to PIN9 (GND). Setpoint value approx. 5V. If a voltage of 5V is not available, check the
supply voltage at plug X30/1 PIN9 (12V) to PIN8 (GND) on the Print ARU.
Check the plug-in contacts and lines of the individual sections (Print ARU).
If the supply voltage deviates substantially from 5V at plug X30/11, then the Print ARU must be replaced (see fault
code ARU 1, steps 1 and 2).
If the supply voltage of 5V is available at plug X30/11, go to step 3.
3. Check the supply voltage for the potentiometer R20/5 on the Print ARU (after resistor R28/9). When doing so,
plug X30/12 must be connected to the Print ARU.
Plug X30/12 PIN1 to plug X30/11 PIN9 (GND): Setpoint value 4.55-4.70V.
Check the supply (GND) for the potentiometer R20/5 at the Print ARU (after resistor R28/10):
Plug X30/12 PIN4 to plug X30/11 PIN9 (GND): Setpoint value 0.43-0.48V.
If the setpoint values are attained at plug X30/12, go to step 4
If the supply voltage is 5V at plug X30/11, but the voltages deviate substantially from the setpoint values at plug
X30/12, go to step 5.

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4. Check the signal voltage at the Print ARU:
Plug X30/12 PIN2 to plug X30/11 PIN9 (GND for potentiometer):
Setpoint value 0.43 to 4.70V (depending on the position of the potentiometer).
If the signal voltage is in the specified range, then the Print ARU must be replaced (see fault code ARU 1,
steps 1 and 2).
If the signal voltage is below or above the specified range, refer to the checks in steps 5, 6 and 7.
5. Check the resistance at the two assigned series resistors on the Print ARU:
Turn the ignition switch to the OFF position and disconnect plug X30/12 at the Print ARU.
Plug X30/11 PIN1 to plug X30/12 PIN1, setpoint value 470 ohms.
Plug X30/12 PIN4 to plug YA1 PIN34, setpoint value 560 ohms.
If a resistance value deviates substantially from the setpoint value, then the Print ARU must be replaced.
If the signal voltage does not reach the setpoint values (see step 4) or if the signal voltage is a constant 5V or 0V
even though the resistance values at the Print ARU are in the specified range, go to step 6.
6. Check the resistance of the potentiometer R20/5 (plug X30/12 disconnected):
Plug X30/12 PIN1 to PIN4, setpoint value 5 kohms ± 5% (any potentiometer position).
Plug X30/12 PIN1to PIN2, setpoint value 0 ohms to 5 kohms ± 5%
(depending on the position of the potentiometer).
Plug X30/12 PIN2 to PIN4, setpoint value 0 ohms to 5 kohms ± 5%
(depending on the position of the potentiometer).
If the resistance deviates from the setpoint value, the resistance must be checked directly at the potentiometer
R20/5 . Do do so, remove the Print ARUand disconnect the tab connections at the potentiometer R20/5. If the
setpoint value is attained at the potentiometer R20/5, then the individual lines between the potentiometer and plug
X30/12 must be checked. (Resistance < 1 ohm). Resistance between the individual lines: infinite. Repair or re-
place faulty lines.
Replace faulty potentiometer R20/5 as required.
7. If the signal voltage at plug X30/12 is outside the setpoint value even though the supply voltage (5V) at plug
X30/11 and the resistance values are ok, then the Print ARU must be replaced. Furthermore, there must be no
connection to another line.
8. Cancel the fault and check whether fault 58 is activated again. Attach the lower armrest cover and fit the armrest.

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ARU - 71 CAN Bus OFF up to DBD100000

Cause:
Data transfer between armrest and vehicle bus does not function.
The Print ARU has not transmitted a message correctly or CAN wiring between Print ARU and vehicle bus is faulty.

The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. The supply to Print ARU in the armrest is faulty.
2. Interruption or contact fault on the CAN bus (vehicle bus), e.g. in the spur line to the Print ARU.
3. Conductive connection or short-circuit between the data lines (terminating resistances excluded) or to other lines
(insulation fault, dirt or moisture between plug-in contacts).
4. Terminating resistor is defective or plug-in contacts at X3/10 are faulty.
5. The screening of the CAN wiring is faulty.
6. The Print ARU is defective.
Remedy:
Use Service Tool "CONTROL modulE status" to check whether other bus users are also offline.
Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine again and check whether
the fault is active again.
1. If fault ARU 71 is active again or if other bus users on the vehicle bus are signalling faults in connection with the
CAN bus, check the CAN bus fuses.
a) If all fuses are ok, go to step 2.
b) Replace defective fuses. Then turn the ignition switch to the ON position. If faults are active again, go to step 2.
2. Continue fault diagnostics, starting with a quick check of the "Vehicle bus status" (steps b and c).
a) Detach the plug of Service Tool DPA from diagnosis socket X9/17. Use switch S31 to select the vehicle bus
(turn switch S31 to upper position). Turn ignition switch to ON position.
b) Check voltages - CAN H and CAN L at diagnosis socket (X9/17 con pin ) .
PINC (CANH) and PIND (CANL) against PINA (GND).
If the voltages are in the specified range, you can assume that the data lines are neither shorted to GND (supply
or screening), nor to a plus supply or to plus 1, plus 2 or plus 3 (12 V screening). Go to step c.
c) Check resistance values - CAN H against CAN L at diagnosis socket .
PINC (CANH) and PIND (CANL) (to do so turn ignition switch to OFF position).
If the resistance considerably deviates from the setpoint when CANH is measured against CANL, the terminating
resistors must be checked one by one (see step 4) and the CAN wiring must be checked for interruptions or short-
circuits (see steps 3b and 3c).
d) Check supply voltage (12V) to the Print ARU in the armrest:
Turn ignition switch to ON position.
If the voltage is >12V (<8V), it is faulty and must be repaired. For details on fault rectification, refer to fault code
ARU 20 (this fault code is active as soon as the supply voltage is < 8V).
e) Check supply (5V) to Print ARU:
NOTE: A voltage regulator at the Print ARU is supplied with 12 V. This supplies 5V to specific components on the
Print ARU and to specific control elements.
Turn ignition switch to ON position.
If the voltage (5V) is not present, detach the plugs to the multi-controller II and to the other control elements at
Print ARU A30. If the supply (5V) is present, there is a short-circuit in the control elements or in their wiring. If the
supply (5V) is not present, there could be other faults: Print ARU defective or short-circuit at the Print ARU.
f) Check the voltages - CANH and CANL at Print ARU plug X30/7:
Turn ignition switch to ON position. PIN3 (CANH) and PIN4 (CANL) against PIN2.
g) Check the screening of the data lines:
Violet line (12V) against black line (GND).
NOTE: The screening and the data lines are twisted together. It ends freely in front of plug X30/7 on the Print ARU.
If the power supply, the voltage values of CAN H and CAN L at plug X30/7 of the Print ARU and the screening
are ok, the Print ARU must be replaced (see fault code ARU 1, steps 1 to 4).

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3. Voltages - CANH and CANL at the Print ARU not ok:
a) Carry out a voltage check at the plugs in the following sequence:
Plug X30/7 at the Print ARU:
PIN3 (CANH) and PIN4 (CANL) against plug X30/1 PIN8 (GND).
If voltages are not ok, detach plug X30/7. Check voltages at the plug part of the CAN wiring. If voltages are not
ok, check data lines between plug X30/7 and the weld points of the spur line (measure e.g. against diagnosis
socket X9/17). If the voltages at plug X30/7 are ok, replace Print ARU if necessary.
b) Continuity check at data lines:
Detach the plugs on the line section concerned. Use an ohmmeter to check the line from one plug to the next
(setpoint < 1 ohm).
If the resistance is > 1 ohm, check the line, plug-in contacts and crimp connections and repair or replace them if
necessary.
c) Short-circuit check between the data lines:
Disconnect plugs X18/4 and YB1.
At plug X30/7, connect an ohmmeter between two pins at a time:
The lines must be interrupted relative to each other (display = infinite).
If an unintended electrical connection is established between the lines: Repair the wiring or replace single lines
or the cable harness.
4. Check the terminating resistors in accordance with the CAN bus diagram
On the vehicle bus, one terminating resistor is integrated in motor control unit EEM2and another terminating re-
sistor is integrated in plug X3/10. (Setpoint of a resistor: 120 ohms).
a) If the data lines do not have any contact faults on the one hand, and, one the other hand, are not shorted to
each other, and if both terminating resistors are ok, the resistance of the two data lines relative to each other
(CANH against CANL) must be 60 ohms at the following measuring points:
Diagnosis socket X9/17, X18/4 (armrest), X30/7 and at the Print ARU (A30).
b) Check of the individual terminating resistors:
Turn ignition switch to OFF position. Disconnect plug X3/10. Check resistance between PINA and PINB:
Setpoint 120 ohms. At the plug part of the cable harness also check the resistance between PINA and PINB:
Setpoint 120 ohms.
If the setpoint of approx. 120 ohms is also reached with this measurement, the terminating resistor in the EEM2
and the lines CANH and CANL between the terminating resistors are ok. If the resistance considerably deviates
from the setpoint, the terminating resistor in the EEM2 and each data line must be checked separately.
Detach plug X70 from the EEM2. Check the terminating resistance between PIN18 (CANH) and PIN42 (CANL)
at the EEM2. Setpoint 120 ohms.

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ARU - 71 CAN Bus OFF from DBD100001

Cause:
Data transfer between armrest and vehicle bus does not function.
The Print ARU has not transmitted a message correctly or CAN wiring between Print ARU and vehicle bus is faulty.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. The supply to Print ARU in the armrest is faulty.
2. Interruption or contact fault on the CAN bus (vehicle bus), e.g. in the spur line to the Print ARU.
3. Conductive connection or short-circuit between the data lines (terminating resistances excluded) or to other lines
(insulation fault, dirt or moisture between plug-in contacts).
4. Terminating resistor is defective or plug-in contacts at X3/10 are faulty.
5. The Print ARU is defective.
Remedy:
Use Service Tool "CONTROL modulE status" to check whether other bus users are also offline.
Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine again and check whether
the fault is active again.
1. If fault ARU 71 is active again or if other bus users on the vehicle bus are signalling faults in connection with the
CAN bus, check the CAN bus fuses.
a) If all fuses are ok, go to step 2.
b) Replace defective fuses. Then turn the ignition switch to the ON position. If faults are active again, go to step 2.
2. Continue fault diagnostics, starting with a quick check of the "Vehicle bus status" (steps b and c).
a) Detach the plug of Service Tool DPA from diagnosis socket X9/17. Turn ignition switch to ON position.
b) Check voltages - CAN H and CAN L at diagnosis socket (X9/17 con pin ).
PINC (CANH) and PIND (CANL) against PINA (GND).
If the voltages are in the specified range, you can assume that the data lines are neither shorted to GND, nor to
a plus supply. Go to step c.
c) Check resistance values - CAN H against CAN L at diagnosis socket .
PINC (CANH) and PIND (CANL) (to do so turn ignition switch to OFF position).
If the resistance considerably deviates from the setpoint when CANH is measured against CANL, the terminating
resistors must be checked one by one (see step 4) and the CAN wiring must be checked for interruptions or short-
circuits (see steps 3b and 3c).
d) Check supply voltage (12V) to the Print ARU in the armrest:
Turn ignition switch to ON position.
If the voltage is >12V (<8V), it is faulty and must be repaired. For details on fault rectification, refer to fault code
ARU 20 (this fault code is active as soon as the supply voltage is < 8V).
e) Check supply (5V) to Print ARU:
NOTE: A voltage regulator at the Print ARU is supplied with 12 V. This supplies 5V to specific components on the
Print ARU and to specific control elements.
Turn ignition switch to ON position.
If the voltage (5V) is not present, detach the plugs to the multi-controller II and to the other control elements at
Print ARU A30. If the supply (5V) is present, there is a short-circuit in the control elements or in their wiring. If the
supply (5V) is not present, there could be other faults: Print ARU defective or short-circuit at the Print ARU.
f) Check the voltages - CAN H and CAN L at Print ARU plug X30/7:
Turn ignition switch to ON position. PIN3 (CANH) and PIN4 (CANL) against PIN2.
If the power supply, the voltage values of CAN H and CAN L at plug X30/7 of the Print ARU are ok, the Print ARU
must be replaced (see fault code ARU 1, steps 1 to 4).
3. Voltages - CANH and CANL at the Print ARU not ok:
a) Carry out a voltage check at the plugs in the following sequence:
Plug X30/7 at the Print ARU:
PIN3 (CANH) and PIN4 (CANL) against plug X30/1 PIN8 (GND).
If voltages are not ok, detach plug X30/7. Check voltages at the plug part of the CAN wiring. If voltages are not
ok, check data lines between plug X30/7 and the weld points of the spur line (measure e.g. against diagnosis
socket X9/17). If the voltages at plug X30/7 are ok, replace Print ARU if necessary.
b) Continuity check at data lines:
Detach the plugs on the line section concerned. Use an ohmmeter to check the line from one plug to the next
(setpoint < 1 ohm). If the resistance is > 1 ohm, check the line, plug-in contacts and crimp connections and repair
or replace them if necessary.

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 4011-117
c) Short-circuit check between the data lines:
Disconnect plugs X18/4 and YB1.
At plug X30/7, connect an ohmmeter between two pins at a time:
The lines must be interrupted relative to each other (display = infinite).
If an unintended electrical connection is established between the lines: Repair the wiring or replace single lines
or the cable harness.
4. Check the terminating resistors in accordance with the CAN bus diagram
On the vehicle bus, one terminating resistor is integrated in motor control unit EEM3 and another terminating re-
sistor is integrated in plug X3/10. (Setpoint of a resistor: 120 ohms).
a) If the data lines do not have any contact faults on the one hand, and, one the other hand, are not shorted to
each other, and if both terminating resistors are ok, the resistance of the two data lines relative to each other
(CANH against CANL) must be 60 ohms at the following measuring points:
Diagnosis socket X9/17, X18/4 (armrest), X30/7 and at the Print ARU (A30).
b) Check of the individual terminating resistors:
Turn ignition switch to OFF position. Disconnect plug X3/10. Check resistance between PINA and PINB:
Setpoint 120 ohms. At the plug part of the cable harness also check the resistance between PINA and PINB:
Setpoint 120 ohms.
If the setpoint of approx. 120 ohms is also reached with this measurement, the terminating resistor in the EEM3
and the lines CANH and CANL between the terminating resistors are ok. If the resistance considerably deviates
from the setpoint, the terminating resistor in the EEM3 and each data line must be checked separately.
Detach plug X89/1 from the EEM3. Check the terminating resistance between PIN35 (CANH) and PIN34 (CANL)
at the EEM3. Setpoint 120 ohms.

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COMPONENTS SUMMARY
ARU Armrest ............................................................................................................................................. Fig. 1
AUX1 1st remote control valve.................................................................................................................... Fig. 1
AUX2 2nd remote control valve .................................................................................................................. Fig. 1
AUX3 3rd remote control valve ................................................................................................................... Fig. 1
AUX4 4th remote control valve ................................................................................................................... Fig. 1
AUX5 5th remote control valve ................................................................................................................... Fig. 1
A2 EEM2 control unit up to DBD100000 ................................................................................................ Fig. 2
A3 EEM3 control unit from DBD100001................................................................................................. Fig. 3
B28 Manual accelerator slider ................................................................................................................. Fig. 4
B30 Longitudinal joystick.......................................................................................................................... Fig. 4
B31 Transverse joystick ........................................................................................................................... Fig. 4
B52 Shift lever for AUX (black)................................................................................................................. Fig. 4
G2/2 Generator Magneton 120A up to DBD100000.................................................................................. Fig. 5
G2/2 Generator Bosch 120A from DBD100001 ........................................................................................ Fig. 5
G2/2/2 2nd generator Magneton 95A ........................................................................................................... Fig. 6
G2/3 Generator Denso 140A up to DBD100000 ....................................................................................... Fig. 6
R20/1 Potentiometer 1st AUX ..................................................................................................................... Fig. 4
R20/2 Potentiometer 2nd AUX .................................................................................................................... Fig. 4
R20/3 Potentiometer 3rd AUX..................................................................................................................... Fig. 4
R20/4 Potentiometer 4th AUX ..................................................................................................................... Fig. 4
R20/5 Potentiometer 5th AUX ..................................................................................................................... Fig. 4
S31 Changeover switch for CAN SGR/FMGR up to DBD100000 ........................................................... Fig. 7
S60/2 Cruise control button......................................................................................................................... Fig. 8
S60/3 Speed button +.................................................................................................................................. Fig. 8
X3/10 Plug connection, terminal resistance ................................................................................................ Fig. 9
X9/17 Socket for diagnosis service tool .................................................................................................... Fig. 10
X18/4 Plug connection, wiring harness, cab right - armrest .......................................................................Fig. 11
X21 Plug connection, multicontroller II - print......................................................................................... Fig. 12
X30/1 Plug connection, supply armrest .................................................................................................... Fig. 13
X30/3 Plug connection, ARU - manual accelerator slider ......................................................................... Fig. 14
X30/4 Plug connection, ARU - AUX control lever ..................................................................................... Fig. 15
X30/5 Plug connection, ARU - AUX joystick ............................................................................................. Fig. 16
X30/7 Plug connection, ARU CAN BUS.................................................................................................... Fig. 17
X30/11 Plug connection, supply - multicontroller print ............................................................................... Fig. 18
X30/12 Plug connection, ARU - potentiometer R20/5 ................................................................................. Fig. 19
X30/15 Plug connection, ARU - potentiometer R20/3 and R20/4 ............................................................... Fig. 20
X30/16 Plug connection, ARU - potentiometer R20/1 and R20/2 ............................................................... Fig. 21
X70 Plug connection, engine control unit EEM2 up to DBD100000 ...................................................... Fig. 22
X89/1 Plug connection for EEM3 engine control unit - engine wiring harness from DBD100001 ............. Fig. 23

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ARU from DBD094271 4011-119

Fig. 1 Fig. 5

Fig. 2 up to DBD100000 Fig. 6

Fig. 3 from DBD100001 Fig. 7

Fig. 4 Fig. 8

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 4011-120

Fig. 9 Fig. 11 up to DBD100000

Fig. 10 up to DBD100000

Fig. 11 from DBD100001

Fig. 10 from DBD100001

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ARU from DBD094271 4011-121

Fig. 12 Fig. 16

Fig. 13 Fig. 17

Fig. 14 Fig. 18

Fig. 15 Fig. 19

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 4011-122

Fig. 20 Fig. 23 from DBD100001

Fig. 21

Fig. 22 up to DBD100000

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ARU from DBD094271 4011-123

*) see Note page 8 ARMREST FUNCTIONAL SCHEMATIC DIAGRAM FOR REMOTE CONTROL
S60/6
A31
X21
*A28 PLUG MODULE
X11 *A30 PRINT ARU
X24/2 VALVES UP TO DBD100000
F19 5A
17 A12 X4/83 X4/90 AUX 1
8 6 F20 5A CAN H
18 +15/1 3 3
7 13 X1 X18/4 F16 5A CAN L
5V 2 +15/2
X24/2 4 2
1 1 7 13 F47 5A CAN +
+15/1 24 1 1
6 10 9 9 CAN -
GND 2 4
X19 2 1 8 10 (16)
CAN +
X7 15 X5/1
S60/8 CAN - X4/91 AUX 2
2 16 CAN H
CAN H 3
3 17 CAN L
A29 X5 CAN L 2
GND GND 4 18 CAN +
3 1
S2/7/3
X

5V CAN -
B30 1 4
0
2 1
GND 3
7 3 X4/92 AUX 3
X

B31 5V CAN H
5 6 1 3
GSV4 CAN L
6 8 2 2
5V CAN +
4 1
S35 CAN -
8 X10/9 2 X10/9 6 8 4
X4 CN1a 10
GND
4 CAN - X4/93 AUX 4
17 A60 ECCU2
X

5V 5V CN3a CAN H
3
1 CAN +
6.4 V with EDC and AUX ON 4 CAN L
B52 2 CAN L 2
16 6.4 V with EDC ON 1 CAN +
X16 CAN H 1
R20/1 0.5 V 560Ω
GND
15 CAN -
6 4
470Ω
4.7 V
4 X10/11 X14/15 A12
A13 F45 5A
5 7 12 +15/1
X4/94 AUX 5
R20/2 0.5 V
560Ω CAN H
3 P8/1 3 4 1 2 3
4.7 V 470Ω X10/12 6 CAN L
1 P8 ICU P8 2
CAN +
2 7 X14/14 X10/14 1
CAN -
X15 5 4 7 4
R20/3 0.5 V 560Ω
6 3
4.7 V
470Ω
(7)
A X3/10 B
4 A14 X20/1 X23/1
(8) F93 5A
5 +30 8 Q
R20/4 0.5 V 560Ω 120 Ω
3
470Ω
4.7 V A12 Central print R20/5 Potentiometer AUX5 X10/14 10-pin plug connection
1 A13 Roof print S2/7/3 Switch, hydraulic master X11 16-pin plug connection
2 A14 Engine print S34 Switch AUX5 X12 4-pin plug connection
X12 A27 CAN module ---> DBD..... S35 Joystick pushbutton X14/14 14-pin plug connection
R20/5 0.5 V 560Ω A28 Plug module ---> DBD..... S60/6 AUX blue pushbutton X14/15 14-pin plug connection
4 A30 Print ARU DBD..... ---> S60/8 Shift pushbutton X15 6-pin plug connection
4.7 V
1 A29 Joystick (float position) X16 6-pin plug connection
A31 Multi controller X1 14-pin plug connection X18/4 18-pin plug connection
2 A60 ECCU2 X3/10 3-pin plug connection X19 2-pin plug connection
X6 0Ω B30 Joystick X4 4-pin plug connection X20/1 20-pin plug connection
longitudinal direction AUX1 X4/83 4-pin plug connection X21 14-pin plug connection
8
5V
6k2 B31 Joystick X4/90 4-pin plug connection X23/1 23-pin plug connection
2 transverse direction AUX2 X4/91 4-pin plug connection X24/2 24-pin plug connection
S34 1k2
B52 Selector lever AUX4 X4/92 4-pin plug connection YA1 44-pin plug connection
3
6k2 CN1a 26-pin plug connection X4/93 4-pin plug connection ---> DBD.....
2
7 CN3a 26-pin plug connection X4/94 4-pin plug connection YB1 44-pin plug connection
0
15/1

1
4 0Ω
5V GND 15/1 GND P8 ICU X5 2-pin plug connection ---> DBD.....
2 P8 10-pin plug connection X5/1 Plug connection (7) Ground point, roof hood, left
4 P8/1 4-pin plug connection X6 8-pin plug connection (8) Ground point, roof hood,
8 *YA1 35 41 32 30 28 26 24 27 31 29 37 9 19 23 34 6 8 39 40 33 3 1 4 2 5 7 R20/1 Potentiometer AUX1 X7 4-pin plug connection right
1 R20/2 Potentiometer AUX2 X10/9 10-pin plug connection (16) Ground, starter
5 *YB1 35 41 32 30 28 26 24 27 31 29 37 9 19 23 34 6 8 39 40 33 3 1 4 2 5 7
7 R20/3 Potentiometer AUX3 X10/11 10-pin plug connection
* A27 CAN MODULE R20/4 Potentiometer AUX4 X10/12 10-pin plug connection

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BLANK PAGE

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ARU from DBD094271 4011-125

A31
ARMREST FUNCTIONAL SCHEMATIC DIAGRAM FOR REMOTE
S60/6 X21 X30/11 A30 PRINT ARU X30/1 X18/4 X24/2
A12
CONTROL VALVES FROM DBD100001
F19 5A
8 6 7 13 17 X4/83 X4/90 AUX 1
F20 5A CAN H
7 13 9 9 18 +15/1 3 3
5V F47 5A CAN L
1 1 8 10 24 +15/1 4 2
CAN +
6 10 1 1
CAN -
X30/19 2 1 X30/7 (11)
2 4
2 16
S60/8 CAN H
3 17 X4/91 AUX 2
CAN L CAN H
4 18 (11) 3
A29 X30/5 CAN L
GND GND
S2/7/3 2
3 CAN +
1
X

5V
B30 1 0
CAN -
1
4
2 3

GND 3
7
6 1 AUX 3
X

B31 5V X4/92
5 GSV4 CAN H
8 2 3
6 CAN L
5V 2
S35
4 2 X10/9 X10/9 6 8 CAN +
1
8 CAN -
4
X30/4 CN1a A60 ECCU2 CN3a
GND
4 10 6.4 V with EDC and AUX ON 4
AUX 4
X

5V 5V CAN L X4/93
1 16 6.4 V with EDC ON 1 CAN H
CAN H 3
B52 2 15 CAN L
2
X30/16 A12 CAN +
R20/1 0.5 V 560Ω
GND A13 X10/11 X14/15 1
6 F45 5A CAN -
4.7 V 470Ω 7 12 +15/1 4
4
5 X10/12 6 A14
R20/2 0.5 V
560Ω X10/14 X10/3 X4/94 AUX 5
3 F212 5A CAN H
4.7 V
470Ω 7 6 +30 3
1 CAN L
2
2 X14/14 CAN +
1
X30/15 4 CAN -
R20/3 0.5 V 560Ω 4
6
4.7 V
470Ω (7)
4 P8 7 5 3 (8)
A X3/10 B
5 P8/1 P8 ICU
R20/4 0.5 V 560Ω CAN L
3 4 120 Ω
4.7 V
470Ω CAN H
1 3
2
X30/12 A12 Central print R20/4 Potentiometer AUX4 X14/14 14-pin plug connection
R20/5 0.5 V
560Ω
A13 Roof print R20/5 Potentiometer AUX5 X14/15 14-pin plug connection
4
4.7 V 470Ω A14 Engine print S2/7/3 Switch, hydraulic master X18/4 18-pin plug connection
1 A30 Print ARU S34 Switch AUX5 X21 14-pin plug connection
2 A29 Joystick S35 Joystick pushbutton X24/2 24-pin plug connection
0Ω A31 Multi controller S60/6 AUX blue pushbutton X30/1 14-pin plug connection
X30/6 A60 ECCU2 S60/8 Shift pushbutton X30/4 4-pin plug connection
8 B30 Joystick (float position) X30/5 2-pin plug connection
5V
6k2 longitudinal direction AUX1 X3/10 3-pin plug connection X30/6 8-pin plug connection
2 B31 Joystick X4/83 4-pin plug connection X30/7 4-pin plug connection
S34 1k2
transverse direction AUX2 X4/90 4-pin plug connection
3 X30/11 16-pin plug connection
6k2 B52 Selector lever AUX4 X4/91 4-pin plug connection X30/12 4-pin plug connection
2
7 CN1a 26-pin plug connection X4/92 4-pin plug connection X30/15 6-pin plug connection
0
1
4 0Ω CN3a 26-pin plug connection X4/93 4-pin plug connection X30/16 6-pin plug connection
2 P8 ICU X4/94 4-pin plug connection X30/19 2-pin plug connection
4 P8 10-pin plug connection X10/3 10-pin plug connection (7) Ground point, roof hood, left
8 P8/1 4-pin plug connection X10/9 10-pin plug connection (8) Ground point, roof hood, right
1 R20/1 Potentiometer AUX1 X10/11 10-pin plug connection (11) Ground point,
5 R20/2 Potentiometer AUX2 X10/12 10-pin plug connection engine cable carrier, rear
7
R20/3 Potentiometer AUX3 X10/14 10-pin plug connection

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BLANK PAGE

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ARU from DBD094271 4011-127

*) see Note page 8 FUNCTIONAL SCHEMATIC DIAGRAM FOR EEM2 UP TO DBD100000

A12 F19 5A

F20 5A
X20/1 F97 10A
+15/1 7 +15/2
ARMREST F16 5A
F94 25A
+15/2 X1/14
(16) 31
*A28 PLUG MODULE X1/10 F92 10A
+30
X1 X18/4
*A30 PRINT ARU X24/2 17 18 2 X5/1
8 10
X3 7 13
B28 5V X70 21 48 70 46 69
1 9 9 (11)
CAN H A14
CAN + 18 A2 EEM2 A2 _GND
X7 15 CAN L
0.4V to 4.7V CAN - 42
X 2 2 16 Supply
CAN H
3 17
GND 4 CAN L
4 18
X1/21
P8/1 4 3 1 2 Pre-glowing and
+15

P8 ICU P8/2 fuel delivery pump X70 X20/1 A50/1 E10/1

*YA1 39 40 25 8 6 33 4 2 3 1 5 7
3 3 12V 4 (11)
K8/2
4 50 12V 5 SSR1
X1/12 30 87
*YB1 39 40 25 8 6 33 4 2 3 1 5 7 +30

1 2
X20/1 (11)
12V
CN3 17
* A27 CAN MODULE A1 ADIC 12V
26 16
M13 (11)
25 Emergency signal
X70
3 M 1
36 0.8 to 4.4 V
A2/2 PCU 2
X70 X9/7 (11)
12V
R8 X23/2 1 7
GND M13 _GND
4 U 23 6
CAN H
PCU activation 20 2 2.5 V
CAN L
44 1 2.5 V
S6
43 5 Emergency shut-down
130 Hz at 900 rpm
B21 X1/3 p 19 8 DZG
335 Hz at 2300 rpm
1 X70
p 34 GND A1 ADIC X1 14-pin plug connection
A2 EEM2 X1/3 1-pin plug connection
X3/20 55 GND A2/2 PCU X1/10 Plug connection
GND
n 1 62 A12 Central print X1/12 Plug connection
B20 2 39 510 Hz at 900 rpm
1300 Hz at 2300 rpm
A14 Engine print X1/14 Plug connection
f 12V A27 CAN module ---> DBD..... X1/21 Plug connection
3 45 A28 Plug module ---> DBD..... X2/22 2-pin plug connection
Switches and A30 Print ARU DBD..... ---> X3 4-pin plug connection
sensors A50/1 Power module X3/12 3-pin plug connection
t X2/22 B20 Engine speed sensor X3/13 3-pin plug connection
GND
B22 1 33 B21 Test switch, fuel delivery pressure X3/20 3-pin plug connection
R 2 PTC 1kΩ to 4.6 kΩ B22 Engine temperature sensor X4/71 4-pin plug connection
9
B23 „Water in fuel“ sensor X5/1 Plug connection
X3/13 X3/12 B28 Manual throttle X7 4-pin plug connection
12V B29 Sensor for charger pressure, X9/7 9-pin plug connection
R A 1 25
0.7 V at water in fuel charged air temperature X18/4 18-pin plug connection
B23 B 2 31 9 V no water in fuel CN3 26-pin plug connection X20/1 20-pin plug connection
U C 3
GND
22 E10/1 Heating flange X23/2 23-pin plug connection
K8/2 Relay, heating flange X24/2 24-pin plug connection
X4/71 M13 Fuel delivery pump X70 70-pin plug connection
GND
p,t 1 59 P8 ICU YA1 44-pin plug connection ---> DBD.....
NTC 32 kΩ to 102 Ω P8/1 4-pin plug connection
B29 2 12 YB1 44-pin plug connection ---> DBD.....
P8/2 4-pin plug connection (11) Ground point, engine device carrier
U,R 3 5V
11 R8 Potentiometer, accelerator pedal (16) Ground point, starter
4 35 1 V to approx. 2 V S6 Switch, engine oil pressure

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4011-128

BLANK PAGE

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ARU from DBD094271 4011-129

FUNCTIONAL SCHEMATIC DIAGRAM FOR EEM3 FROM DBD100001

A14
X12/1 F207 5A
2 +15

X1/30/EEM F203 30A

A12 +30
F19 5A

F20 5A
+15/1

ARMREST X89/1 40 9 8 3 2 11 10 5 6
17 18 X24/2 A3 EEM3
(11) CAN H (2)
A30 PRINT ARU 35
X30/1 X18/4 CAN L Supply F208 10A
34 +30
8 10 (11)
X30/3 7 13
B28 M13
1 9 9 X12/1
5V 12V
X30/7 Pre-glowing and K5/LP 9 3 M 1
0.4V to 4.7V fuel delivery pump 4
X 2 2 16 3 5
3
CAN H X89/1
17 1 2
CAN L 55 4 GND
GND 4 4 18 X12/1
(11)

X1/30/1 E10/1
+30
P8/1 4 3
P8 ICU + -
P8/2
3 K8/2
4 3 5
(12)

1 2
X36/1 X2/19 X2/19
4
A1 ADIC CN3 5
26
25
A1 ADIC X4/4 4-pin plug connection
A3 EEM3 X4/70 4-pin plug connection
A7 ID module X10/18 10-pin plug connection
A12 Central print X12/1 12-pin plug connection
Emergency signal A14 Engine print X18/4 18-pin plug connection
R8 X4/70 X24/3 X10/18 X89/1 A30 Print ARU X24/2 24-pin plug connection
4 16 10 79 0.8 to 4.4 V B28 Manual throttle X24/3 24-pin plug connection
CN3 26-pin plug connection X30/1 14-pin plug connection
E10/1 Heating flange X30/3 4-pin plug connection
K5/LP Relay, fuel delivery pump X30/7 4-pin plug connection
K8/2 Relay, heating flange X36/1 36-pin plug connection
M13 Fuel delivery pump X89/1 89-pin plug connection
P8 ICU (2) Ground point, EEM3 control unit
A7 ID module Engine identification P8/1 4-pin plug connection (11) Ground point, engine cable carrier,
X4/4 X89/1
12V P8/2 4-pin plug connection rear
4 21 R8 Potentiometer, accelerator pedal (12) Ground point, engine cable carrier,
GND front
120 Ω 1 29 120 Ω
X1/30/1 Screw connection
CAN L X1/30/EEM Screw connection
2 52
CAN H X2/19 2-pin plug connection
3 53

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ARU from DBD094271 4011-131

*) see Note page 8

FUNCTIONAL SCHEMATIC DIAGRAM FOR FMGR - SGR UP TO DBD100000
X24/2
ARMREST (16) F19 5A
17 +15/1 F51 10A F18 5A
F20 5A +15/1 +15/1
*A28 PLUG MODULE 18 F14 7.5A A12 F9 10A
F16 5A GND +30 +30 A24 HYDROSTAT
X21 X11 *A30 PRINT ARU X1 X18/4 2 +15/2
3R7
A31 2 9 8 10
X5/1 X24/2 1 6 X24/2 21 23 M
1 1 7 13
S60/1 9 9
13 3 (16) (16) 3R7
X7 15 A4/3 10 14 13 A4/4 X16/21 13 12 3
CAN - CAN H
S60/2 2 16 1 A4 FMGR 17 1 A21 SGR
CAN H CAN L X6/9 E F L M H K B
11 11 3 17 3 18 2
CAN L Supply Supply
4 18 2

GND
11 V
S60/3
10 12 S4/4
X6/3 X24/3 A4/2 1 12 2 11 9 10 3
S60/4

0 V or 5 V
3 10 8 NEUTRAL LIMP HOME circuit
9 4 X16/21
2 11 7 DEAD MAN GND
GSV2 10
S60/5 4 12 6 12 V
Shuttle lever 14 Select 0 V** for FORWARDS
12 5 1 2 2 12 V
8 Select 0 V** for REVERSE
5 1 1 7 11 FORWARDS
*YA1 21 17 15 13 11 8 6 4 2 3 1 33 5 7 A23 ELECTRONICS
6 3 3 8 10 REVERSE **) Only if the
X4/59/b (A) and X4/59/c (B) A23 8 5 7 6

X4/59/b
X4/59/a
*YB1 21 17 15 13 11 8 6 4 2 3 1 33 5 7 plug connection is linked.
A21/4
* A27 CAN MODULE 11 X6/1

CAN H

CAN +
CAN L
12 4

CAN -
X24/3
2 19 A21/5 1
A12 X14/15 X10/11 A13 X10/12 P8 P8 ICU P8/1 1 21 3 3
F45 5A
+15/1 12 7 6 7 4 3 20 9 2
5 3 X4/59/c
3 2 A24 Hydrostat X5/1 Plug connection
Brake
X14/14 4 1 A27 CAN module ---> DBD..... X6/1 4-pin plug connection
X4/14 X24/3 A4/2 A28 Plug module ---> DBD..... X6/3 6-pin plug connection
P8/2 3 4 1 GSV2
6 A30 Print ARU DBD..... ---> X6/9 7-pin plug connection
A14 X20/1 X23/1 X10/14 12
F93 5A (7) S25 3.9 Ω A31 Multi controller X7 4-pin plug connection
+30 8 Q 7 (8) 3 4 14 3 V B17 Angle of rotation sensor, clutch X10/11 10-pin plug connection
S5 2 5 13 3 V CN3 26-pin plug connection X10/12 10-pin plug connection
P8 ICU X10/14 10-pin plug connection
P8 10-pin plug connection X11 16-pin plug connection
CN3 X24/3 A4/2 Clutch P8/1 4-pin plug connection X14/14 14-pin plug connection
A1 ADIC CAN L GSV2 P8/2 4-pin plug connection X14/15 14-pin plug connection
25 1 12 6
3.9 Ω R8 Potentiometer, accelerator pedal X16/21 16-pin plug connection
CAN H S46
26 A4/1 S4/4 Shuttle lever X18/4 18-pin plug connection
2 24 15 3 V S5 Switch for brake light X20/1 20-pin plug connection
S25 Switch for steering brake X21 14-pin plug connection
A4/4 S46 Switch, clutch X23/1 23-pin plug connection
A1 ADIC GND
1 13 4 S60/1 F/R button X23/2 23-pin plug connection
CAN H

A2 EEM2
CAN L

B17 5.6V S60/2 Cruise control button X24/2 24-pin plug connection
A4 FMGR 2 14 11
S60/3 Speed button + X24/3 24-pin plug connection
A4/1 18-pin plug connection U 3 15 12 1.1 to 4 V S60/4 Speed button - X70 70-pin plug connection
A4/2 18-pin plug connection S60/5 HTS button YA1 44-pin plug connection
A4/3 15-pin plug connection X1 14-pin plug connection ---> DBD.....
A4/4 18-pin plug connection X4/70 A4/4 Accelerator pedal X4/14 4-pin plug connection YB1 44-pin plug connection
A12 Central print GND X4/59/a 3-pin plug connection ---> DBD.....
1 1
A13 Roof print
X70 18 42 3 X4/59/b 3-pin plug connection (7) Ground point, roof hood, left
A14 Engine print R8 6 4.4 to 0.8 V X4/59/c 3-pin plug connection (8) Ground point, roof hood, right
A21 SGR transmission controller
A2 EEM2 5.8V
2 10 X4/70 4-pin plug connection (16) Ground point, starter
A21/4 12-pin plug connection
A21/5 12-pin plug connection 4 3 0.8 to 4.4 V
A23 Electronics X70 X23/2
A23 12-pin plug connection 36 U

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ARU from DBD094271 4011-133

FUNCTIONAL SCHEMATIC DIAGRAM FOR FMGR - SGR FROM DBD100001

ARMREST
A12 A24 HYDROSTAT

X30/11
F19 5A F51 10A F18 5A
+15/1 +15/1
A30 PRINT ARU 3R7
(11) F20 5A F14 7.5A F9 10A
X21 X30/1 X18/4 +15/1 +30 +30
M
A31 2 9 8 10 X24/2 17 18 X24/2 1 6 X24/2 21 23
1 1 7 13 3R7

S60/1 9 9
13 3 (11) (11)
X30/7 A4/3 10 14 13 A4/4 X16/21 13 12 3 X6/9 E F L M H K B
CAN H
S60/2 2 16 A4 FMGR 17 1 A21 SGR

GND
CAN H CAN L

11 V
11 11 3 17 3 18 2 Supply
CAN L Supply
4 18 2
S60/3
A23 1 12 2 11 9 10 3
10 12 S4/4

0 V or 5 V
X6/3 X24/3 A4/2 LIMP HOME circuit
S60/4 3 10 8 NEUTRAL
9 4 X16/21
2 11 7 DEAD MAN GND
GSV2 10
S60/5 4 12 6 12 V
Shuttle lever 14 Select 0 V** with FORWARDS
12 5 1 2 2 12 V
8 Select 0 V** with REVERSE A23 ELECTRONICS
5 1 1 7 11 FORWARDS
**) Only if the A23 8 5 7 6
6 3 3 8 10 REVERSE
X4/59/b (A) and X4/59/c (B)

X4/59/b
X4/59/a
plug connection is linked.
A21/4 X6/1
11 4

CAN H
CAN L
X24/3 12 1
2 19 A21/5
1 21 3 3
A12 X14/15 X10/11 A13 X10/12 P8 P8 ICU P8/1 3 20 9 2
F45 5A
+15/1 12 7 6 7 4 X4/59/c
5 3 A1 ADIC S60/3 Speed button +
X4/14 X24/3 A4/2 Brake A3 EEM3 S60/4 Speed button -
3 GSV2
1 12 6 A4 FMGR S60/5 HTS button
S25 3.9 Ω
3 4 14 3 V A4/1 18-pin plug connection X4/14 4-pin plug connection
A14 X10/3 X10/14 X14/14 P8/2 3 4 A4/2 18-pin plug connection X4/59/a 3-pin plug connection
F212 5A S5 2 5 13 3 V A4/3 15-pin plug connection X4/59/b 3-pin plug connection
+30 6 7 4 (7)
A4/4 18-pin plug connection X4/59/c 3-pin plug connection
(8) A12 Central print X4/70 4-pin plug connection
X24/3 A4/2 Clutch A13 Roof print X6/1 4-pin plug connection
GSV2 A14 Engine print X6/3 6-pin plug connection
1 12 6
3.9 Ω A21 SGR transmission controller X6/9 7-pin plug connection
S46 A4/1 A21/4 12-pin plug connection X10/3 10-pin plug connection
2 24 15 3 V A21/5 12-pin plug connection X10/11 10-pin plug connection
CAN H
CAN L

A23 Electronics X10/12 10-pin plug connection

A4/4 A23 12-pin plug connection X10/14 10-pin plug connection
GND A24 Hydrostat X10/18 10-pin plug connection
1 13 4
5.6V A30 Print ARU X14/14 14-pin plug connection
B17 2 14 11 A31 Multi controller X14/15 14-pin plug connection
U 3 15 12 1.1 to 4 V B17 Angle of rotation sensor, clutch X16/21 16-pin plug connection
CN3 26-pin plug connection X18/4 18-pin plug connection
A1 ADIC CN3 P8 ICU X21 14-pin plug connection
CAN L P8 10-pin plug connection X24/2 24-pin plug connection
25 X4/70 A4/4 Accelerator pedal
CAN H GND P8/1 4-pin plug connection X24/3 24-pin plug connection
26 1 1 P8/2 4-pin plug connection X30/1 14-pin plug connection
3 6 4.4 to 0.8 V R8 Potentiometer, accelerator pedal X30/7 4-pin plug connection
X89/1 35 34 R8
5.8V S4/4 Shuttle lever X30/11 16-pin plug connection
2 10 S5 Switch for brake light X89/1 89-pin plug connection
A3 EEM3
4 3 0.8 to 4.4 V S25 Switch for steering brake (7) Ground point, roof hood, left
S46 Switch, clutch (8) Ground point, roof hood, right
S60/1 F/R button (11) Ground point, engine cable
X89/1 X10/18 X24/3 S60/2 Cruise control button carrier, rear
79 10 16

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 4011-135

FAULTCODES AUX
AUX1 - 11 Missing acknowledgment message 1 nominal value ....................................................................... 137
AUX1 - 12 Missing acknowledgment message 2 nominal value ....................................................................... 137
AUX1 - 13 Implausible acknowledgment message 1 nominal value ................................................................. 138
AUX1 - 14 Implausible acknowledgment message 2 nominal value ................................................................. 138
AUX1 - 16 Controller fault (EEPROM inconsistent) .......................................................................................... 139
AUX1 - 21 Undervoltage - supply voltage below 8.2 VDC ................................................................................ 139
AUX1 - 22 Overvoltage - supply voltage above 18 VDC ................................................................................... 139
AUX1 - 23 Spool deflection too short ................................................................................................................ 140
AUX1 - 24 Spool deflection excessive .............................................................................................................. 140
AUX1 - 25 Float position not reached ............................................................................................................... 140
AUX1 - 26 Manual operation ............................................................................................................................. 141
AUX1 - 31 Undervoltage - supply voltage below 8.0 VDC ................................................................................ 141
AUX1 - 32 Overvoltage - supply voltage above 36 VDC ................................................................................... 142
AUX1 - 41 High Overvoltage - supply voltage above 45 VDC .......................................................................... 142
AUX1 - 42 Output stage fault ............................................................................................................................ 143
AUX1 - 43 Position transducer fault .................................................................................................................. 143
AUX1 - 81 Valve spool cannot brought back to neutral position ....................................................................... 144
AUX1 - 82 Valve spool not in neutral when switched on ................................................................................... 144
AUX2 - 11 Missing acknowledgment message 1 nominal value ....................................................................... 145
AUX2 - 12 Missing acknowledgment message 2 nominal value ....................................................................... 145
AUX2 - 13 Implausible acknowledgment message 1 nominal value ................................................................. 146
AUX2 - 14 Implausible acknowledgment message 2 nominal value ................................................................. 146
AUX2 - 16 Controller Fault (EEPROM inconsistent) ......................................................................................... 147
AUX2 - 21 Undervoltage - supply voltage below 8.2 VDC ................................................................................ 147
AUX2 - 22 Overvoltage - supply voltage above 18 VDC ................................................................................... 147
AUX2 - 23 Spool deflection too short ................................................................................................................ 148
AUX2 - 24 Spool deflection excessive .............................................................................................................. 148
AUX2 - 25 Float position not reached ............................................................................................................... 148
AUX2 - 26 Manual operation ............................................................................................................................. 149
AUX2 - 31 Undervoltage - supply voltage below 8.0 VDC ................................................................................ 149
AUX2 - 32 Overvoltage - supply voltage above 36 VDC ................................................................................... 150
AUX2 - 41 High overvoltage - supply voltage above 45 VDC ........................................................................... 150
AUX2 - 42 Output stage fault ............................................................................................................................ 151
AUX2 - 43 Position transducer fault .................................................................................................................. 151
AUX2 - 81 Valve spool cannot brought back to neutral position ....................................................................... 152
AUX2 - 82 Valve spool not in neutral when switched on ................................................................................... 152
AUX3 - 11 Missing acknowledgment message 1 nominal value ....................................................................... 153
AUX3 - 12 Missing acknowledgment message 2 nominal value ....................................................................... 153
AUX3 - 13 Implausible acknowledgment message 1 nominal value ................................................................. 154
AUX3 - 14 Implausible acknowledgment message 2 nominal value ................................................................. 154
AUX3 - 16 Controller Fault (EEPROM inconsistent) ......................................................................................... 155
AUX3 - 21 Undervoltage - supply voltage below 8.2 VDC ................................................................................ 155
AUX3 - 22 Overvoltage - supply voltage above 18 VDC ................................................................................... 155
AUX3 - 23 Spool deflection too short ................................................................................................................ 156
AUX3 - 24 Spool deflection excessive .............................................................................................................. 156
AUX3 - 25 Float position not reached ............................................................................................................... 156
AUX3 - 26 Manual operation ............................................................................................................................. 157
AUX3 - 31 Undervoltage - supply voltage below 8.0 VDC ................................................................................ 157
AUX3 - 32 Overvoltage - supply voltage above 36 VDC ................................................................................... 158
AUX3 - 41 High Overvoltage - supply voltage above 45 VDC .......................................................................... 158

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AUX3 - 42 Output stage fault ............................................................................................................................ 159
AUX3 - 43 Position transducer fault .................................................................................................................. 159
AUX3 - 81 Valve spool cannot brought back to neutral position ....................................................................... 160
AUX3 - 82 Valve spool not in neutral when switched on ................................................................................... 160
AUX4 - 11 Missing acknowledgment message 1 nominal value ....................................................................... 161
AUX4 - 12 Missing acknowledgment message 2 nominal value ....................................................................... 161
AUX4 - 13 Implausible acknowledgment message 1 nominal value ................................................................. 162
AUX4 - 14 Implausible acknowledgment message 2 nominal value ................................................................. 162
AUX4 - 16 Controller Fault (EEPROM inconsistent) ......................................................................................... 163
AUX4 - 21 Undervoltage - supply voltage below 8.2 VDC ................................................................................ 163
AUX4 - 22 Overvoltage - supply voltage above 18 VDC ................................................................................... 163
AUX4 - 23 Spool deflection too short ................................................................................................................ 164
AUX4 - 24 Spool deflection excessive .............................................................................................................. 164
AUX4 - 25 Float position not reached ............................................................................................................... 164
AUX4 - 26 Manual operation ............................................................................................................................. 165
AUX4 - 31 Undervoltage - supply voltage below 8.0 VDC ................................................................................ 165
AUX4 - 32 Overvoltage - supply voltage above 36 VDC ................................................................................... 166
AUX4 - 41 High Overvoltage - supply voltage above 45 VDC .......................................................................... 166
AUX4 - 42 Output stage fault ............................................................................................................................ 167
AUX4 - 43 Position transducer fault .................................................................................................................. 167
AUX4 - 81 Valve spool cannot brought back to neutral position ....................................................................... 168
AUX4 - 82 Valve spool not in neutral when switched on ................................................................................... 168
AUX5 - 11 Missing acknowledgment message 1 nominal value ....................................................................... 169
AUX5 - 12 Missing acknowledgment message 2 nominal value ....................................................................... 169
AUX5 - 13 Implausible acknowledgment message 1 nominal value ................................................................. 170
AUX5 - 14 Implausible acknowledgment message 2 nominal value ................................................................. 170
AUX5 - 16 Controller Fault (EEPROM inconsistent) ......................................................................................... 171
AUX5 - 21 Undervoltage - supply voltage below 8.2 VDC ................................................................................ 171
AUX5 - 22 Overvoltage - supply voltage above 18 VDC ................................................................................... 171
AUX5 - 23 Spool deflection too short ................................................................................................................ 172
AUX5 - 24 Spool deflection excessive .............................................................................................................. 172
AUX5 - 25 Float position not reached ............................................................................................................... 172
AUX5 - 26 Manual operation ............................................................................................................................. 173
AUX5 - 31 Undervoltage - supply voltage below 8.0 VDC ................................................................................ 173
AUX5 - 32 Overvoltage - supply voltage above 36 VDC ................................................................................... 174
AUX5 - 41 High Overvoltage - supply voltage above 45 VDC .......................................................................... 174
AUX5 - 42 Output stage fault ............................................................................................................................ 175
AUX5 - 43 position Transducer Fault ................................................................................................................ 175
AUX5 - 81 Valve spool cannot brought back to neutral position ....................................................................... 176
AUX5 - 82 Valve spool not in neutral when switched on ................................................................................... 176
COMPONENTS SUMMARY ............................................................................................................................. 178

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AUX1 - 11 Missing acknowledgment message 1 nominal value

Cause:
The fault is active if no nominal value message is sent from the armrest via the CAN bus within 500 ms. The valve
recognises this as a fault and reports it using the diagnosis message. The fault is stored and is displayed on the ADIC
by a warning triangle.
Reaction of the valve:
• Valve is set to the neutral position.
• If valid messages are received within 1...4s, the valve returns to the given setting. If a signal is active for
more than 4s, the valve remains in neutral and can only be actuated again once neutral has been received.
Possible causes:
• CAN bus fault on the vehicle bus
Solution:
NOTE: Before starting the troubleshooting procedure, check whether the ARU or ECCU2 fault codes are active. If
yes, then address these faults first of all.
Turn the ignition off and on again and check whether fault AUX1 11 is occurring again. If the fault is again active, go
to step 1.
1. Reconfigure valve AUX1 to another AUX no. using the service tool. (e.g. to AUX2) Ensure that there are no active
fault codes on AUX2.
2. Test that the valve is functioning correctly using the newly assigned AUX no. (use the “AUX2 RAISE; LOWER;
NEUTRAL and FLOAT POSITION“ service tool monitor functions)
If the fault code is still active, the valve should be replaced.
NOTE: If fault code 11 is still active, it is now displayed in conjunction with the newly assigned AUX no. In our case,
fault code AUX2 11.

AUX1 - 12 Missing acknowledgment message 2 nominal value

Cause:
The fault is active if no nominal value message is sent from the armrest via the CAN bus within 500 ms. The valve
recognises this as a fault and reports it using the diagnosis message. The fault is stored and is displayed on the ADIC
by a warning triangle.
Reaction of the valve:
• Valve is set to the neutral position.
• If valid messages are received within 1...4s, the valve returns to the given setting. If a signal is active for
more than 4s, the valve remains in neutral and can only be actuated again once neutral has been received.
Possible causes:
• CAN bus fault on the vehicle bus
Solution:
NOTE: Before starting the troubleshooting procedure, check whether the ARU or ECCU2 fault codes are active. If
yes, then address these faults first of all.
Turn the ignition off and on again and check whether fault AUX1 12 is occurring again. If the fault is again active, go
to step 1.
1. Reconfigure valve AUX1 to another AUX no. using the service tool. (e.g. to AUX2) Ensure that there are no active
fault codes on AUX2.
2. Test that the valve is functioning correctly using the newly assigned AUX no. (use the “AUX2 RAISE; LOWER;
NEUTRAL and FLOAT POSITION“ service tool monitor functions)
If the fault code is still active, the valve should be replaced.
NOTE: If fault code 12 is still active, it is now displayed in conjunction with the newly assigned AUX no. In our case,
fault code AUX2 12.

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AUX1 - 13 Implausible acknowledgment message 1 nominal value

Cause:
Data from the CAN bus is implausible (e.g. "neutral" or "float position" commands at the same time). The fault is stored
and signalled on the ADIC by a warning triangle.
Possible causes:
1. Fault in the electronics of valve AUX1
2. CAN bus fault on the vehicle bus
Solution:
Use the “CONTROL MODULE STATUS“ service tool monitor to check whether all bus users are ONLINE.
NOTE: Before starting the troubleshooting procedure, check whether the ARU or ECCU2 fault codes are active. If
yes, then address these faults first of all.
1. Use the “NUMBER OF AUX“ service tool monitor function to check whether all the valves fitted are recognised
by the ARU.
2. Reconfigure valve AUX1 to another AUX no. using the service tool. (e.g. to AUX2) Ensure that there are no active
fault codes on AUX2.
3. Test that the valve is functioning correctly using the newly assigned AUX no. (use the “AUX2 RAISE; LOWER;
NEUTRAL and FLOAT POSITION“ service tool monitor functions)
If the fault code is still active, the valve should be replaced.
NOTE: If fault code 13 is still active, it is now displayed in conjunction with the newly assigned AUX no. In our case,
fault code AUX2 13.

AUX1 - 14 Implausible acknowledgment message 2 nominal value

Cause:
Data from the CAN bus is implausible (e.g. "neutral" or "float position" commands at the same time). The fault is stored
and signalled on the ADIC by a warning triangle.
Possible causes:
1. Fault in the electronics of valve AUX1
2. CAN bus fault on the vehicle bus
Solution:
Use the “CONTROL MODULE STATUS“ service tool monitor to check whether all bus users are ONLINE.
NOTE: Before starting the troubleshooting procedure, check whether the ARU or ECCU2 fault codes are active. If
yes, then address these faults first of all.
1. Use the “NUMBER OF AUX“ service tool monitor function to check whether all the valves fitted are recognised
by the ARU.
2. Reconfigure valve AUX1 to another AUX no. using the service tool. (e.g. to AUX2) Ensure that there are no active
fault codes on AUX2.
3. Test that the valve is functioning correctly using the newly assigned AUX no. (use the “AUX2 RAISE; LOWER;
NEUTRAL and FLOAT POSITION“ service tool monitor functions)
If the fault code is still active, the valve should be replaced.
NOTE: If fault code 14 is still active, it is now displayed in conjunction with the newly assigned AUX no. In our case,
fault code AUX2 14.

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AUX1 - 16 Controller fault (EEPROM inconsistent)

Cause:
Certain cells of the EEPROM are checked during run-up. If their content is implausible, this fault is recognized and
displayed.
Valve reaction:
• The valve remains in neutral position and displays fault code 16.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC.

Replace the remote valve.

Look to service tool function:
• "CONFIGURATION OF AUX-VALVES".
AUX1 - 21 Undervoltage - supply voltage below 8.2 VDC
Cause:
The supply voltage of the remote valve controller is below 8.2 VDC. Valve operates normal as long supply voltage is
above 8 VDC.
Solution:
Failure will be stored.
1. Check the supply line on the AUX connector X4/90 PIN1 (+12V) against PIN4 (GND).
2. Up to DBD100000:
Check the supply voltage up to fuse F47 (15/1) 5A and connector X5/1 (GND) at the A12.
From DBD100001:
Check the supply voltage up to fuse F47 (15/1) 5A at the A12 and grounding point 11.
3. Check vehicle battery and charge circuit.
4. If the AUX are displayed OFFLINE at service tool, probably the power supply is out of work. No reporting of fault
code numbers.

AUX1 - 22 Overvoltage - supply voltage above 18 VDC

Cause:
The supply voltage of the remote valve controller is above 18 VDC. Valve operates normal as long supply voltage is
below 36 VDC.
Solution:
Failure will be stored.

Check batterie voltage or loading voltage of the generator clamp B+ against ground. (loading voltage 13.8V - 14.5V).
If the bord voltage is OK, change the control valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

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AUX1 - 23 Spool deflection too short

Cause:
This fault occurs often, if the AUX sticks for the AUX are not in neutral and the engine is not running.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC. Start the engine and the fault should not oc-
cure again, as long as the spool is moveable and fault's 81 and 82 don't occure.

AUX1 - 24 Spool deflection excessive

Cause:
This fault is detected if the valve recognizes that the spool moved too far, or does not return to neutral through spring
force.
Valve reaction:
• The valve switches to neutral and displays fault code 24. It can only be deflected if the valve is in neutral and
the neutral setpoint was received.
• The valve tries to support the spring by applying current to the opposite coil.
• If this current applic.is unsuccessful, the internal safety transistor is switched off and fault 81 occurs.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC.
• Check the observing of the mounting rules.

AUX1 - 25 Float position not reached

Cause:
If the float position required by the setpoint is not reached within a certain period of time, this fault code is displayed.
Valve reaction:
• The valve shifts to neutral position. It can only be deflected when the valve is in neutral and the neutral set-
point has been received.
This fault occurs often, if the AUX-Sticks for the AUXs are not in neutral and the engine is not running or the
spool is not moveable in the control valve.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC. Start the engine and the fault should not oc-
cure again, as long as the spool is moveable and fault's 81 and 82 don't occure.

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AUX1 - 26 Manual operation

Cause:
Manual operation is detected when both valve and setpoint are neutral, diagnosis detects no faults, and the valve
leaves the neutral zone.
Valve reaction:
• Valve does not counter-act.
• Fault 26 is displayed as long as the valve is deflected.
• When both valve and setpoint are neutral, fault is no longer present.
• If a setpoint other than neutral is set during deflection, this is not accepted and fault 26 continues to be dis-
played until valve and setpoint are in neutral once more.
Solution:
Failure will be stored. If, in the above case, the valve but not the setpoint is in neutral, fault code 17 (no fault, but
waiting for setpoint neutral) is not displayed. Instead fault code 26 remains until the setpoint is neutral.

AUX1 - 31 Undervoltage - supply voltage below 8.0 VDC

Cause:
The supply voltage of the remote valve controller is below 8.0 VDC.
Valve reaction:
• The valve goes to neutral position and displays fault code 31.
• If the voltage rises above 8.0 VDC within 1...4 s the valve returns to the desired position and shows fault
code 21.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC.
1. Check the supply line on the AUX connector X4/90 PIN1 (+12V) against PIN4 (GND).
2. Up to DBD100000:
Check the supply voltage up to fuse F47 (15/1) 5A and connector X5/1 (GND) at the A12.
From DBD100001:
Check the supply voltage up to fuse F47 (15/1) 5A at the A12 and grounding point 11.
3. Check vehicle battery and charge circuit.
4. If the AUX are displayed OFFLINE at service tool, probably the power supply is out of work. No reporting of fault
code numbers.

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AUX1 - 32 Overvoltage - supply voltage above 36 VDC

Cause:
The supply voltage of the remote valve controller is above 36 VDC.
Valve reaction:
• The valve switches to neutral.
• If the voltage drops below 36 VDC within 1...4 s, the valve returns to the desired position and displays fault
code 22.
• If the voltage exceeds 36 VDC for more than 4 s, the valve remains in neutral and can only be deflected if
the voltage drops below 18 VDC.
• If the fault code is remedied, but the setpoint is not neutral, fault code 17 appears.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC.

Check the batterie voltage or the loading voltage of the generator clamp B+ against ground
(loading voltage 13.8V - 14.5V). If the bord voltage is OK, change the control valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

AUX1 - 41 High Overvoltage - supply voltage above 45 VDC

Cause:
The supply voltage of the remote valve controller is above 45 VDC.
Valve reaction:
• The valve switches to neutral and also switches off the internal safety transistor (to increase electric
strength).
• The valve can only be deflected, if the voltage lies below 18 VDC, the neutral setpoint was received and the
valve is in neutral.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC. In this case control section must switch to
neutral itself. Therefore message "fault 17: no fault, but waiting for setpoint neutral" is not displayed, as once safety
transistor has been switched off and valve can no longer perform a complete diagnosis (above all output stage dia-
gnosis, due to being no voltage there).

Check batterie voltage or loading voltage of the generator clamp B+ against ground (loading voltage 13.8V - 14.5V).
If the bord voltage is OK, change the control valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

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AUX1 - 42 Output stage fault

Cause:
When switched on, the valve performs a brief self-test. During operation the trigger voltage is compared with the so-
lenoid voltage and the solenoid current is checked for plausibility.
Valve reaktion:
• The valve goes to neutral position a. switches off the internal safety transistor.
• Through the shortcutted output stage, the condition is hold until switching off.
• Interrupt solenoid or missing connector, the fault extinguish after 1 sec if the true value and the valve is not
neutral.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC. The operation board must himself go to neu-
tral. Fault 17 (no fault) does not occur because after switching of the safety transsitor, the valve could not do the dia-
gnostic in a correct way. The valve goes himself to neutral, but fault disappears after the valve was remoted with
neutral.

Turn the keyswitch off and back on - if fault code 42 re-occurs, replace the remote valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

AUX1 - 43 Position transducer fault

Cause:
On start-up the position transducer undergoes diagnosis. Failure of the position transducer connector and open circuit
in the secondary system are recognized here.
Valve reaction:
• The valve goes to neutral, switches off the internal safety transistor and displays fault code 43.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC. The operation board must himself go to neu-
tral. Fault 17 (no fault) does not occur because after switching of the safety transsitor, the valve could not do the dia-
gnostic in a correct way.

During operations the position transducer fault cannot be diagnosed in a correct way. If the position transducer con-
nector or the pins of the secundary spool fall down, the position signal reaches a special value (middle way of lower).
Therefore comes following faults:
• At true value neutral: "hand operated" = faultcode 26.
• At true value raise or lower:
first "spool deflection too short or excessive" = faultcode 23 or 24,
afterwards "valve does not go back to neutral" = faultcode 81.
Change the valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

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AUX1 - 81 Valve spool cannot brought back to neutral position

Cause:
The valve could not either be brought back with springpower nore through electrical supply of the opposite placed
spool to the neutral position.
Valve reaktion:
• The valve put out the faultcode 81.
• The intern security transistor is switched off and the driver for the extern security relais at voltage/PWM
remoted. You can only start steering if valve is in neutral and the main value is beeing recieved.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC. The operation board must himself go to neu-
tral. Fault 17 (no fault) does not occur because after switching of the safety transsitor, the valve could not do the dia-
gnostic in a correct way. Here has the valve no change to move the spoolto neutral. There is an extern switch off from
the oilstream necessary.

Turn the keyswitch on, if fault code 81 re-occurs replace the remote.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

AUX1 - 82 Valve spool not in neutral when switched on

Cause:
Valve noticed, that spool is not in neutral pos. at switching on.
Valve reaktion:
• Valve stays in neutral pos.and send fault 82. Beginn steering if the valve stands in neutral and the isvalue is
recieved. A pushing back of the slide does not happen, because the pos.sensor is beeing moved and a
return could move the slide out of neutral.
• The intern security transistor a. driver of the extern security relais at supply/PWM are being switched,
because there could be a fault of the pos. sensor.
Solution:
Failure will be stored and signaled with a warning triangel on the ADIC. The servicepart must switch himself to neutral.
The message "faultcode 17: is no mistake but wait for main value neutral" does not come here, because the valve
after switching off the security tranistor is not able to do the diagnostics in right order. Mainpoint the amplifier diagno-
stics because of the missing voltage.

Turn the keyswitch on, if fault code 82 re-occurs, replace the remote valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

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 4011-145

AUX2 - 11 Missing acknowledgment message 1 nominal value

Cause:
The fault is active if no nominal value message is sent from the armrest via the CAN bus within 500 ms. The valve
recognises this as a fault and reports it using the diagnosis message. The fault is stored and is displayed on the ADIC
by a warning triangle.
Reaction of the valve:
• Valve is set to the neutral position.
• If valid messages are received within 1...4s, the valve returns to the given setting. If a signal is active for
more than 4s, the valve remains in neutral and can only be actuated again once neutral has been received.
Possible causes:
• CAN bus fault on the vehicle bus
Solution:
NOTE: Before starting the troubleshooting procedure, check whether the ARU or ECCU2 fault codes are active. If
yes, then address these faults first of all.
Turn the ignition off and on again and check whether fault AUX2 11 is occurring again. If the fault is again active, go
to step 1.
1. Reconfigure valve AUX2 to another AUX no. using the service tool. (e.g. to AUX1) Ensure that there are no active
fault codes on AUX1.
2. Test that the valve is functioning correctly using the newly assigned AUX no. (use the “AUX1 RAISE; LOWER;
NEUTRAL and FLOAT POSITION“ service tool monitor functions)
If the fault code is still active, the valve should be replaced.
NOTE: If fault code 11 is still active, it is now displayed in conjunction with the newly assigned AUX no. In our case,
fault code AUX1 11.

AUX2 - 12 Missing acknowledgment message 2 nominal value

Cause:
The fault is active if no nominal value message is sent from the armrest via the CAN bus within 500 ms. The valve
recognises this as a fault and reports it using the diagnosis message. The fault is stored and is displayed on the ADIC
by a warning triangle.
Reaction of the valve:
• Valve is set to the neutral position.
• If valid messages are received within 1...4s, the valve returns to the given setting. If a signal is active for
more than 4s, the valve remains in neutral and can only be actuated again once neutral has been received.
Possible causes:
• CAN bus fault on the vehicle bus
Solution:
NOTE: Before starting the troubleshooting procedure, check whether the ARU or ECCU2 fault codes are active. If
yes, then address these faults first of all.
Turn the ignition off and on again and check whether fault AUX2 12 is occurring again. If the fault is again active, go
to step 1.
1. Reconfigure valve AUX2 to another AUX no. using the service tool. (e.g. to AUX1) Ensure that there are no active
fault codes on AUX1.
2. Test that the valve is functioning correctly using the newly assigned AUX no. (use the “AUX1 RAISE; LOWER;
NEUTRAL and FLOAT POSITION“ service tool monitor functions)
If the fault code is still active, the valve should be replaced.
NOTE: If fault code 12 is still active, it is now displayed in conjunction with the newly assigned AUX no. In our case,
fault code AUX1 12.

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4011-146

AUX2 - 13 Implausible acknowledgment message 1 nominal value

Cause:
Data from the CAN bus is implausible (e.g. "neutral" or "float position" commands at the same time). The fault is stored
and signalled on the ADIC by a warning triangle.
Possible causes:
1. Fault in the electronics of valve AUX2
2. CAN bus fault on the vehicle bus
Solution:
Use the “CONTROL MODULE STATUS“ service tool monitor to check whether all bus users are ONLINE.
NOTE: Before starting the troubleshooting procedure, check whether the ARU or ECCU2 fault codes are active. If
yes, then address these faults first of all.
1. Use the “NUMBER OF AUX“ service tool monitor function to check whether all the valves fitted are recognised
by the ARU.
2. Reconfigure valve AUX2 to another AUX no. using the service tool. (e.g. to AUX1) Ensure that there are no active
fault codes on AUX1.
3. Test that the valve is functioning correctly using the newly assigned AUX no. (use the “AUX1 RAISE; LOWER;
NEUTRAL and FLOAT POSITION“ service tool monitor functions)
If the fault code is still active, the valve should be replaced.
NOTE: If fault code 13 is still active, it is now displayed in conjunction with the newly assigned AUX no. In our case,
fault code AUX1 13.

AUX2 - 14 Implausible acknowledgment message 2 nominal value

Cause:
Data from the CAN bus is implausible (e.g. "neutral" or "float position" commands at the same time). The fault is stored
and signalled on the ADIC by a warning triangle.
Possible causes:
1. Fault in the electronics of valve AUX2
2. CAN bus fault on the vehicle bus
Solution:
Use the “CONTROL MODULE STATUS“ service tool monitor to check whether all bus users are ONLINE.
NOTE: Before starting the troubleshooting procedure, check whether the ARU or ECCU2 fault codes are active. If
yes, then address these faults first of all.
1. Use the “NUMBER OF AUX“ service tool monitor function to check whether all the valves fitted are recognised
by the ARU.
2. Reconfigure valve AUX2 to another AUX no. using the service tool. (e.g. to AUX1) Ensure that there are no active
fault codes on AUX1.
3. Test that the valve is functioning correctly using the newly assigned AUX no. (use the “AUX1 RAISE; LOWER;
NEUTRAL and FLOAT POSITION“ service tool monitor functions)
If the fault code is still active, the valve should be replaced.
NOTE: If fault code 14 is still active, it is now displayed in conjunction with the newly assigned AUX no. In our case,
fault code AUX1 14.

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AUX2 - 16 Controller Fault (EEPROM inconsistent)

Cause:
Certain cells of the EEPROM are checked during run-up. If their content is implausible, this fault is recognized and
displayed.
Valve reaction:
• The valve remains in neutral position and displays fault code 16.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC.

Replace the remote valve.

Look to service tool function:
• "CONFIGURATION OF AUX-VALVES".

AUX2 - 21 Undervoltage - supply voltage below 8.2 VDC

Cause:
The supply voltage of the remote valve controller is below 8.2 VDC. Valve operates normal as long supply voltage is
above 8 VDC.
Solution:
Failure will be stored.
1. Check the supply line on the AUX connector X4/91 PIN1 (+12V) against PIN4 (GND).
2. Up to DBD100000:
Check the supply voltage up to fuse F47 (15/1) 5A and connector X5/1 (GND) at the A12.
From DBD100001:
Check the supply voltage up to fuse F47 (15/1) 5A at the A12 and grounding point 11.
3. Check vehicle battery and charge circuit.
4. If the AUX are displayed OFFLINE at service tool, probably the power supply is out of work. No reporting of fault
code numbers.

AUX2 - 22 Overvoltage - supply voltage above 18 VDC

Cause:
The supply voltage of the remote valve controller is above 18 VDC. Valve operates normal as long supply voltage is
below 36 VDC.
Solution:
Failure will be stored.

Check batterie voltage or loading voltage of the generator clamp B+ against ground. (loading voltage 13.8V - 14.5V).
If the bord voltage is OK, change the control valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

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4011-148

AUX2 - 23 Spool deflection too short

Cause:
This fault occurs often, if the AUX-Sticks for the AUXs are not in neutral and the engine is not running.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC. Start the engine and the fault should not oc-
cure again, as long as the spool is moveable and fault's 81 and 82 don't occure.

AUX2 - 24 Spool deflection excessive

Cause:
This fault is detected if the valve recognizes that the spool moved too far, or does not return to neutral through spring
force.
Valve reaction:
• The valve switches to neutral and displays fault code 24. It can only be deflected if the valve is in neutral and
the neutral setpoint was received.
• The valve tries to support the spring by applying current to the opposite coil.
• If this current applic.is unsuccessful, the internal safety transistor is switched off and fault 81 occurs.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC.
• Check the observing of the mounting rules.

AUX2 - 25 Float position not reached

Cause:
If the float position required by the setpoint is not reached within a certain period of time, this fault code is displayed.
Valve reaction:
• The valve shifts to neutral position. It can only be deflected when the valve is in neutral and the neutral set-
point has been received.
This fault occurs often, if the AUX-Stickss for the AUXs are not in neutral and the engine is not running or the
spool is not moveable in the control valve.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC. Start the engine and the fault should not oc-
cure again, as long as the spool is moveable and fault's 81 and 82 don't occure.

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AUX2 - 26 Manual operation

Cause:
Manual operation is detected when both valve and setpoint are neutral, diagnosis detects no faults, and the valve
leaves the neutral zone.
Valve reaction:
• Valve does not counter-act.
• Fault 26 is displayed as long as the valve is deflected.
• When both valve and setpoint are neutral, fault is no longer present.
• If a setpoint other than neutral is set during deflection, this is not accepted and fault 26 continues to be dis-
played until valve and setpoint are in neutral once more.
Solution:
Failure will be stored. If, in the above case, the valve but not the setpoint is in neutral, fault code 17 (no fault, but
waiting for setpoint neutral) is not displayed. Instead fault code 26 remains until the setpoint is neutral.

AUX2 - 31 Undervoltage - supply voltage below 8.0 VDC

Cause:
The supply voltage of the remote valve controller is below 8.0 VDC.
Valve reaction:
• The valve goes to neutral position and displays fault code 31.
• If the voltage rises above 8.0 VDC within 1...4 s the valve returns to the desired position and shows fault
code 21.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC.
1. Check the supply line on the AUX connector X4/91 PIN1 (+12V) against PIN4 (GND).
2. Up to DBD100000:
Check the supply voltage up to fuse F47 (15/1) 5A and connector X5/1 (GND) at the A12.
From DBD100001:
Check the supply voltage up to fuse F47 (15/1) 5A at the A12 and grounding point 11.
3. Check vehicle battery and charge circuit.
4. If the AUX are displayed OFFLINE at service tool, probably the power supply is out of work. No reporting of fault
code numbers.

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4011-150

AUX2 - 32 Overvoltage - supply voltage above 36 VDC

Cause:
The supply voltage of the remote valve controller is above 36 VDC.
Valve Reaction:
• The valve switches to neutral.
• If the voltage drops below 36 VDC within 1...4 s, the valve returns to the desired position and displays fault
code 22.
• If the voltage exceeds 36 VDC for more than 4 s, the valve remains in neutral and can only be deflected if
the voltage drops below 18 VDC.
• If the fault code is remedied, but the setpoint is not neutral, fault code 17 appears.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC.

Check the batterie voltage or the loading voltage of the generator clamp B+ against ground
(loading voltage 13.8V - 14.5V). If the bord voltage is OK, change the control valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

AUX2 - 41 High overvoltage - supply voltage above 45 VDC

Cause:
The supply voltage of the remote valve controller is above 45 VDC.
Valve Reaction:
• The valve switches to neutral and also switches off the internal safety transistor (to increase electric
strength).
• The valve can only be deflected, if the voltage lies below 18 VDC, the neutral setpoint was received and the
valve is in neutral.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC. In this case control section must switch to
neutral itself. Therefore message "fault 17: no fault, but waiting for setpoint neutral" is not displayed, as once safety
transistor has been switched off and valve can no longer perform a complete diagnosis (above all output stage dia-
gnosis, due to being no voltage there).

Check batterie voltage or loading voltage of the generator clamp B+ against ground (loading voltage 13.8V - 14.5V).
If the bord voltage is OK, change the control valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

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 4011-151

AUX2 - 42 Output stage fault

Cause:
When switched on, the valve performs a brief selftest. During operation the trigger voltage is compared with the so-
lenoid voltage and the solenoid current is checked for plausibility.
Valve Reaktion:
• The valve goes to neutral position and switches off the internal safety transistor.
• Through the shortcutted output stage, the condition is hold until switching off.
• Interrupt solenoid or missing connector, the fault extinguish after 1 sec if the true value and the valve is not
neutral.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC. The operation board must himself go to neu-
tral. Fault 17 (no fault) does not occur because after switching of the safety transsitor, the valve could not do the dia-
gnostic in a correct way. The valve goes himself to neutral, but fault disappears after the valve was remoted with
neutral.

Turn the keyswitch off and back on - if fault code 42 re-occurs, replace the remote valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

AUX2 - 43 Position transducer fault

Cause:
On start-up the position transducer undergoes diagnosis. Failure of the position transducer connector and open circuit
in the secondary system are recognized here.
Valve reaction:
• The valve goes to neutral, switches off the internal safety transistor and displays fault code 43.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC. The operation board must himself go to neu-
tral. Fault 17 (no fault) does not occur because after switching of the safety transsitor, the valve could not do the dia-
gnostic in a correct way.

During operations the position transducer fault cannot be diagnosed in a correct way. If the position transducer con-
nector or the pins of the secundary spool fall down, the position signal reaches a special value (middle way of lower).
Therefore comes following faults:
• At true value neutral: "hand operated" = faultcode 26.
• At true value raise or lower:
first "spool deflection too short or excessive" = faultcode 23 or 24,
afterwards "valve does not go back to neutral" = faultcode 81.
Change the valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

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AUX2 - 81 Valve spool cannot brought back to neutral position

Cause:
The valve could not either be brought back with springpower nore through electrical supply of the opposite placed
spool to the neutral position.
Valve Reaktion:
• The valve put out the faultcode 81.
• The intern security transistor is switched off and the driver for the extern security relais at voltage/PWM
remoted. You can only start steering if valve is in neutral and the main value is beeing recieved.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC. The operation board must himself go to neu-
tral. Fault 17 (no fault) does not occur because after switching of the safety transsitor, the valve could not do the dia-
gnostic in a correct way.

Here has the valve no change to move the spoolto neutral. There is an extern switch off from the oilstream necessary.
Turn the keyswitch on, if fault code 81 re-occurs replace the remote.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

AUX2 - 82 Valve spool not in neutral when switched on

Cause:
Valve noticed, that spool is not in neutral pos.at switching on.
Valve reaktion:
• Valve stays in neutral pos.and send fault 82. Beginn steering if the valve stands in neutral and the isvalue is
recieved. A pushing back of the slide does not happen, because the pos.sensor is beeing moved and a
return could move the slide out of neutral.
• The intern security transistor a. driver of the extern security relais at supply/PWM are being switched,
because there could be a fault of the pos.sensor.
Solution:
Failure will be stored and signaled with a warning triangel on the ADIC. The servicepart must switch himself to neutral.
The message "faultcode 17: is no mistake but wait for main value neutral" does not come here, because the valve
after switching off the security tranistor is not able to do the diagnostics in right order. Mainpoint the amplifier diagno-
stics because of the missing voltage.

Turn the keyswitch on, if fault code 82 reoccurs, replace the remote valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

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 4011-153

AUX3 - 11 Missing acknowledgment message 1 nominal value

Cause:
The fault is active if no nominal value message is sent from the armrest via the CAN bus within 500 ms. The valve
recognises this as a fault and reports it using the diagnosis message. The fault is stored and is displayed on the ADIC
by a warning triangle.
Reaction of the valve:
• Valve is set to the neutral position.
• If valid messages are received within 1...4s, the valve returns to the given setting. If a signal is active for
more than 4s, the valve remains in neutral and can only be actuated again once neutral has been received.
Possible causes:
• CAN bus fault on the vehicle bus
Solution:
NOTE: Before starting the troubleshooting procedure, check whether the ARU or ECCU2 fault codes are active. If
yes, then address these faults first of all.
Turn the ignition off and on again and check whether fault AUX3 11 is occurring again. If the fault is again active, go
to step 1.
1. Reconfigure valve AUX3 to another AUX no. using the service tool. (e.g. to AUX1) Ensure that there are no active
fault codes on AUX1.
2. Test that the valve is functioning correctly using the newly assigned AUX no. (use the “AUX1 RAISE; LOWER;
NEUTRAL and FLOAT POSITION“ service tool monitor functions)
If the fault code is still active, the valve should be replaced.
NOTE: If fault code 11 is still active, it is now displayed in conjunction with the newly assigned AUX no. In our case,
fault code AUX1 11.

AUX3 - 12 Missing acknowledgment message 2 nominal value

Cause:
The fault is active if no nominal value message is sent from the armrest via the CAN bus within 500 ms. The valve
recognises this as a fault and reports it using the diagnosis message. The fault is stored and is displayed on the ADIC
by a warning triangle.
Reaction of the valve:
• Valve is set to the neutral position.
• If valid messages are received within 1...4s, the valve returns to the given setting. If a signal is active for
more than 4s, the valve remains in neutral and can only be actuated again once neutral has been received.
Possible causes:
• CAN bus fault on the vehicle bus
Solution:
NOTE: Before starting the troubleshooting procedure, check whether the ARU or ECCU2 fault codes are active. If
yes, then address these faults first of all.
Turn the ignition off and on again and check whether fault AUX3 12 is occurring again. If the fault is again active, go
to step 1.
1. Reconfigure valve AUX3 to another AUX no. using the service tool. (e.g. to AUX1) Ensure that there are no active
fault codes on AUX1.
2. Test that the valve is functioning correctly using the newly assigned AUX no. (use the “AUX1 RAISE; LOWER;
NEUTRAL and FLOAT POSITION“ service tool monitor functions)
If the fault code is still active, the valve should be replaced.
NOTE: If fault code 12 is still active, it is now displayed in conjunction with the newly assigned AUX no. In our case,
fault code AUX1 12.

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4011-154

AUX3 - 13 Implausible acknowledgment message 1 nominal value

Cause:
Data from the CAN bus is implausible (e.g. "neutral" or "float position" commands at the same time). The fault is stored
and signalled on the ADIC by a warning triangle.
Possible causes:
1. Fault in the electronics of valve AUX3
2. CAN bus fault on the vehicle bus
Solution:
Use the “CONTROL MODULE STATUS“ service tool monitor to check whether all bus users are ONLINE.
NOTE: Before starting the troubleshooting procedure, check whether the ARU or ECCU2 fault codes are active. If
yes, then address these faults first of all.
1. Use the “NUMBER OF AUX“ service tool monitor function to check whether all the valves fitted are recognised
by the ARU.
2. Reconfigure valve AUX3 to another AUX no. using the service tool. (e.g. to AUX1) Ensure that there are no active
fault codes on AUX1.
3. Test that the valve is functioning correctly using the newly assigned AUX no. (use the “AUX1 RAISE; LOWER;
NEUTRAL and FLOAT POSITION“ service tool monitor functions)
If the fault code is still active, the valve should be replaced.
NOTE: If fault code 13 is still active, it is now displayed in conjunction with the newly assigned AUX no. In our case,
fault code AUX1 13.

AUX3 - 14 Implausible acknowledgment message 2 nominal value

Cause:
Data from the CAN bus is implausible (e.g. "neutral" or "float position" commands at the same time). The fault is stored
and signalled on the ADIC by a warning triangle.
Possible causes:
1. Fault in the electronics of valve AUX3
2. CAN bus fault on the vehicle bus
Solution:
Use the “CONTROL MODULE STATUS“ service tool monitor to check whether all bus users are ONLINE.
NOTE: Before starting the troubleshooting procedure, check whether the ARU or ECCU2 fault codes are active. If
yes, then address these faults first of all.
1. Use the “NUMBER OF AUX“ service tool monitor function to check whether all the valves fitted are recognised
by the ARU.
2. Reconfigure valve AUX3 to another AUX no. using the service tool. (e.g. to AUX1) Ensure that there are no active
fault codes on AUX1.
3. Test that the valve is functioning correctly using the newly assigned AUX no. (use the “AUX1 RAISE; LOWER;
NEUTRAL and FLOAT POSITION“ service tool monitor functions)
If the fault code is still active, the valve should be replaced.
NOTE: If fault code 14 is still active, it is now displayed in conjunction with the newly assigned AUX no. In our case,
fault code AUX1 14.

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 4011-155

AUX3 - 16 Controller Fault (EEPROM inconsistent)

Cause:
Certain cells of the EEPROM are checked during run-up. If their content is implausible, this fault is recognized and
displayed.
Valve reaction:
• The valve remains in neutral position and displays fault code 16.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC.

Replace the remote valve.

Look to service tool function:
• "CONFIGURATION OF AUX-VALVES".

AUX3 - 21 Undervoltage - supply voltage below 8.2 VDC

Cause:
The supply voltage of the remote valve controller is below 8.2 VDC. Valve operates normal as long supply voltage is
above 8 VDC.
Solution:
Failure will be stored.
1. Check the supply line on the AUX connector X4/92 PIN1 (+12V) against PIN4 (GND).
2. Up to DBD100000:
Check the supply voltage up to fuse F47 (15/1) 5A and connector X5/1 (GND) at the A12.
From DBD100001:
Check the supply voltage up to fuse F47 (15/1) 5A at the A12 and grounding point 11.
3. Check vehicle battery and charge circuit.
4. If the AUX are displayed OFFLINE at service tool, probably the power supply is out of work. No reporting of fault
code numbers.

AUX3 - 22 Overvoltage - supply voltage above 18 VDC

Cause:
The supply voltage of the remote valve controller is above 18 VDC. Valve operates normal as long supply voltage is
below 36 VDC.
Solution:
Failure will be stored.

Check batterie voltage or loading voltage of the generator clamp B+ against ground. (loading voltage 13.8V - 14.5V).
If the bord voltage is OK, change the control valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

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AUX3 - 23 Spool deflection too short

Cause:
This fault occurs often, if the AUX-Sticks for the AUXs are not in neutral and the engine is not running.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC. Start the engine and the fault should not oc-
cure again, as long as the spool is moveable and fault's 81 and 82 don't occure.

AUX3 - 24 Spool deflection excessive

Cause:
This fault is detected if the valve recognizes that the spool moved too far, or does not return to neutral through spring
force.
Valve reaction:
• The valve switches to neutral and displays fault code 24. It can only be deflected if the valve is in neutral and
the neutral setpoint was received.
• The valve tries to support the spring by applying current to the opposite coil.
• If this current applic.is unsuccessful, the internal safety transistor is switched off and fault 81 occurs.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC.
• Check the observing of the mounting rules.

AUX3 - 25 Float position not reached

Cause:
If the float position required by the setpoint is not reached within a certain period of time, this fault code is displayed.
Valve reaction:
• The valve shifts to neutral position. It can only be deflected when the valve is in neutral and the neutral set-
point has been received.
This fault occurs often, if the AUX-Stickss for the AUXs are not in neutral and the engine is not running or the
spool is not moveable in the control valve.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC. Start the engine and the fault should not oc-
cure again, as long as the spool is moveable and fault's 81 and 82 don't occure.

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AUX3 - 26 Manual operation

Cause:
Manual operation is detected when both valve and setpoint are neutral, diagnosis detects no faults, and the valve
leaves the neutral zone.
Valve reaction:
• Valve does not counter-act.
• Fault 26 is displayed as long as the valve is deflected.
• When both valve and setpoint are neutral, fault is no longer present.
• If a setpoint other than neutral is set during deflection, this is not accepted and fault 26 continues to be dis-
played until valve and setpoint are in neutral once more.
Solution:
Failure will be stored. If, in the above case, the valve but not the setpoint is in neutral, fault code 17 (no fault, but
waiting for setpoint neutral) is not displayed. Instead fault code 26 remains until the setpoint is neutral.

AUX3 - 31 Undervoltage - supply voltage below 8.0 VDC

Cause:
The supply voltage of the remote valve controller is below 8.0 VDC.
Valve reaction:
• The valve goes to neutral position and displays fault code 31.
• If the voltage rises above 8.0 VDC within 1...4 s the valve returns to the desired position and shows fault
code 21.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC.
1. Check the supply line on the AUX connector X4/92 PIN1 (+12V) against PIN4 (GND).
2. Up to DBD100000:
Check the supply voltage up to fuse F47 (15/1) 5A and connector X5/1 (GND) at the A12.
From DBD100001:
Check the supply voltage up to fuse F47 (15/1) 5A at the A12 and grounding point 11.
3. Check vehicle battery and charge circuit.
4. If the AUX are displayed OFFLINE at service tool, probably the power supply is out of work. No reporting of fault
code numbers.

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AUX3 - 32 Overvoltage - supply voltage above 36 VDC

Cause:
The supply voltage of the remote valve controller is above 36 VDC.
Valve Reaction:
• The valve switches to neutral.
• If the voltage drops below 36 VDC within 1...4 s, the valve returns to the desired position and displays fault
code 22.
• If the voltage exceeds 36 VDC for more than 4 s, the valve remains in neutral and can only be deflected if
the voltage drops below 18 VDC.
• If the fault code is remedied, but the setpoint is not neutral, fault code 17 appears.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC.

Check the batterie voltage or the loading voltage of the generator clamp B+ against ground
(loading voltage 13.8V - 14.5V). If the bord voltage is OK, change the control valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

AUX3 - 41 High Overvoltage - supply voltage above 45 VDC

Cause:
The supply voltage of the remote valve controller is above 45 VDC.
Valve Reaction:
• The valve switches to neutral and also switches off the internal safety transistor (to increase electric
strength).
• The valve can only be deflected, if the voltage lies below 18 VDC, the neutral setpoint was received and the
valve is in neutral.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC. In this case control section must switch to
neutral itself. Therefore message "fault 17: no fault, but waiting for setpoint neutral" is not displayed, as once safety
transistor has been switched off and valve can no longer perform a complete diagnosis (above all output stage dia-
gnosis, due to being no voltage there).

Check batterie voltage or loading voltage of the generator clamp B+ against ground (loading voltage 13.8V - 14.5V).
If the bord voltage is OK, change the control valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

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 4011-159

AUX3 - 42 Output stage fault

Cause:
When switched on, the valve performs a brief selftest. During operation the trigger voltage is compared with the so-
lenoid voltage and the solenoid current is checked for plausibility.
Valve Reaktion:
• The valve goes to neutral position and switches off the internal safety transistor.
• Through the shortcutted output stage, the condition is hold until switching off.
• Interrupt solenoid or missing connector, the fault extinguish after 1 sec if the true value and the valve is not
neutral.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC. The operation board must himself go to neu-
tral. Fault 17 (no fault) does not occur because after switching of the safety transsitor, the valve could not do the dia-
gnostic in a correct way. The valve goes himself to neutral, but fault disappears after the valve was remoted with
neutral.

Turn the keyswitch off and back on. If fault code 42 reoccurs, replace the remote valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

AUX3 - 43 Position transducer fault

Cause:
On start-up the position transducer under goes diagnosis. Failure of the position transducer connector and open cir-
cuit in the secondary system are recognized here.
Valve reaction:
• The valve goes to neutral, switches off the internal safety transistor and displays fault code 43.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC. The operation board must himself go to neu-
tral. Fault 17 (no fault) does not occur because after switching of the safety transsitor, the valve could not do the dia-
gnostic in a correct way.

During operations the position transducer fault cannot be diagnosed in a correct way. If the position transducer con-
nector or the pins of the secundary spool fall down, the position signal reaches a special value (middle way of lower).
Therefore comes following faults:
• At true value neutral: "hand operated" = faultcode 26.
• At true value raise or lower:
first "spool deflection too short or excessive" = faultcode 23 or 24,
afterwards "valve does not go back to neutral" = faultcode 81.
Change the valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

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AUX3 - 81 Valve spool cannot brought back to neutral position

Cause:
The valve could not either be brought back with springpower nore through electrical supply of the opposite placed
spool to the neutral position.
Valve Reaktion:
• The valve put out the faultcode 81.
• The intern security transistor is switched off and the driver for the extern security relais at voltage/PWM
remoted. You can only start steering if valve is in neutral and the main value is beeing recieved.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC. The operation board must himself go to neu-
tral. Fault 17 (no fault) does not occur because after switching of the safety transsitor, the valve could not do the dia-
gnostic in a correct way.

Here has the valve no change to move the spoolto neutral. There is an extern switch off from the oilstream necessary.
Turn the keyswitch on, if fault code 81 reoccurs replace the remote.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

AUX3 - 82 Valve spool not in neutral when switched on

Cause:
Valve noticed, that spool is not in neutral pos.at switching on.
Valve reaktion:
• Valve stays in neutral pos.and send fault 82. Beginn steering if the valve stands in neutral and the isvalue is
recieved. A pushing back of the slide does not happen, because the pos.sensor is beeing moved and a
return could move the slide out of neutral.
• The intern security transistor a. driver of the extern security relais at supply/PWM are being switched,
because there could be a fault of the pos.sensor.
Solution:
Failure will be stored and signaled with a warning triangel on the ADIC. The servicepart must switch himself to neutral.
The message "faultcode 17: is no mistake but wait for main value neutral" does not come here, because the valve
after switching off the security tranistor is not able to do the diagnostics in right order. Mainpoint the amplifier diagno-
stics because of the missing voltage.

Turn the keyswitch on, if fault code 82 reoccurs, replace the remote valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

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 4011-161

AUX4 - 11 Missing acknowledgment message 1 nominal value

Cause:
The fault is active if no nominal value message is sent from the armrest via the CAN bus within 500 ms. The valve
recognises this as a fault and reports it using the diagnosis message. The fault is stored and is displayed on the ADIC
by a warning triangle.
Reaction of the valve:
• Valve is set to the neutral position.
• If valid messages are received within 1...4s, the valve returns to the given setting. If a signal is active for
more than 4s, the valve remains in neutral and can only be actuated again once neutral has been received.
Possible causes:
• CAN bus fault on the vehicle bus
Solution:
NOTE: Before starting the troubleshooting procedure, check whether the ARU or ECCU2 fault codes are active. If
yes, then address these faults first of all.
Turn the ignition off and on again and check whether fault AUX4 11 is occurring again. If the fault is again active, go
to step 1.
1. Reconfigure valve AUX4 to another AUX no. using the service tool. (e.g. to AUX1) Ensure that there are no active
fault codes on AUX1.
2. Test that the valve is functioning correctly using the newly assigned AUX no. (use the “AUX1 RAISE; LOWER;
NEUTRAL and FLOAT POSITION“ service tool monitor functions)
If the fault code is still active, the valve should be replaced.
NOTE: If fault code 11 is still active, it is now displayed in conjunction with the newly assigned AUX no. In our case,
fault code AUX1 11.

AUX4 - 12 Missing acknowledgment message 2 nominal value

Cause:
The fault is active if no nominal value message is sent from the armrest via the CAN bus within 500 ms. The valve
recognises this as a fault and reports it using the diagnosis message. The fault is stored and is displayed on the ADIC
by a warning triangle.
Reaction of the valve:
• Valve is set to the neutral position.
• If valid messages are received within 1...4s, the valve returns to the given setting. If a signal is active for
more than 4s, the valve remains in neutral and can only be actuated again once neutral has been received.
Possible causes:
• CAN bus fault on the vehicle bus
Solution:
NOTE: Before starting the troubleshooting procedure, check whether the ARU or ECCU2 fault codes are active. If
yes, then address these faults first of all.
Turn the ignition off and on again and check whether fault AUX4 12 is occurring again. If the fault is again active, go
to step 1.
1. Reconfigure valve AUX4 to another AUX no. using the service tool. (e.g. to AUX1) Ensure that there are no active
fault codes on AUX1.
2. Test that the valve is functioning correctly using the newly assigned AUX no. (use the “AUX1 RAISE; LOWER;
NEUTRAL and FLOAT POSITION“ service tool monitor functions)
If the fault code is still active, the valve should be replaced.
NOTE: If fault code 12 is still active, it is now displayed in conjunction with the newly assigned AUX no. In our case,
fault code AUX1 12.

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AUX4 - 13 Implausible acknowledgment message 1 nominal value

Cause:
Data from the CAN bus is implausible (e.g. "neutral" or "float position" commands at the same time). The fault is stored
and signalled on the ADIC by a warning triangle.
Possible causes:
1. Fault in the electronics of valve AUX4
2. CAN bus fault on the vehicle bus
Solution:
Use the “CONTROL MODULE STATUS“ service tool monitor to check whether all bus users are ONLINE.
NOTE: Before starting the troubleshooting procedure, check whether the ARU or ECCU2 fault codes are active. If
yes, then address these faults first of all.
1. Use the “NUMBER OF AUX“ service tool monitor function to check whether all the valves fitted are recognised
by the ARU.
2. Reconfigure valve AUX4 to another AUX no. using the service tool. (e.g. to AUX1) Ensure that there are no active
fault codes on AUX1.
3. Test that the valve is functioning correctly using the newly assigned AUX no. (use the “AUX1 RAISE; LOWER;
NEUTRAL and FLOAT POSITION“ service tool monitor functions)
If the fault code is still active, the valve should be replaced.
NOTE: If fault code 13 is still active, it is now displayed in conjunction with the newly assigned AUX no. In our case,
fault code AUX1 13.

AUX4 - 14 Implausible acknowledgment message 2 nominal value

Cause:
Data from the CAN bus is implausible (e.g. "neutral" or "float position" commands at the same time). The fault is stored
and signalled on the ADIC by a warning triangle.
Possible causes:
1. Fault in the electronics of valve AUX4
2. CAN bus fault on the vehicle bus
Solution:
Use the “CONTROL MODULE STATUS“ service tool monitor to check whether all bus users are ONLINE.
NOTE: Before starting the troubleshooting procedure, check whether the ARU or ECCU2 fault codes are active. If
yes, then address these faults first of all.
1. Use the “NUMBER OF AUX“ service tool monitor function to check whether all the valves fitted are recognised
by the ARU.
2. Reconfigure valve AUX4 to another AUX no. using the service tool. (e.g. to AUX1) Ensure that there are no active
fault codes on AUX1.
3. Test that the valve is functioning correctly using the newly assigned AUX no. (use the “AUX1 RAISE; LOWER;
NEUTRAL and FLOAT POSITION“ service tool monitor functions)
If the fault code is still active, the valve should be replaced.
NOTE: If fault code 14 is still active, it is now displayed in conjunction with the newly assigned AUX no. In our case,
fault code AUX1 14.

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AUX4 - 16 Controller Fault (EEPROM inconsistent)

Cause:
Certain cells of the EEPROM are checked during run-up. If their content is implausible, this fault is recognized and
displayed.
Valve reaction:
• The valve remains in neutral position and displays fault code 16.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC.

Replace the remote valve.

Look to service tool function:
• "CONFIGURATION OF AUX-VALVES".

AUX4 - 21 Undervoltage - supply voltage below 8.2 VDC

Cause:
The supply voltage of the remote valve controller is below 8.2 VDC. Valve operates normal as long supply voltage is
above 8 VDC.
Solution:
Failure will be stored.
1. Check the supply line on the AUX connector X4/93 PIN1 (+12V) against PIN4 (GND).
2. Up to DBD100000:
Check the supply voltage up to fuse F47 (15/1) 5A and connector X5/1 (GND) at the A12.
From DBD100001:
Check the supply voltage up to fuse F47 (15/1) 5A at the A12 and grounding point 11.
3. Check vehicle battery and charge circuit.
4. If the AUX are displayed OFFLINE at service tool, probably the power supply is out of work. No reporting of fault
code numbers.

AUX4 - 22 Overvoltage - supply voltage above 18 VDC

Cause:
The supply voltage of the remote valve controller is above 18 VDC. Valve operates normal as long supply voltage is
below 36 VDC.
Solution:
Failure will be stored.

Check batterie voltage or loading voltage of the generator clamp B+ against ground. (loading voltage 13.8V - 14.5V).
If the bord voltage is OK, change the control valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

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AUX4 - 23 Spool deflection too short

Cause:
This fault occurs often, if the AUX-Sticks for the AUXs are not in neutral and the engine is not running.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC. Start the engine and the fault should not oc-
cure again, as long as the spool is moveable and fault's 81 and 82 don't occure.

AUX4 - 24 Spool deflection excessive

Cause:
This fault is detected if the valve recognizes that the spool moved too far, or does not return to neutral through spring
force.
Valve reaction:
• The valve switches to neutral and displays fault code 24. It can only be deflected if the valve is in neutral and
the neutral setpoint was received.
• The valve tries to support the spring by applying current to the opposite coil.
• If this current applic.is unsuccessful, the internal safety transistor is switched off and fault 81 occurs.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC.
• Check the observing of the mounting rules.

AUX4 - 25 Float position not reached

Cause:
If the float position required by the setpoint is not reached within a certain period of time, this fault code is displayed.
Valve reaction:
• The valve shifts to neutral position. It can only be deflected when the valve is in neutral and the neutral set-
point has been received.
This fault occurs often, if the AUX-Stickss for the AUXs are not in neutral and the engine is not running or the
spool is not moveable in the control valve.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC. Start the engine and the fault should not oc-
cure again, as long as the spool is moveable and fault's 81 and 82 don't occure.

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AUX4 - 26 Manual operation

Cause:
Manual operation is detected when both valve and setpoint are neutral, diagnosis detects no faults, and the valve
leaves the neutral zone.
Valve reaction:
• Valve does not counter-act.
• Fault 26 is displayed as long as the valve is deflected.
• When both valve and setpoint are neutral, fault is no longer present.
• If a setpoint other than neutral is set during deflection, this is not accepted and fault 26 continues to be dis-
played until valve and setpoint are in neutral once more.
Solution:
Failure will be stored. If, in the above case, the valve but not the setpoint is in neutral, fault code 17 (no fault, but
waiting for setpoint neutral) is not displayed. Instead fault code 26 remains until the setpoint is neutral.

AUX4 - 31 Undervoltage - supply voltage below 8.0 VDC

Cause:
The supply voltage of the remote valve controller is below 8.0 VDC.
Valve reaction:
• The valve goes to neutral position and displays fault code 31.
• If the voltage rises above 8.0 VDC within 1...4 s the valve returns to the desired position and shows fault
code 21.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC.
1. Check the supply line on the AUX connector X4/93 PIN1 (+12V) against PIN4 (GND).
2. Up to DBD100000:
Check the supply voltage up to fuse F47 (15/1) 5A and connector X5/1 (GND) at the A12.
From DBD100001:
Check the supply voltage up to fuse F47 (15/1) 5A at the A12 and grounding point 11.
3. Check vehicle battery and charge circuit.
4. If the AUX are displayed OFFLINE at service tool, probably the power supply is out of work. No reporting of fault
code numbers.

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AUX4 - 32 Overvoltage - supply voltage above 36 VDC

Cause:
The supply voltage of the remote valve controller is above 36 VDC.
Valve Reaction:
• The valve switches to neutral.
• If the voltage drops below 36 VDC within 1...4 s, the valve returns to the desired position and displays fault
code 22.
• If the voltage exceeds 36 VDC for more than 4 s, the valve remains in neutral and can only be deflected if
the voltage drops below 18 VDC.
• If the fault code is remedied, but the setpoint is not neutral, fault code 17 appears.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC.

Check the batterie voltage or the loading voltage of the generator clamp B+ against ground
(loading voltage 13.8V - 14.5V). If the bord voltage is OK, change the control valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

AUX4 - 41 High Overvoltage - supply voltage above 45 VDC

Cause:
The supply voltage of the remote valve controller is above 45 VDC.
Valve Reaction:
• The valve switches to neutral and also switches off the internal safety transistor (to increase electric
strength).
• The valve can only be deflected, if the voltage lies below 18 VDC, the neutral setpoint was received and the
valve is in neutral.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC. In this case control section must switch to
neutral itself. Therefore message "fault 17: no fault, but waiting for setpoint neutral" is not displayed, as once safety
transistor has been switched off and valve can no longer perform a complete diagnosis (above all output stage dia-
gnosis, due to being no voltage there).

Check batterie voltage or loading voltage of the generator clamp B+ against ground (loading voltage 13.8V - 14.5V).
If the bord voltage is OK, change the control valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

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 4011-167

AUX4 - 42 Output stage fault

Cause:
When switched on, the valve performs a brief selftest. During operation the trigger voltage is compared with the so-
lenoid voltage and the solenoid current is checked for plausibility.
Valve Reaktion:
• The valve goes to neutral position and switches off the internal safety transistor.
• Through the shortcutted output stage, the condition is hold until switching off.
• Interrupt solenoid or missing connector, the fault extinguish after 1 sec if the true value and the valve is not
neutral.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC. The operation board must himself go to neu-
tral. Fault 17 (no fault) does not occur because after switching of the safety transsitor, the valve could not do the dia-
gnostic in a correct way. The valve goes himself to neutral, but fault disappears after the valve was remoted with
neutral.

Turn the keyswitch off and back on. If fault code 42 reoccurs, replace the remote valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

AUX4 - 43 Position transducer fault

Cause:
On start-up the position transducer undergoes diagnosis. Failure of the position transducer connector and open circuit
in the secondary system are recognized here.
Valve reaction:
• The valve goes to neutral, switches off the internal safety transistor and displays fault code 43.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC. The operation board must himself go to neu-
tral. Fault 17 (no fault) does not occur because after switching of the safety transsitor, the valve could not do the dia-
gnostic in a correct way.

During operations the position transducer fault cannot be diagnosed in a correct way. If the position transducer con-
nector or the pins of the secundary spool fall down, the position signal reaches a special value (middle way of lower).
Therefore comes following faults:
• At true value neutral: "hand operated" = faultcode 26.
• At true value raise or lower:
first "spool deflection too short or excessive" = faultcode 23 or 24,
afterwards "valve does not go back to neutral" = faultcode 81.
Change the valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

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AUX4 - 81 Valve spool cannot brought back to neutral position

Cause:
The valve could not either be brought back with springpower nore through electrical supply of the opposite placed
spool to the neutral position.
Valve Reaktion:
• The valve put out the faultcode 81.
• The intern security transistor is switched off and the driver for the extern security relais at voltage/PWM
remoted. You can only start steering if valve is in neutral and the main value is beeing recieved.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC. The operation board must himself go to neu-
tral. Fault 17 (no fault) does not occur because after switching of the safety transsitor, the valve could not do the dia-
gnostic in a correct way.

Here has the valve no change to move the spoolto neutral. There is an extern switch off from the oilstream necessary.
Turn the keyswitch on, if fault code 81 reoccurs replace the remote.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

AUX4 - 82 Valve spool not in neutral when switched on

Cause:
Valve noticed, that spool is not in neutral pos.at switching on.
Valve reaktion:
• Valve stays in neutral pos.and send fault 82. Beginn steering if the valve stands in neutral and the isvalue is
recieved. A pushing back of the slide does not happen, because the pos.sensor is beeing moved and a
return could move the slide out of neutral.
• The intern security transistor a. driver of the extern security relais at supply/PWM are being switched,
because there could be a fault of the pos.sensor.
Solution:
Failure will be stored and signaled with a warning triangel on the ADIC. The servicepart must switch himself to neutral.
The message "faultcode 17: is no mistake but wait for main value neutral" does not come here, because the valve
after switching off the security tranistor is not able to do the diagnostics in right order. Mainpoint the amplifier diagno-
stics because of the missing voltage.

Turn the keyswitch on, if fault code 82 reoccurs, replace the remote valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

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AUX5 - 11 Missing acknowledgment message 1 nominal value

Cause:
The fault is active if no nominal value message is sent from the armrest via the CAN bus within 500 ms. The valve
recognises this as a fault and reports it using the diagnosis message. The fault is stored and is displayed on the ADIC
by a warning triangle.
Reaction of the valve:
• Valve is set to the neutral position.
• If valid messages are received within 1...4s, the valve returns to the given setting. If a signal is active for
more than 4s, the valve remains in neutral and can only be actuated again once neutral has been received.
Possible causes:
• CAN bus fault on the vehicle bus
Solution:
NOTE: Before starting the troubleshooting procedure, check whether the ARU or ECCU2 fault codes are active. If
yes, then address these faults first of all.
Turn the ignition off and on again and check whether fault AUX5 11 is occurring again. If the fault is again active, go
to step 1.
1. Reconfigure valve AUX5 to another AUX no. using the service tool. (e.g. to AUX1) Ensure that there are no active
fault codes on AUX1.
2. Test that the valve is functioning correctly using the newly assigned AUX no. (use the “AUX1 RAISE; LOWER;
NEUTRAL and FLOAT POSITION“ service tool monitor functions)
If the fault code is still active, the valve should be replaced.
NOTE: If fault code 11 is still active, it is now displayed in conjunction with the newly assigned AUX no. In our case,
fault code AUX1 11.

AUX5 - 12 Missing acknowledgment message 2 nominal value

Cause:
The fault is active if no nominal value message is sent from the armrest via the CAN bus within 500 ms. The valve
recognises this as a fault and reports it using the diagnosis message. The fault is stored and is displayed on the ADIC
by a warning triangle.
Reaction of the valve:
• Valve is set to the neutral position.
• If valid messages are received within 1...4s, the valve returns to the given setting. If a signal is active for
more than 4s, the valve remains in neutral and can only be actuated again once neutral has been received.
Possible causes:
• CAN bus fault on the vehicle bus
Solution:
NOTE: Before starting the troubleshooting procedure, check whether the ARU or ECCU2 fault codes are active. If
yes, then address these faults first of all.
Turn the ignition off and on again and check whether fault AUX5 12 is occurring again. If the fault is again active, go
to step 1.
1. Reconfigure valve AUX5 to another AUX no. using the service tool. (e.g. to AUX1) Ensure that there are no active
fault codes on AUX1.
2. Test that the valve is functioning correctly using the newly assigned AUX no. (use the “AUX1 RAISE; LOWER;
NEUTRAL and FLOAT POSITION“ service tool monitor functions)
If the fault code is still active, the valve should be replaced.
NOTE: If fault code 12 is still active, it is now displayed in conjunction with the newly assigned AUX no. In our case,
fault code AUX1 12.

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AUX5 - 13 Implausible acknowledgment message 1 nominal value

Cause:
Data from the CAN bus is implausible (e.g. "neutral" or "float position" commands at the same time). The fault is stored
and signalled on the ADIC by a warning triangle.
Possible causes:
1. Fault in the electronics of valve AUX5
2. CAN bus fault on the vehicle bus
Solution:
Use the “CONTROL MODULE STATUS“ service tool monitor to check whether all bus users are ONLINE.
NOTE: Before starting the troubleshooting procedure, check whether the ARU or ECCU2 fault codes are active. If
yes, then address these faults first of all.
1. Use the “NUMBER OF AUX“ service tool monitor function to check whether all the valves fitted are recognised
by the ARU.
2. Reconfigure valve AUX5 to another AUX no. using the service tool. (e.g. to AUX1) Ensure that there are no active
fault codes on AUX1.
3. Test that the valve is functioning correctly using the newly assigned AUX no. (use the “AUX1 RAISE; LOWER;
NEUTRAL and FLOAT POSITION“ service tool monitor functions)
If the fault code is still active, the valve should be replaced.
NOTE: If fault code 13 is still active, it is now displayed in conjunction with the newly assigned AUX no. In our case,
fault code AUX1 13.

AUX5 - 14 Implausible acknowledgment message 2 nominal value

Cause:
Data from the CAN bus is implausible (e.g. "neutral" or "float position" commands at the same time). The fault is stored
and signalled on the ADIC by a warning triangle.
Possible causes:
1. Fault in the electronics of valve AUX5
2. CAN bus fault on the vehicle bus
Solution:
Use the “CONTROL MODULE STATUS“ service tool monitor to check whether all bus users are ONLINE.
NOTE: Before starting the troubleshooting procedure, check whether the ARU or ECCU2 fault codes are active. If
yes, then address these faults first of all.
1. Use the “NUMBER OF AUX“ service tool monitor function to check whether all the valves fitted are recognised
by the ARU.
2. Reconfigure valve AUX5 to another AUX no. using the service tool. (e.g. to AUX1) Ensure that there are no active
fault codes on AUX1.
3. Test that the valve is functioning correctly using the newly assigned AUX no. (use the “AUX1 RAISE; LOWER;
NEUTRAL and FLOAT POSITION“ service tool monitor functions)
If the fault code is still active, the valve should be replaced.
NOTE: If fault code 14 is still active, it is now displayed in conjunction with the newly assigned AUX no. In our case,
fault code AUX1 14.

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AUX5 - 16 Controller Fault (EEPROM inconsistent)

Cause:
Certain cells of the EEPROM are checked during run-up. If their content is implausible, this fault is recognized and
displayed.
Valve reaction:
• The valve remains in neutral position and displays fault code 16.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC.

Replace the remote valve.

Look to service tool function:
• "CONFIGURATION OF AUX-VALVES".

AUX5 - 21 Undervoltage - supply voltage below 8.2 VDC

Cause:
The supply voltage of the remote valve controller is below 8.2 VDC. Valve operates normal as long supply voltage is
above 8 VDC.
Solution:
Failure will be stored.
1. Check the supply line on the AUX connector X4/94 PIN1 (+12V) against PIN4 (GND).
2. Up to DBD100000:
Check the supply voltage up to fuse F47 (15/1) 5A and connector X5/1 (GND) at the A12.
From DBD100001:
Check the supply voltage up to fuse F47 (15/1) 5A at the A12 and grounding point 11.
3. Check vehicle battery and charge circuit.
4. If the AUX are displayed OFFLINE at service tool, probably the power supply is out of work. No reporting of fault
code numbers.

AUX5 - 22 Overvoltage - supply voltage above 18 VDC

Cause:
The supply voltage of the remote valve controller is above 18 VDC. Valve operates normal as long supply voltage is
below 36 VDC.
Solution:
Failure will be stored.

Check batterie voltage or loading voltage of the generator clamp B+ against ground. (loading voltage 13.8V - 14.5V).
If the bord voltage is OK, change the control valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

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AUX5 - 23 Spool deflection too short

Cause:
This fault occurs often, if the AUX-Sticks for the AUXs are not in neutral and the engine is not running.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC. Start the engine and the fault should not oc-
cure again, as long as the spool is moveable and fault's 81 and 82 don't occure.

AUX5 - 24 Spool deflection excessive

Cause:
This fault is detected if the valve recognizes that the spool moved too far, or does not return to neutral through spring
force.
Valve reaction:
• The valve switches to neutral and displays fault code 24. It can only be deflected if the valve is in neutral and
the neutral setpoint was received.
• The valve tries to support the spring by applying current to the opposite coil.
• If this current applic.is unsuccessful, the internal safety transistor is switched off and fault 81 occurs.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC.
• Check the observing of the mounting rules.

AUX5 - 25 Float position not reached

Cause:
If the float position required by the setpoint is not reached within a certain period of time, this fault code is displayed.
Valve reaction:
• The valve shifts to neutral position. It can only be deflected when the valve is in neutral and the neutral set-
point has been received.
This fault occurs often, if the AUX-Stickss for the AUXs are not in neutral and the engine is not running or the
spool is not moveable in the control valve.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC. Start the engine and the fault should not oc-
cure again, as long as the spool is moveable and fault's 81 and 82 don't occure.

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AUX5 - 26 Manual operation

Cause:
Manual operation is detected when both valve and setpoint are neutral, diagnosis detects no faults, and the valve
leaves the neutral zone.
Valve reaction:
• Valve does not counter-act.
• Fault 26 is displayed as long as the valve is deflected.
• When both valve and setpoint are neutral, fault is no longer present.
• If a setpoint other than neutral is set during deflection, this is not accepted and fault 26 continues to be dis-
played until valve and setpoint are in neutral once more.
Solution:
Failure will be stored. If, in the above case, the valve but not the setpoint is in neutral, fault code 17 (no fault, but
waiting for setpoint neutral) is not displayed. Instead fault code 26 remains until the setpoint is neutral.

AUX5 - 31 Undervoltage - supply voltage below 8.0 VDC

Cause:
The supply voltage of the remote valve controller is below 8.0 VDC.
Valve reaction:
• The valve goes to neutral position and displays fault code 31.
• If the voltage rises above 8.0 VDC within 1...4 s the valve returns to the desired position and shows fault
code 21.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC.
1. Check the supply line on the AUX connector X4/94 PIN1 (+12V) against PIN4 (GND).
2. Up to DBD100000:
Check the supply voltage up to fuse F47 (15/1) 5A and connector X5/1 (GND) at the A12.
From DBD100001:
Check the supply voltage up to fuse F47 (15/1) 5A at the A12 and grounding point 11.
3. Check vehicle battery and charge circuit.
4. If the AUX are displayed OFFLINE at service tool, probably the power supply is out of work. No reporting of fault
code numbers.

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AUX5 - 32 Overvoltage - supply voltage above 36 VDC

Cause:
The supply voltage of the remote valve controller is above 36 VDC.
Valve Reaction:
• The valve switches to neutral.
• If the voltage drops below 36 VDC within 1...4 s, the valve returns to the desired position and displays fault
code 22.
• If the voltage exceeds 36 VDC for more than 4 s, the valve remains in neutral and can only be deflected if
the voltage drops below 18 VDC.
• If the fault code is remedied, but the setpoint is not neutral, fault code 17 appears.
Solution:
Failure will be stored and signaled with warning triangle on the ADIC.

Check the batterie voltage or the loading voltage of the generator clamp B+ against ground
(loading voltage 13.8V - 14.5V). If the bord voltage is OK, change the control valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

AUX5 - 41 High Overvoltage - supply voltage above 45 VDC

Cause:
The supply voltage of the remote valve controller is above 45 VDC.
Valve Reaction:
• The valve switches to neutral and also switches off the internal safety transistor (to increase electric
strength).
• The valve can only be deflected, if the voltage lies below 18 VDC, the neutral setpoint was received and the
valve is in neutral.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC. In this case control section must switch to
neutral itself. Therefore message "fault 17: no fault, but waiting for setpoint neutral" is not displayed, as once safety
transistor has been switched off and valve can no longer perform a complete diagnosis (above all output stage dia-
gnosis, due to being no voltage there).

Check batterie voltage or loading voltage of the generator clamp B+ against ground (loading voltage 13.8V - 14.5V).
If the bord voltage is OK, change the control valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

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AUX5 - 42 Output stage fault

Cause:
When switched on, the valve performs a brief selftest. During operation the trigger voltage is compared with the so-
lenoid voltage and the solenoid current is checked for plausibility.
Valve Reaktion:
• The valve goes to neutral position and switches off the internal safety transistor.
• Through the shortcutted output stage, the condition is hold until switching off.
• Interrupt solenoid or missing connector, the fault extinguish after 1 sec if the true value and the valve is not
neutral.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC. The operation board must himself go to neu-
tral. Fault 17 (no fault) does not occur because after switching of the safety transsitor, the valve could not do the dia-
gnostic in a correct way. The valve goes himself to neutral, but fault disappears after the valve was remoted with
neutral.

Turn the keyswitch off and back on - if fault code 42 reoccurs, replace the remote valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

AUX5 - 43 position Transducer Fault

Cause:
On start-up the position transducer undergoes diagnosis. Failure of the position transducer connector and open circuit
in the secondary system are recognized here.
Valve reaction:
• The valve goes to neutral, switches off the internal safety transistor and displays fault code 43.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC. The operation board must himself go to neu-
tral. Fault 17 (no fault) does not occur because after switching of the safety transsitor, the valve could not do the dia-
gnostic in a correct way.

During operations the position transducer fault cannot be diagnosed in a correct way. If the position transducer con-
nector or the pins of the secundary spool fall down, the position signal reaches a special value (middle way of lower).
Therefore comes following faults:
• At true value neutral: "hand operated" = faultcode 26.
• At true value raise or lower:
first "spool deflection too short or excessive" = faultcode 23 or 24,
afterwards "valve does not go back to neutral" = faultcode 81.
Change the valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

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AUX5 - 81 Valve spool cannot brought back to neutral position

Cause:
The valve could not either be brought back with springpower nore through electrical supply of the opposite placed
spool to the neutral position.
Valve Reaktion:
• The valve put out the faultcode 81.
• The intern security transistor is switched off and the driver for the extern security relais at voltage/PWM
remoted. You can only start steering if valve is in neutral and the main value is beeing recieved.
Solution:
Failure will be stored and signaled with a warning triangle on the ADIC. The operation board must himself go to neu-
tral. Fault 17 (no fault) does not occur because after switching of the safety transsitor, the valve could not do the dia-
gnostic in a correct way.

Here has the valve no change to move the spoolto neutral. There is an extern switch off from the oilstream necessary.
Turn the keyswitch on, if fault code 81 reoccurs replace the remote.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

AUX5 - 82 Valve spool not in neutral when switched on

Cause:
Valve noticed, that spool is not in neutral pos.at switching on.
Valve reaktion:
• Valve stays in neutral pos.and send fault 82. Beginn steering if the valve stands in neutral and the isvalue is
recieved. A pushing back of the slide does not happen, because the pos.sensor is beeing moved and a
return could move the slide out of neutral.
• The intern security transistor a. driver of the extern security relais at supply/PWM are being switched,
because there could be a fault of the pos.sensor.
Solution:
Failure will be stored and signaled with a warning triangel on the ADIC. The servicepart must switch himself to neutral.
The message "faultcode 17: is no mistake but wait for main value neutral" does not come here, because the valve
after switching off the security tranistor is not able to do the diagnostics in right order. Mainpoint the amplifier diagno-
stics because of the missing voltage.

Turn the keyswitch on, if fault code 82 reoccurs, replace the remote valve.
Look at service tool function:
• "CONFIGURATION AUX-VALVES".

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BLANK PAGE

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COMPONENTS SUMMARY
(11) Ground point engine device carrier up to DBD100000 ..................................................................... Fig. 1
(11) Ground point engine cable carrier, rear from DBD100001 ............................................................... Fig. 2
AUX1 1st remote control valve.................................................................................................................... Fig. 3
AUX2 2nd remote control valve .................................................................................................................. Fig. 3
AUX3 3rd remote control valve ................................................................................................................... Fig. 3
AUX4 4th remote control valve ................................................................................................................... Fig. 3
AUX5 5th remote control valve ................................................................................................................... Fig. 3
B30 Longitudinal joystick ......................................................................................................................... Fig. 3
B31 Transverse joystick ........................................................................................................................... Fig. 3
B52 Shift lever for AUX (black)................................................................................................................. Fig. 3
S34 5th AUX button ................................................................................................................................ Fig. 3
S60/6 AUX blue button ............................................................................................................................... Fig. 3
X4/90 Plug connection AUX1...................................................................................................................... Fig. 4
X4/91 Plug connection AUX2...................................................................................................................... Fig. 4
X4/92 Plug connection AUX3...................................................................................................................... Fig. 4
X4/93 Plug connection AUX4...................................................................................................................... Fig. 5
X4/94 Plug connection AUX5...................................................................................................................... Fig. 5

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Fig. 1 up to DBD100000 Fig. 4 up to DBD100000

Fig. 2 from DBD100001

Fig. 4 from DBD100001

Fig. 3

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Fig. 5 up to DBD100000

Fig. 5 from DBD100001

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FAULTCODES ECCU2
ECCU2 - 1 Processor memory fault .................................................................................................................. 183
ECCU2 - 2 Processor fault ................................................................................................................................ 183
ECCU2 - 3 Processor fault ................................................................................................................................ 183
ECCU2 - 4 Processor fault ................................................................................................................................ 184
ECCU2 - 5 Processor fault ................................................................................................................................ 184
ECCU2 - 14 Differential lock switch in ON position - signal permanently at + .................................................. 184
ECCU2 - 15 Hydraulic Master switch: EHS position - signal permanently at + ................................................ 185
ECCU2 - 20 Rear PTO shaft - signal from left-hand external button is permanently at + ................................. 185
ECCU2 - 22 Rear PTO shaft - signal from right-hand external button is permanently at + .............................. 186
ECCU2 - 26 Rear PTO shaft - signal from button in ON position is permanently at + ...................................... 186
ECCU2 - 27 Rear PTO shaft - signal from button in OFF position is permanently at + .................................... 187
ECCU2 - 28 Front PTO shaft - signal from button in ON position is permanently at + ..................................... 187
ECCU2 - 29 Front PTO shaft - signal from button in OFF position is permanently at + ................................... 188
ECCU2 - 31 Rear PTO shaft - signal from Management button in ON position is permanently at + ................ 188
ECCU2 - 34 Differential lock switch in MANAGEMENT position - signal permanently at + .............................. 189
ECCU2 - 35 Front hitch - signal from LOWER button is permanently at + ....................................................... 189
ECCU2 - 36 Front hitch - signal from RAISE button is permanently at + .......................................................... 190
ECCU2 - 37 Field end management (HTS) button in RECORD position - signal permanently at + ................. 190
ECCU2 - 38 Field end management button in PLAY position - signal permanently at + .................................. 191
ECCU2 - 41 Front PTO shaft - slip too high ...................................................................................................... 191
ECCU2 - 43 Rear PTO shaft - slip too high ...................................................................................................... 191
ECCU2 - 44 Front PTO shaft - speed was detected although PTO shaft is off ................................................ 192
ECCU2 - 45 Rear PTO shaft - speed was detected although PTO shaft is off ................................................. 192
ECCU2 - 46 Front PTO speed - no signal from speed sensor .......................................................................... 192
ECCU2 - 47 PTO shaft speed rear - no signal from speed sensor ................................................................... 193
ECCU2 - 48 Front PTO shaft - ON button pressed for too long ........................................................................ 193
ECCU2 - 49 Rear PTO shaft - ON button pressed for too long ........................................................................ 194
ECCU2 - 50 Differential lock does not switch ON ............................................................................................. 194
ECCU2 - 51 Front PTO shaft does not switch ON ............................................................................................ 195
ECCU2 - 52 Rear PTO shaft does not switch ON ............................................................................................. 195
ECCU2 - 53 Reversing fan does not switch ON up to DBD100000 .................................................................. 196
ECCU2 - 53 Reversing fan does not switch ON from DBD100001 ................................................................... 196
ECCU2 - 54 Oil preheating does not switch ON ............................................................................................... 197
ECCU2 - 55 Differential lock - output stage temperature too high .................................................................... 197
ECCU2 - 56 Front PTO shaft - output stage temperature too high ................................................................... 198
ECCU2 - 57 Rear PTO shaft - output stage temperature too high .................................................................... 198
ECCU2 - 58 Reversing fan - overtemperature of power stage up to DBD100000 ............................................ 199
ECCU2 - 58 Reversing fan - overtemperature of power stage from DBD100001 ............................................. 199
ECCU2 - 59 Oil preheating - output stage temperature too high ...................................................................... 200
ECCU2 - 65 Front PTO shaft - current was measured although PTO shaft is off ............................................. 200
ECCU2 - 66 Front PTO shaft - no current was measured although PTO shaft is on ........................................ 201
ECCU2 - 67 Rear PTO shaft - current was measured although PTO shaft is off ............................................. 201
ECCU2 - 68 Rear PTO shaft - no current was measured although PTO shaft is on ........................................ 202
ECCU2 - 72 Front hitch position sensor - value exceeds permissible range .................................................... 202
ECCU2 - 73 Front hitch position sensor - value below permissible range ........................................................ 203
ECCU2 - 85 AUX 1 switched off because temperature is too high ................................................................... 203
ECCU2 - 86 AUX 2 switched off because temperature is too high ................................................................... 204
ECCU2 - 87 AUX 3 switched off because temperature is too high ................................................................... 204
ECCU2 - 88 AUX 4 switched off because temperature is too high ................................................................... 205
ECCU2 - 89 AUX 5 switched off because temperature is too high ................................................................... 205

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ECCU2 - 98 12 V supply voltage too high (>16V) ............................................................................................. 206
ECCU2 - 99 12 V supply voltage too low (<10V) .............................................................................................. 206
ECCU2 - 100 12 V supply voltage too high (>16V) ........................................................................................... 207
ECCU2 - 101 12 V supply voltage too low (<10V) ............................................................................................ 207
ECCU2 - 110 Vehicle BUS OFF up to DBD100000 .......................................................................................... 208
ECCU2 - 110 Vehicle BUS OFF from DBD100001 ........................................................................................... 209
ECCU2 - 120 ISO Bus OFF .............................................................................................................................. 211
ECCU2 - 130 Front external button "RAISE front hitch" - signal permanently at + ........................................... 212
ECCU2 - 131 Front external button "LOWER front hitch" - signal permanently at + ......................................... 213
ECCU2 - 132 Front external button "Raise auxiliary valve" - signal permanently at + ...................................... 214
ECCU2 - 133 Front external button "Lower auxiliary valve" - signal permanently at + ..................................... 215
ECCU2 - 134 Rear external button "Raise auxiliary valve" - signal permanently at + ...................................... 215
ECCU2 - 135 Rear external button "Lower auxiliary valve" - signal permanently at + ...................................... 216
ECCU2 - 136 Hydraulic Master switch in EDC+AUX position - signal permanently at + .................................. 216
ECCU2 - 137 Engine speed reduction switch in ON position - signal permanently at + ................................... 217
ECCU2 - 200 A bulb in the left-hand indicator is defective (implement) ........................................................... 217
ECCU2 - 201 A bulb in the stop lights is defective (implement) ........................................................................ 218
ECCU2 - 202 A bulb in the stop lights is defective (implement) ........................................................................ 218
ECCU2 - 203 A bulb in the sidelights is defective (implement) ......................................................................... 219
ECCU2 - 204 A bulb in the worklights is defective (implement) ........................................................................ 219
ECCU2 - 220 No communication with ARU ...................................................................................................... 220
ECCU2 - 221 No communication with AUX 1 ................................................................................................... 220
ECCU2 - 222 No communication with EDC ...................................................................................................... 221
ECCU2 - 223 No communication with the EEM up to DBD100000 .................................................................. 221
ECCU2 - 223 No communication with the EEM from DBD100001 ................................................................... 222
ECCU2 - 224 No communication with the FMGR ............................................................................................. 222
ECCU2 - 225 No communication with ICU ........................................................................................................ 223
COMPONENTS SUMMARY ............................................................................................................................. 225
FUNCTIONAL SCHEMATIC DIAGRAM FOR ECCU2 UP TO DBD100000 ..................................................... 241
FUNCTIONAL SCHEMATIC DIAGRAM FOR ECCU2 FROM DBD100001 ..................................................... 245
FUNCTIONAL SCHEMATIC DIAGRAM FOR REMOTE CONTROL VALVES -
ADDITIONAL FUNCTIONS UP TO DBD100000 .............................................................................................. 249
FUNCTIONAL SCHEMATIC DIAGRAM FOR REMOTE CONTROL VALVES -
ADDITIONAL FUNCTIONS FROM DBD100001 ............................................................................................... 251

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ECCU2 - 1 Processor memory fault

Cause:
Control unit processor fault: internal component of control unit defective.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Processor defective.
2. Problem during reprogramming.
3. Fault occurring sporadically as a result of interruptions in the power supply.
4. EMC (electromagnetic compatibility) problem.
Remedy:
Ensure that ECCU2 has a good connection to battery plus and ground (see schematic ECCU2). Should the fault have
occurred immediately after reprogramming ECCU2, programming should be repeated, since a fault has probably oc-
curred during programming.

ECCU2 - 2 Processor fault

Cause:
Control unit processor fault: internal component of control unit defective.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Processor defective.
2. Problem during reprogramming.
3. Fault occurring sporadically as a result of interruptions in the power supply.
4. EMC (electromagnetic compatibility) problem.
Remedy:
Ensure that ECCU2 has a good connection to battery plus and ground (see schematic ECCU2). Should the fault have
occurred immediately after reprogramming ECCU2, programming should be repeated, since a fault has probably oc-
curred during programming.

ECCU2 - 3 Processor fault

Cause:
Control unit processor fault: internal component of control unit defective.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Processor defective.
2. Problem during reprogramming.
3. Fault occurring sporadically as a result of interruptions in the power supply.
4. EMC (electromagnetic compatibility) problem.
Remedy:
Ensure that ECCU2 has a good connection to battery plus and ground (see schematic ECCU2). Should the fault have
occurred immediately after reprogramming ECCU2, programming should be repeated, since a fault has probably oc-
curred during programming.

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ECCU2 - 4 Processor fault

Cause:
Control unit processor fault: internal component of control unit defective.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Processor defective.
2. Problem during reprogramming.
3. Fault occurring sporadically as a result of interruptions in the power supply.
4. EMC (electromagnetic compatibility) problem.
Remedy:
Ensure that ECCU2 has a good connection to battery plus and ground (see schematic ECCU2). Should the fault have
occurred immediately after reprogramming ECCU2, programming should be repeated, since a fault has probably oc-
curred during programming.

ECCU2 - 5 Processor fault

Cause:
Control unit processor fault: internal component of control unit defective.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Processor defective.
2. Problem during reprogramming.
3. Fault occurring sporadically as a result of interruptions in the power supply.
4. EMC (electromagnetic compatibility) problem.
Remedy:
Ensure that ECCU2 has a good connection to battery plus and ground (see schematic ECCU2). Should the fault have
occurred immediately after reprogramming ECCU2, programming should be repeated, since a fault has probably oc-
curred during programming.

ECCU2 - 14 Differential lock switch in ON position -

signal permanently at +
Cause:
The signal at this input is permanently plus (12V), although it should be clocked (GSV4). The fault is stored.
GSV4 = 5.3 V / 50 Hz
Possible causes:
1. Signal line of switch S2/56 is shorted to plus.
2. ECCU2 has an internal defect.
Remedy:
Faults ECCU2 15 to 38 or 130 to 137 can also be active. If some of these faults occur at the same time, the fault can
also be caused by the supply as they are also supplied by the same output (GSV4).
Check the supply line from CN1a PIN10 to the individual functions (see corresponding faults).
Use Service Tool monitor function:
DIFFERENTIAL LOCK switch in position
1. Turn switch S2/56 to the OFF position. If the data value remains in the ON position, there is a short-circuit to plus
or ECCU2 has an internal defect.
2. Disconnect plug CN3b from ECCU2 and read off the data value:
a) If the data value remains ON, ECCU2 has an internal defect and must be replaced.
b) If the data value changes to OFF, the signal line is shorted to plus. Check signal line from plug CN3b PIN23
via X24/5 PIN1 to switch S2/56 and repair if necessary.

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ECCU2 - 15 Hydraulic Master switch: EHS position -

signal permanently at +
Cause:
The signal at this input is permanently plus (12V), although it should be clocked (GSV4). The fault is stored.
GSV4 = 5.3 V / 50 Hz
Possible causes:
1. Signal line of switch S2/7/3 is shorted to plus.
2. ECCU2 has an internal defect.
Remedy:
Faults ECCU2 15 to 38 or 130 to 137 can also be active. If some of these faults occur at the same time, the fault can
also be caused by the supply as they are also supplied by the same output (GSV4).
Check the supply line from CN1a PIN10 to the individual functions (see corresponding faults).
Use Service Tool monitor function:
SWITCH FOR HYDRAULIC MASTER AUXILIARY VALVES ON
1. Turn switch S2/7/3 to the OFF position. If the data value remains in the ON position, there is a short-circuit to plus
or ECCU2 has an internal defect.
2. Disconnect plug CN3a from ECCU2 and read off the data value:
a) If the data value remains ON, ECCU2 has an internal defect and must be replaced.
b) If the data value changes to OFF, the signal line is shorted to plus. Check signal line from CN3a PIN4 via
X10/9 PIN6 to switch S2/7/3 and repair if necessary.

ECCU2 - 20 Rear PTO shaft - signal from left-hand external button is

permanently at +
Cause:
The signal at this input is permanently plus (12V), although it should be clocked (GSV4). The fault is stored.
GSV4 = 5.3 V / 50 Hz
Possible causes:
1. Signal line of button S17/1 is shorted to plus.
2. ECCU2 has an internal defect.
Remedy:
Faults ECCU2 14 to 38 or 130 to 137 can also be active. If some of these faults occur at the same time, the fault can
also be caused by the supply as they are also supplied by the same output (GSV4).
Check the supply line from CN1a PIN10 to the individual functions (see corresponding faults).
Use Service Tool monitor function: REAR PTO shaft SWITCH
1. If the data value remains in the ON position when the button is not pressed, there is a short-circuit to plus or
ECCU2 has an internal defect.
2. Disconnect plug CN3a from ECCU2 and read off the data value:

a) If the data value remains ON, ECCU2 has an internal defect and must be replaced.

b) If the data value changes, the signal line is shorted to plus. Check signal line from plug CN3a PIN21 to button
S17/1 and repair if necessary.

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ECCU2 - 22 Rear PTO shaft - signal from right-hand external button

is permanently at +
Cause:
The signal at this input is permanently plus (12V), although it should be clocked (GSV4). The fault is stored.
GSV4 = 5.3 V / 50 Hz
Possible causes:
1. Signal line of button S17/2 is shorted to plus.
2. ECCU2 has an internal defect.
Remedy:
Faults ECCU2 14 to 38 or 130 to 137 can also be active. If some of these faults occur at the same time, the fault can
also be caused by the supply as they are also supplied by the same output (GSV4).
Check the supply line from CN1a PIN10 to the individual functions (see corresponding faults).
Use Service Tool monitor function: REAR PTO shaft ON SWITCH
1. If the data value remains in the ON position when the button is not pressed, there is a short-circuit to plus or
ECCU2 has an internal defect.
2. Disconnect plug CN3a from ECCU2 and read off the data value:

a) If the data value remains ON, ECCU2 has an internal defect and must be replaced.

b) If the data value changes, the signal line is shorted to plus. Check signal line from plug CN3a PIN22 to button
S17/2 and repair if necessary.

ECCU2 - 26 Rear PTO shaft - signal from button in ON position is

permanently at +
Cause:
The signal at this input is permanently plus (12V), although it should be clocked (GSV4). The fault is stored.
GSV4 = 5.3 V / 50 Hz
Possible causes:
1. Signal line of button S2/70/2 is shorted to plus.
2. ECCU2 has an internal defect.
Remedy:
Faults ECCU2 14 to 38 or 130 to 137 can also be active. If some of these faults occur at the same time, the fault can
also be caused by the supply as they are also supplied by the same output (GSV4).
Check the supply line from CN1a PIN10 to the individual functions (see corresponding faults).
Use Service Tool monitor function: REAR PTO shaft SWITCH
1. Turn switch S2/70/2 to centre position. If the data value remains in the ON position, there is a short-circuit to plus
or ECCU2 has an internal defect.
2. Disconnect plug CN3b from ECCU2 and read off the data value:

a) If the data value remains ON, ECCU2 has an internal defect and must be replaced.

b) If the data value changes, the signal line is shorted to plus. Check signal line from plug CN3b PIN33 via
X24/5 PIN14 to button S2/70/2 and repair if necessary.

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ECCU2 - 27 Rear PTO shaft - signal from button in OFF position is

permanently at +
Cause:
The signal at this input is permanently plus (12V), although it should be clocked (GSV4). The fault is stored.
GSV4 = 5.3 V / 50 Hz
Possible causes:
1. Signal line of button S2/70/2 is shorted to plus.
2. ECCU2 has an internal defect.
Remedy:
Faults ECCU2 14 to 38 or 130 to 137 can also be active. If some of these faults occur at the same time, the fault can
also be caused by the supply as they are also supplied by the same output (GSV4).
Check the supply line from CN1a PIN10 to the individual functions (see corresponding faults).
Use Service Tool monitor function: REAR PTO shaft SWITCH
1. Turn switch S2/70/2 to centre position. If the data value remains in the OFF position, there is a short-circuit to plus
or ECCU2 has an internal defect.
2. Disconnect plug CN3b from ECCU2 and read off the data value:

a) If the data value remains OFF, ECCU2 has an internal defect and must be replaced.

b) If the data value changes, the signal line is shorted to plus. Check signal line from plug CN3b PIN32 via
X24/5 PIN15 to button S2/70/2 and repair if necessary.

ECCU2 - 28 Front PTO shaft - signal from button in ON position is

permanently at +
Cause:
The signal at this input is permanently plus (12V), although it should be clocked (GSV4). The fault is stored.
GSV4 = 5.3 V / 50 Hz
Possible causes:
1. Signal line of button S2/70/1 is shorted to plus.
2. ECCU2 has an internal defect.
Remedy:
Faults ECCU2 14 to 38 or 130 to 137 can also be active. If some of these faults occur at the same time, the fault can
also be caused by the supply as they are also supplied by the same output (GSV4).
Check the supply line from CN1a PIN10 to the individual functions (see corresponding faults).
Use Service Tool monitor function: FRONT PTO shaft SWITCH
1. Turn switch S2/70/1 to centre position. If the data value remains in the ON position, there is a short-circuit to plus
or ECCU2 has an internal defect.
2. Disconnect plug CN3b from ECCU2 and read off the data value:
a) If the data value remains ON, ECCU2 has an internal defect and must be replaced.

b) If the data value changes, the signal line is shorted to plus. Check signal line from plug CN3b PIN31 via
X24/5 PIN17 to button S2/70/1 and repair if necessary.

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ECCU2 - 29 Front PTO shaft - signal from button in OFF position is

permanently at +
Cause:
The signal at this input is permanently plus (12V), although it should be clocked (GSV4). The fault is stored.
GSV4 = 5.3 V / 50 Hz
Possible causes:
1. Signal line of button S2/70/1 is shorted to plus.
2. ECCU2 has an internal defect.
Remedy:
Faults ECCU2 14 to 38 or 130 to 137 can also be active. If some of these faults occur at the same time, the fault can
also be caused by the supply as they are also supplied by the same output (GSV4).
Check the supply line from CN1a PIN10 to the individual functions (see corresponding faults).
Use Service Tool monitor function: FRONT PTO shaft SWITCH
1. Turn switch S2/70/1 to centre position. If the data value remains in the OFF position, there is a short-circuit to plus
or ECCU2 has an internal defect.
2. Disconnect plug CN3b from ECCU2 and read off the data value:
a) If the data value remains OFF, ECCU2 has an internal defect and must be replaced.

b) If the data value changes, the signal line is shorted to plus. Check signal line from plug CN3b PIN30 via
X24/5 PIN18 to button S2/70/1 and repair if necessary.

ECCU2 - 31 Rear PTO shaft - signal from Management button in ON

position is permanently at +
Cause:
The signal at this input is permanently plus (12V), although it should be clocked (GSV4). The fault is stored.
GSV4 = 5.3 V / 50 Hz
Possible causes:
1. Signal line of button S2/71 is shorted to plus.
2. ECCU2 has an internal defect.
Remedy:
Faults ECCU2 14 to 38 or 130 to 137 can also be active. If some of these faults occur at the same time, the fault can
also be caused by the supply as they are also supplied by the same output (GSV4).
Check the supply line from CN1a PIN10 to the individual functions (see corresponding faults).
Use Service Tool monitor function:
REAR PTO shaft MANAGEMENT SWITCH
1. If the data value remains in the ON position when button S2/71 is not pressed, there is a short-circuit to plus or
ECCU2 has an internal defect.
2. Disconnect plug CN3a from ECCU2 and read off the data value:
a) If the data value remains ON, ECCU2 has an internal defect and must be replaced.
b) If the data value changes to OFF, the signal line is shorted to plus. Check signal line from CN3a PIN20 via
X24/5 PIN16 to button S2/71 and repair if necessary.

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ECCU2 - 34 Differential lock switch in MANAGEMENT position -

signal permanently at +
Cause:
The signal at this input is permanently plus (12V), although it should be clocked (GSV4).
The fault is stored.
GSV4 = 5.3 V / 50 Hz
Possible causes:
1. Signal line of switch S2/56 is shorted to plus.
2. ECCU2 has an internal defect.
Remedy:
Faults ECCU2 14 to 38 or 130 to 137 can also be active. If some of these faults occur at the same time, the fault can
also be caused by the supply as they are also supplied by the same output (GSV4).
Check the supply line from CN1a PIN10 to the individual functions (see corresponding faults).
Use Service Tool monitor function:
DIFFERENTIAL LOCK switch in MANAGEMENT position
1. Turn switch S2/56 to the OFF position. If the data value remains in the ON position, there is a short-circuit to plus
or ECCU2 has an internal defect.
2. Disconnect plug CN3b from ECCU2 and read off the data value:
a) If the data value remains ON, ECCU2 has an internal defect and must be replaced.
b) If the data value changes to OFF, the signal line is shorted to plus. Check signal line from plug CN3b PIN24
via X24/5 PIN2 to switch S2/56 and repair if necessary.

ECCU2 - 35 Front hitch - signal from LOWER button is

permanently at +
Cause:
The signal at this input is permanently plus (12V), although it should be clocked (GSV4). The fault is stored.
GSV4 = 5.3 V / 50 Hz
Possible causes:
1. Signal line of button S28/1 is shorted to plus.
2. ECCU2 has an internal defect.
Remedy:
Faults ECCU2 14 to 38 or 130 to 137 can also be active. If some of these faults occur at the same time, the fault can
also be caused by the supply as they are also supplied by the same output (GSV4).
Check the supply line from CN1a PIN10 to the individual functions (see corresponding faults).
Use Service Tool monitor function:
LOWER FRONT HITCH MANAGEMENT SWITCH
1. Do not press the button. If the data value of the monitor function remains ON, there is a short-circuit to plus or
ECCU2 has an internal defect.
2. Disconnect plug CN3a from ECCU2 and read off the data value:
a) If the data value remains ON, ECCU2 has an internal defect and must be replaced.
b) If the data value changes to OFF, the signal line is shorted to plus. Check signal line from plug CN3a PIN16
via X18/4 PIN7 to button S28/1 and repair if necessary.

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ECCU2 - 36 Front hitch - signal from RAISE button is

permanently at +
Cause:
The signal at this input is permanently plus (12V), although it should be clocked (GSV4). The fault is stored.
GSV4 = 5.3 V / 50 Hz
Possible causes:
1. Signal line of button S28/1 is shorted to plus.
2. ECCU2 has an internal defect.
Remedy:
Faults ECCU2 14 to 38 or 130 to 137 can also be active. If some of these faults occur at the same time, the fault can
also be caused by the supply as they are also supplied by the same output (GSV4).
Check the supply line from CN1a PIN10 to the individual functions (see corresponding faults).
Use Service Tool monitor function:
RAISE FRONT HITCH MANAGEMENT SWITCH
1. Do not press the button. If the data value of the monitor function remains ON, there is a short-circuit to plus or
ECCU2 has an internal defect.
2. Disconnect plug CN3a from ECCU2 and read off the data value:
a) If the data value remains ON, ECCU2 has an internal defect and must be replaced.
b) If the data value changes to OFF, the signal line is shorted to plus. Check signal line from plug CN3a PIN17
via X18/4 PIN6 to button S28/1 and repair if necessary.

ECCU2 - 37 Field end management (HTS) button in RECORD

position - signal permanently at +
Cause:
The signal at this input is permanently plus (12V), although it should be clocked (GSV4). The fault is stored.
GSV4 = 5.3 V / 50 Hz
Possible causes:
1. Signal line of button S2/15/6 is shorted to plus.
2. ECCU2 has an internal defect.
Remedy:
Faults ECCU2 14 to 38 or 130 to 137 can also be active. If some of these faults occur at the same time, the fault can
also be caused by the supply as they are also supplied by the same output (GSV4).
Check the supply line from CN1a PIN10 to the individual functions (see corresponding faults).
Use Service Tool monitor function: HTS SWITCH - RECORD
1. Turn switch S2/15/6 to centre position. If the data value remains in the ON position, there is a short-circuit to plus
or ECCU2 has an internal defect.
2. Disconnect plug CN3a from ECCU2 and read off the data value:
a) If the data value remains ON, ECCU2 has an internal defect and must be replaced.
b) If the data value changes to OFF, the signal line is shorted to plus. Check signal line from plug CN3a PIN18
via X24/5 PIN22 to button S2/15/6 and repair if necessary.

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ECCU2 - 38 Field end management button in PLAY position - signal

permanently at +
Cause:
The signal at this input is permanently plus (12V), although it should be clocked (GSV4). The fault is stored.
GSV4 = 5.3 V / 50 Hz
Possible causes:
1. Signal line of button S2/15/6 is shorted to plus.
2. ECCU2 has an internal defect.
Remedy:
Faults ECCU2 14 to 37 or 130 to 137 can also be active. If some of these faults occur at the same time, the fault can
also be caused by the supply as they are also supplied by the same output (GSV4).
Check the supply line from CN1a PIN10 to the individual functions (see corresponding faults).
Use Service Tool monitor function: HTS SWITCH - PLAY
1. Turn switch S2/15/6 to centre position. If the data value remains in the ON position, there is a short-circuit to plus
or ECCU2 has an internal defect.
2. Disconnect plug CN3a from ECCU2 and read off the data value:
a) If the data value remains ON, ECCU2 has an internal defect and must be replaced.
b) If the data value changes to OFF, the signal line is shorted to plus. Check signal line from plug CN3a PIN19
via X24/5 PIN24 to button S2/15/6 and repair if necessary.

ECCU2 - 41 Front PTO shaft - slip too high

Cause:
Starting 10 seconds after PTO shaft ON, a PTO shaft speed setpoint is determined in accordance with the engine
speed. If the current PTO shaft speed is lower than this setpoint by approx. 10%, this fault is activated.
Possible causes:
1. PTO shaft load too high.
2. PTO shaft clutch pressure too low.
Remedy:
Make sure that slippage of the PTO shaft clutch is neither caused by excessive load on the implement nor by insuf-
ficient pressure in the clutch.
1. Check clutch pressure of PTO shaft. Check whether the slider in solenoid valve Y4 is jammed. Check clutch
linings.

ECCU2 - 43 Rear PTO shaft - slip too high

Cause:
Starting 10 seconds after PTO shaft ON, a PTO shaft speed setpoint is determined in accordance with the engine
speed. If the current PTO shaft speed is lower than this setpoint by approx. 10%, this fault is activated.
Possible causes:
1. PTO shaft load too high.
2. PTO shaft clutch pressure too low.
Remedy:
Make sure that slippage of the PTO shaft clutch is neither caused by heavy implements nor by insufficient pressure
in the clutch.
1. Check clutch pressure of PTO shaft. Check whether the slider in solenoid valve Y5 is jammed. Check clutch
linings.

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ECCU2 - 44 Front PTO shaft - speed was detected although PTO

shaft is off
Cause:
ECCU2 monitors the speed of the PTO shaft starting 100 seconds after switch-off or after engine start. This fault code
is triggered if the speed exceeds the threshold value of 200 rpm.
Possible causes:
1. Clutch valve defective.
Remedy:
1. Switch the engine off.
2. Check the clutch pressure (0 bar) of the PTO shaft when the PTO shaft is OFF. Check whether the slider in sole-
noid valve Y4 is jammed. Check clutch linings.

ECCU2 - 45 Rear PTO shaft - speed was detected although PTO

shaft is off
Cause:
ECCU2 monitors the speed of the PTO shaft starting 100 seconds after switch-off or after engine start. This fault code
is triggered if the speed exceeds the threshold value of 200 rpm.
Possible causes:
1. Clutch valve defective.
Remedy:
1. Switch the engine off.
2. Check the clutch pressure (0 bar) of the PTO shaft when the PTO shaft is OFF. Check whether the slider in sole-
noid valve Y5 is jammed. Check clutch linings.

ECCU2 - 46 Front PTO speed - no signal from speed sensor

Cause:
ECCU2 monitors the output speed of the PTO shaft clutch starting 10 seconds after switch-on. This fault code is trig-
gered if the output speed falls below the threshold value of 200 rpm.
Possible causes:
1. Seasonal switch-off in OFF position.
2. Signal line of speed sensor B8 interrupted.
3. Supply to speed sensor interrupted.
4. Clutch pressure of PTO shaft too low.
5. ECCU2 defective.
Remedy:
Make sure that the PTO shaft is neither blocked by the implement nor by internal faults of the PTO shaft gearbox.
Seasonal switch-off must be in the ON position!
1. Detach plug from speed sensor B8 and connect test adapter 380000061 in between. Cancel fault and turn ignition
switch to OFF position. After approx. 5 seconds, turn ignition switch to ON position.

a) If the fault is activated again, the signal line is shorted to plus or ground or is interrupted. Check signal line from
CN3b PIN22 X3/21 PIN2 to sensor B8 PINB and repair if necessary.

b) If the fault is not activated again, go to step 2.

2. Start the engine and switch on the front PTO shaft. Check the frequency at PINB. Within 10 seconds (after PTO
shaft ON) > 100 Hz must be reached.

a) If no frequency is measured, replace sensor B8.

b) If a frequency of > 100 Hz is measured and the fault is activated again, the fault is caused by ECCU2. Replace
ECCU2.

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ECCU2 - 47 PTO shaft speed rear - no signal from speed sensor

Description:
The ECCU2 monitors the power take-off shaft coupling output speed from 10 seconds after switching on. This fault
code is triggered if the output speed falls below the threshold value of 200 rpm.
Possible Cause:
1. Control lever PTO 540/1000 or ECO/NORMAL in position „neutral“
2. Signal cable from speed sensor B7 broken
3. Supply from speed sensor interrupted
4. PTO shaft - coupling pressure too low
5. ECCU2 faulty
Remedy:
Ensure that the PTO shaft is not blocked by the mounted implement nor by internal PTO shaft drive faults.
A PTO shaft speed (540/540E/1000/1000E) must be selected!
1. Detach connector from speed sensor B7 and connect test adapter 380000070 in between. Check the 12 volt sup-
ply voltage between PIN1 and PIN3. Clear error and switch start switch to the OFF position. After about 5 seconds
switch start switch to the ON position.
a) If the error becomes active again, a short-circuit of the signal cable on positive or earth occurs or an interrupt.
Check signal cable from CN2/E PIN20 to sensor B7 PIN2 and repair if necessary.
b) If the fault continues to be active, go to step 2.
2. Start the engine and switch on the rear PTO shaft. Check the frequency on PIN2. 70 Hz must be reached within
10 seconds > (after PTO shaft ON).
a) If no frequency is measured, replace sensor B7.
b) If the frequency is measured at > 70 Hz and the fault is still active, the fault is in the ECCU2. Replace the
ECCU2.

ECCU2 - 48 Front PTO shaft - ON button pressed for too long

Cause:
The signal issued by the front PTO shaft ON button is present permanently or the button was pressed for too long (>
10 seconds). The fault is stored.
Possible causes:
1. Button S2/70/1 has an internal defect. (does not open)
2. The signal line for PTO shaft ON is shorted to the clocked supply (GSV4).
3. Incorrect operation. (pressed for > 10 seconds)
Remedy:
Use Service Tool monitor function: FRONT PTO shaft ON SWITCH
1. Cancel fault, turn ignition switch to OFF position (at least 10 secs) and make sure that the button is not pressed.
Turn ignition switch to ON position. Read off the data value of the front PTO shaft on switch monitor function. If
the data value remains "ON", there is a fault in the button or in the wiring.
Remove button S2/70/1 and detach plug.

a) If the data value is still "ON", there is a short-circuit in the wiring. (see step 2)

b) If the data value changes when the plug is disconnected, replace the button.
2. Check signal line from S2/70/1 via X24/5 PIN17 to CN3b PIN31 and repair if necessary.

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ECCU2 - 49 Rear PTO shaft - ON button pressed for too long

Cause:
The signal issued by the rear PTO shaft ON button is present permanently or the button was pressed for too long
(> 10 seconds). The fault is stored.
Possible causes:
1. Button S2/70/2 has an internal defect. (does not open)
2. The signal line for PTO shaft ON is shorted to the clocked supply (GSV4).
3. Incorrect operation. (pressed for > 10 seconds)
Remedy:
Use Service Tool monitor function: REAR PTO shaft ON SWITCH
1. Cancel fault, turn ignition switch to OFF position (at least 10 secs) and make sure that the button is not pressed.
Turn ignition switch to ON position. Read off the data value of the rear PTO shaft on switch monitor function. If
the data value remains "ON", there is a fault in the button or in the wiring.
Remove button S2/70/2 and detach plug.

a) If the data value is still "ON", there is a short-circuit in the wiring. (see step 2)

b) If the data value changes when the plug is disconnected, replace the button.
2. Check signal line from S2/70/2 via X24/5 PIN14 to CN3b PIN33 and repair if necessary.

ECCU2 - 50 Differential lock does not switch ON

Cause:
ECCU2 does not detect any current at output CN3b PIN5 although the differential lock is switched on.
Possible causes:
1. Interruption in solenoid coil.
2. Interruption in the lines to solenoid valve Y10.
3. Ground short-circuit of the solenoid coil.
4. Ground line to solenoid valve is shorted to ground.
5. ECCU2 defective.
Remedy:
1. Detach the plug on solenoid valve Y10 and carry out an insulation test. Check resistance of PIN1 and PIN2
against valve housing. If the resistance is not infinite, replace the solenoid coil.
2. Check the resistance of the solenoid coil (PIN1 against PIN2):
Setpoint = 8 ohms at 20 °C.

a) If the resistance is outside the setpoint range, replace the solenoid coil.

b) If the resistance is in the specified range, the fault is caused by the wiring between ECCU2 and
solenoid valve Y10.
Check wiring from Y10 PIN1 to CN3b PIN5 and Y10 PIN2 to grounding point 16 and repair if necessary.
3. If the fault is still active, replace ECCU2.

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ECCU2 - 51 Front PTO shaft does not switch ON

Cause:
ECCU2 does not detect any current at output CN2/E PIN7 although the PTO shaft is switched on.
Possible causes:
1. Interruption in solenoid coil.
2. Interruption in the lines to solenoid valve Y4.
3. Ground short-circuit of the solenoid coil.
4. Ground line to solenoid valve is shorted to ground.
5. ECCU2 defective.
Remedy:
1. Detach the plug on solenoid valve Y4 and carry out an insulation test. Check resistance of PIN1 and PIN2 against
valve housing. If the resistance is not infinite, replace the solenoid coil.
2. Check the resistance of the solenoid coil (PIN1 against PIN2):
Setpoint = 8.5 - 9.7 ohms at 25 °C.
a) If the resistance is outside the setpoint range, replace the solenoid coil.
b) If the resistance is in the specified range, the fault is caused by the wiring between ECCU2 and
solenoid valve Y4.
Check wiring from Y4 PIN2 to CN3b PIN6 and Y4 PIN1 to CN2/E PIN7 and repair if necessary.
3. If the fault is still active, replace ECCU2.

ECCU2 - 52 Rear PTO shaft does not switch ON

Cause:
ECCU2 does not detect any current at output CN3b PIN18 although the PTO shaft is switched on.
Possible causes:
1. Interruption in solenoid coil.
2. Interruption in the lines to solenoid valve Y5.
3. Ground short-circuit of the solenoid coil.
4. Ground line to solenoid valve is shorted to ground.
5. ECCU2 defective.
Remedy:
1. Detach the plug on solenoid valve Y5 and carry out an insulation test. Check resistance of PIN1 and PIN2 against
valve housing. If the resistance is not infinite, replace the solenoid coil.
2. Check the resistance of the solenoid coil (PIN1 against PIN2):
Setpoint = 8.5 - 9.7 ohms at 25 °C.
a) If the resistance is outside the setpoint range, replace the solenoid coil.
b) If the resistance is in the specified range, the fault is caused by the wiring between ECCU2 and
solenoid valve Y5.
Check wiring from Y5 PIN1 to CN3b PIN14 and Y5 PIN2 to CN3b PIN18 and repair if necessary.
3. If the fault is still active, replace ECCU2.

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ECCU2 - 53 Reversing fan does not switch ON up to DBD100000

Description:
When the reversing fan is switched on the reversing fan relay is not activated The ECCU2 detects no current at output
CN3b PIN8.
Possible Cause:
1. Control wire open
2. Reversing fan relay faulty
3. ECCU2 faulty
Remedy:
1. Extract the connector CN3b from the ECCU2 and the relay K5/16 from the relay socket.
Measure for continuity between connector CN3b PIN8, X24/3 PIN16, X23/1 PINH, X2/25 PIN1 and the relay sok-
ket K5/16 PIN1. Measure for continuity between grounding point 11, connector X2/25 PIN2 and relay socket
K5/16 PIN2.
a) If a break is detected, the cable must be repaired or replaced.
b) If no break is detected, relay K5/16 must be replaced.
2. If the error continues to be active, the ECCU2 must be replaced.

ECCU2 - 53 Reversing fan does not switch ON from DBD100001

Description:
The reversing fan relay is not triggered when th reversing filter is switched on. The ECCU2 detects no current at output
CN3b PIN8.
Possible Cause:
1. Control cable break
2. Engine print faulty
3. Reversing fan relay faulty
4. ECCU2 faulty
Remedy:
1. Disconnect the plug CN3b from the ECCU2 and the plug X6/2 from the engine print.
Measure for continuity between plug CN3b PIN8 and plug X6/2 PIN3.
a) If you detect a break, you mst repair or replace the cable.
b) If you do not detect a break, go to step 2.
2. Check the engine print for a break.
Measure for continuity between plug X6/2 PIN3 and relay socket K5/FAN PIN1.
Measure for continuity between screwed connection X1/31/1 and relay socket K5/FAN PIN2.
a) If you detect a break, you must replace the engine print.
b) If you do not detect a break, you must replace the relay K5/FAN.
3. If the fault becomes active again, you must replace the ECCU2.

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ECCU2 - 54 Oil preheating does not switch ON

Cause:
ECCU2 does not detect any current at output CN3b PIN16 although the oil preheating is switched on.
Possible causes:
1. Interruption in solenoid coil.
2. Interruption in the lines to the solenoid coil.
3. Ground short-circuit of the solenoid coil.
4. Ground line to Y8 is shorted to ground.
5. ECCU2 defective.
Remedy:
1. Detach the plug at Y8 and carry out an insulation test. Check resistance of PIN1 and PIN2 against valve housing.
If the resistance is not infinite, replace the solenoid coil.
2. Check the resistance of the solenoid coil (PIN1 to PIN2):
Setpoint value = 8.5 - 9.7 ohms at 25 °C.
a) If the resistance is outside the setpoint range, replace Y8.
b) If the resistance is in the specified range, there is a fault in the wiring between ECCU2 and Y8.
Check the line from Y8 PIN1 to CN3b PIN16 and repair it, if necessary.
Check the line from Y8 PIN2 via weld point X0/7/5 to grounding point 11 and repair it, if necessary.
3. If the fault is still active, replace ECCU2.

ECCU2 - 55 Differential lock - output stage temperature too high

Cause:
ECCU2 detects that the temperature at the output stage is too high.
Possible causes:
1. Short-circuit in the solenoid coil.
2. Plus control line to solenoid valve Y10 is shorted to ground.
3. ECCU2 defective.
Remedy:
1. Detach the plug on solenoid valve Y10 and carry out an insulation test. Check resistance of PIN1 and PIN2
against valve housing. If the resistance is not infinite, replace the solenoid coil.
2. Check the resistance of the solenoid coil (PIN1 against PIN2):
Setpoint = 8 ohms at 20 °C.
a) If the resistance is outside the setpoint range, replace the solenoid coil.
b) If the resistance is in the specified range, the fault is caused by the wiring between ECCU2 and solenoid valve
Y10. Check control line from Y10 PIN1 to CN3b PIN5 and repair if necessary.
3. If the fault is still active, replace ECCU2.

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ECCU2 - 56 Front PTO shaft - output stage temperature too high

Cause:
ECCU2 detects that the temperature at the output stage is too high.
Possible causes:
1. Short-circuit in the solenoid coil.
2. Plus control line to solenoid valve Y4 is shorted to ground.
3. ECCU2 defective.
Remedy:
1. Detach the plug on solenoid valve Y4 and carry out an insulation test. Check resistance of PIN1 and PIN2 against
valve housing. If the resistance is not infinite, replace the solenoid coil.
2. Check the resistance of the solenoid coil (PIN1 against PIN2):
Setpoint = 8.5 - 9.7 ohms at 25 °C.
a) If the resistance is outside the setpoint range, replace the solenoid coil.
b) If the resistance is in the specified range, the fault is caused by the wiring between ECCU2 and solenoid valve
Y4. Check control line from Y4 PIN2 to CN3b PIN6 and repair if necessary.
3. If the fault is still active, replace ECCU2.

ECCU2 - 57 Rear PTO shaft - output stage temperature too high

Cause:
ECCU2 detects that the temperature at the output stage is too high.
Possible causes:
1. Short-circuit in the solenoid coil.
2. Plus control line to solenoid valve Y5 is shorted to ground.
3. ECCU2 defective.
Remedy:
1. Detach the plug on solenoid valve Y5 and carry out an insulation test. Check resistance of PIN1 and PIN2 against
valve housing. If the resistance is not infinite, replace the solenoid coil.
2. Check the resistance of the solenoid coil (PIN1 against PIN2):
Setpoint = 8.5 - 9.7 ohms at 25 °C.
a) If the resistance is outside the setpoint range, replace the solenoid coil.
b) If the resistance is in the specified range, the fault is caused by the plus control line between ECCU2 and so-
lenoid valve Y5. Check control line from Y5 PIN1 to CN3b PIN14 and repair if necessary.
3. If the fault is still active, replace ECCU2.

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ECCU2 - 58 Reversing fan - overtemperature of power stage up to

DBD100000
Description:
The ECCU2 detects too high a temperature at the power stage.
Possible Cause:
1. Control cable short-circuit
2. Reversing fan relay faulty
3. ECCU2 faulty
Remedy:
1. Disconnect the connector CN3b from the ECCU2 and the relay K5/16 from the relay socket.
Measure for short-circuit between connector CN3b PIN8 and earth.
a) If you detect no short-circuit, you must repair or replace the cable.
b) If you detect no short-circuit, you must replace relay K5/16.
2. If the fault becomes active again, you must replace the ECCU2.

ECCU2 - 58 Reversing fan - overtemperature of power stage

from DBD100001
Description:
The ECCU2 detects too high a temperature at the power stage.
Possible Cause:
1. Control cable short-circuit
2. Engine print faulty
3. Reversing fan relay faulty
4. ECCU2 faulty
Remedy:
1. Disconnect the connector CN3b from the ECCU2 and the connector X6/2 from the engine print.
Measure for short-circuit between connector CN3b PIN8 and earth.
a) If you detect no short-circuit, you must repair or replace the cable.
b) If you detect no short-circuit.go to step 2.
2. Check the engine print for short-circuit to earth.
Measure for short-circuit between connector X6/2 PIN3 and earth.
a) If you detect a short-circuit, you must replace the engine print.
b) If you detect no short-circuit, you must replace the relay K5/FAN.
3. If the fault becomes active again, you must replace the ECCU2.

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ECCU2 - 59 Oil preheating - output stage temperature too high

Cause:
ECCU2 detects that the temperature at the output stage is too high.
Possible causes:
1. Short-circuit in the solenoid coil.
2. Plus control line to solenoid valve Y8 is shorted to ground.
3. ECCU2 defective.
Remedy:
1. Detach plug Y8 on solenoid valve Y8 and carry out an insulation test. Check resistance of PIN1 and PIN2 against
valve housing. If the resistance is not infinite, replace the solenoid coil.
2. Check the resistance of the solenoid coil (PIN1 against PIN2):
Setpoint = 8.5 - 9.7 ohms at 25 °C.
a) If the resistance is outside the setpoint range, replace the solenoid coil.
b) If the resistance is in the specified range, the fault is caused by the wiring between ECCU2 and solenoid valve
Y8.
Check control line from Y8 PIN1 to CN3b PIN16 and repair if necessary.
3. If the fault is still active, replace ECCU2.

ECCU2 - 65 Front PTO shaft - current was measured although PTO

shaft is off
Cause:
ECCU2 detects a current at output CN2/E PIN7 although the PTO shaft is not switched on.
Possible causes:
1. Solenoid valve control line shorted to plus.
2. ECCU2 defective.
Remedy:
1. Turn ignition switch to OFF position. Disconnect plug CN2/E. After approx. 5 seconds turn ignition switch back to
ON position and cancel fault. If the fault is activated again, ECCU2 has an internal defect and must be replaced.
If the fault is not activated again, continue with step 2.
2. Turn ignition switch to OFF position. Disconnect plug CN3b. Connect plug CN2/E. After approx. 5 seconds turn
ignition switch back to ON position. If the fault is activated again, there is a short-circuit to the wiring to solenoid
valve Y4. Check the lines and repair if required.
If the fault is not activated, continue with step 3.
3. Turn ignition switch to OFF position. Connect plug CN3b. After approx. 5 seconds turn ignition switch back to ON
position. If the fault is activated again, ECCU2 has an internal defect and must be replaced.

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ECCU2 - 66 Front PTO shaft - no current was measured although

PTO shaft is on
Cause:
ECCU2 does not detect any current at output CN2/E PIN7 although the PTO shaft is switched on.
Possible causes:
1. Interruption in solenoid coil.
2. Interruption in the lines to solenoid valve Y4.
3. Ground short-circuit of the solenoid coil.
4. Ground line to solenoid valve is shorted to ground.
5. ECCU2 defective.
Remedy:
1. Detach the plug on solenoid valve Y4 and carry out an insulation test. Check resistance of PIN1 and PIN2 against
valve housing. If the resistance is not infinite, replace the solenoid coil.
2. Check the resistance of the solenoid coil (PIN1 against PIN2):
Setpoint = 8.5 - 9.7 ohms at 25 °C.
a) If the resistance is outside the setpoint range, replace the solenoid coil.
b) If the resistance is in the specified range, the fault is caused by the wiring between ECCU2 and
solenoid valve Y4.
Check wiring from Y4 PIN2 to CN3b PIN6 and Y4 PIN1 to CN2/E PIN7 and repair if necessary.
3. If the fault is still active, replace ECCU2.

ECCU2 - 67 Rear PTO shaft - current was measured although PTO

shaft is off
Cause:
ECCU2 detects a current at output CN3b PIN18 although the PTO shaft is not switched on.
Possible causes:
1. Solenoid valve control line shorted to plus.
2. ECCU2 defective.
Remedy:
1. Turn ignition switch to OFF position. Disconnect line of plug CN3b PIN18. After approx. 5 seconds turn ignition
switch back to ON position and cancel fault. If the fault is activated again, ECCU2 has an internal defect and must
be replaced. If the fault is not activated again, continue with step 2.
2. Turn ignition switch to OFF position. Reconnect line of plug CN3b PIN18. Disconnect line of plug CN3b PIN14.
After approx. 5 seconds turn ignition switch back to ON position. If the fault is activated again, there is a short-
circuit to the wiring to solenoid valve Y5. Check the lines and repair if required.
If the fault is not activated, continue with step 3.
3. Turn ignition switch to OFF position. Connect line of plug CN3b PIN14. After approx. 5 seconds turn ignition
switch back to ON position. If the fault is activated again, ECCU2 has an internal defect and must be replaced.

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ECCU2 - 68 Rear PTO shaft - no current was measured although

PTO shaft is on
Cause:
ECCU2 does not detect any current at output CN3b PIN18 although the PTO shaft is switched on.
Possible causes:
1. Interruption in solenoid coil.
2. Interruption in the lines to solenoid valve Y5.
3. Ground short-circuit of the solenoid coil.
4. Ground line to solenoid valve is shorted to ground.
5. ECCU2 defective.
Remedy:
1. Detach the plug on solenoid valve Y5 and carry out an insulation test. Check resistance of PIN1 and PIN2 against
valve housing. If the resistance is not infinite, replace the solenoid coil.
2. Check the resistance of the solenoid coil (PIN1 against PIN2):
Setpoint = 8.5 - 9.7 ohms at 25 °C.
a) If the resistance is outside the setpoint range, replace the solenoid coil.
b) If the resistance is in the specified range, the fault is caused by the wiring between ECCU2 and
solenoid valve Y5.
Check wiring from Y5 PIN1 to CN3b PIN14 and Y5 PIN2 to CN3b PIN18 and repair if necessary.
3. If the fault is still active, replace ECCU2.

ECCU2 - 72 Front hitch position sensor - value exceeds

permissible range
Cause:
The voltage at the input of ECCU2 (CN3a PIN8) is >6.6V.
The fault is stored.
Possible causes:
1. Signal line is shorted to a plus line.
2. Sensor B19 has an internal defect (shorted to plus).
3. Ground line to sensor interrupted.
4. ECCU2 has an internal defect.
Remedy:
The sensor B19 can only output a voltage value of 25 % to 75 % of the supply voltage, irrespective of the setting. If
8V are supplied, the voltage output ranges from 2 V to 6V. If this fault is active, it cannot be remedied by resetting the
sensor.
1. Detach the plug from the sensor and connect measuring adapter 380000067 in between (sensor connected). Use
a voltmeter to measure the voltage between PIN2 (signal) and PIN1 (ground) (ignition switch in ON position). A
voltage between 2V and 6V must be present. If it is > 6.6 V, the signal line is shorted to plus or the sensor is de-
fective.
2. Disconnect plug of sensor B19 and measure the voltage at PIN2.
a)
Up to DBD100000:
If the voltage exceeds 6V, there is a short-circuit to plus. Check wiring from B19 PIN2 via X3/22 PIN2 and X23/2
PINT to CN3a PIN8 and repair if required.
From DBD100001:
If the voltage exceeds 6V, there is a short-circuit to plus. Check wiring from B19 PIN2 via X3/22 PIN2 to CN3a
PIN8 and repair if required.
b) If the voltage is approx. 0 V, the sensor is defective and must be replaced.
3. If you cannot detect a fault in steps 1 and 2, ECCU2 is defective and must be replaced.

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ECCU2 - 73 Front hitch position sensor - value below

permissible range
Cause:
The voltage at the input of ECCU2 (CN3a PIN8) is <1.8V.
The fault is stored.
Possible causes:
1. Signal line is shorted to ground.
2. Sensor B19 has an internal defect (shorted to ground).
3. Plus line to sensor interrupted.
4. ECCU2 has an internal defect.
Remedy:
The sensor B19 can only output a voltage value of 25 % to 75 % of the supply voltage, irrespective of the setting. If
8V are supplied, the voltage output ranges from 2 V to 6V. If this fault is active, it cannot be remedied by resetting the
sensor. (Check supply voltage)
1. Detach plug from sensor B19 and connect measuring adapter 380000067 in between (sensor connected). Use
a voltmeter to measure the voltage between PIN2 (signal) and PIN1 (ground) (ignition switch in ON position). A
voltage between 2V and 6V must be present. If this voltage is below 1.8 V, the signal line is shorted to ground or
the sensor is defective.
2. Detach signal line from plug and measure the signal voltage (PIN2).
a)
Up to DBD100000:
If the voltage at PIN2 of the sensor ranges between 2V and 6V, there is a short-circuit to ground. Check wiring
from B19 PIN2 via X3/22 PIN2 and X23/2 PINT to CN3a PIN8 and repair if required.
From DBD100001:
If the voltage at PIN2 of the sensor ranges between 2V and 6V, there is a short-circuit to ground. Check wiring
from B19 PIN2 via X3/22 PIN2 to CN3a PIN8 and repair if required.
b) If you still measure a voltage below 1.8V, the sensor is defective and must be replaced.
3. If you cannot detect a fault in steps 1 and 2, ECCU2 is defective and must be replaced.

ECCU2 - 85 AUX 1 switched off because temperature is too high

Cause:
AUX 1 signals a temperature > 110°C.

The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. The temperature of the hydraulic fluid is > 110°C.
2. The temperature sensor in AUX 1 is defective.
NOTE: If an AUX is switched off because the temperature is too high, it will not automatically switch on again once
it has cooled down, but the ignition switch must be turned to the OFF position once (> 5 secs) (RESET).
Remedy:
Faults ECCU2 86, 87, 88 and 89 can also be active. If the temperature of several AUX is > 110°C, there is a mecha-
nical defect in the hydraulic system. (see workshop manual, Chapter 8)
Use monitor function AUX VALVE TEMPERATURE.
1. Cancel fault codes and turn ignition switch to the OFF position. Afterwards turn ignition switch back to the ON
position and check whether 85 is still active. If the fault is active again, read off the temperature of all AUX units.
If the value of AUX 1 > 110°C and if the values of the other AUX are considerably lower, the temperature sensor
in AUX 1 is defective. Replace AUX 1.
2. Cancel fault code and turn ignition switch to OFF position. After 5 seconds, turn ignition switch to the ON position
and check whether fault 85 is still active.

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ECCU2 - 86 AUX 2 switched off because temperature is too high

Cause:
AUX 2 signals a temperature > 110°C.

The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. The temperature of the hydraulic fluid is > 110°C.
2. The temperature sensor in AUX 2 is defective.
NOTE: If an AUX is switched off because the temperature is too high, it will not automatically switch on again once
it has cooled down, but the ignition switch must be turned to the OFF position once (RESET).
Remedy:
Faults ECCU2 85, 87, 88 and 89 can also be active. If the temperature of several AUX is > 110°C, there is a mecha-
nical defect in the hydraulic system. (see workshop manual, Chapter 8)
Use monitor function AUX VALVE TEMPERATURE.
1. Cancel fault codes and turn ignition switch to the OFF position. After 5 seconds, turn ignition switch back to the
ON position and check whether fault 86 is still activated. If the fault is active again, read off the temperature of all
AUX units.
If the value of AUX 2 > 110°C and if the values of the other AUX are considerably lower, the temperature sensor
in AUX 2 is defective. Replace AUX 2.
2. Cancel fault code and turn ignition switch to OFF position. After 5 seconds, turn ignition switch to the ON position
and check whether fault 86 is still active.

ECCU2 - 87 AUX 3 switched off because temperature is too high

Cause:
AUX 3 signals a temperature > 110°C.

The fault is stored and signalled on the instrument panel by a warning triangle.

Possible causes:
1. The temperature of the hydraulic fluid is > 110°C.
2. The temperature sensor in AUX 3 is defective.
NOTE: If an AUX is switched off because the temperature is too high, it will not automatically switch on again once
it has cooled down, but the ignition switch must be turned to the OFF position once (RESET).
Remedy:
Faults ECCU2 85, 86, 88 and 89 can also be active. If the temperature of several AUX is > 110°C, there is a mecha-
nical defect in the hydraulic system. (see workshop manual, Chapter 8)
Use monitor function AUX VALVE TEMPERATURE.
1. Cancel fault codes and turn ignition switch to the OFF position. After 5 seconds, turn ignition switch back to the
ON position and check whether fault 87 is still activated. If the fault is active again, read off the temperature of all
AUX units.
If the value of AUX 3 > 110°C and if the values of the other AUX are considerably lower, the temperature sensor
in AUX 3 is defective. Replace AUX 3.
2. Cancel fault code and turn ignition switch to OFF position. After 5 seconds, turn ignition switch to the ON position
and check whether fault 87 is still active.

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ECCU2 - 88 AUX 4 switched off because temperature is too high

Cause:
AUX 4 signals a temperature > 110°C.

The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. The temperature of the hydraulic fluid is > 110°C.
2. The temperature sensor in AUX 4 is defective.
NOTE: If an AUX is switched off because the temperature is too high, it will not automatically switch on again once
it has cooled down, but the ignition switch must be turned to the OFF position once (RESET).
Remedy:
Faults ECCU2 85, 86, 87 and 89 can also be active. If the temperature of several AUX is > 110°C, there is a mecha-
nical defect in the hydraulic system. (see workshop manual, Chapter 8)
Use monitor function AUX VALVE TEMPERATURE.
1. Cancel fault codes and turn ignition switch to the OFF position. After 5 seconds, turn ignition switch back to the
ON position and check whether fault 88 is still activated. If the fault is active again, read off the temperature of all
AUX units.
If the value of AUX 4 > 110°C and if the values of the other AUX are considerably lower, the temperature sensor
in AUX 4 is defective. Replace AUX 4.
2. Cancel fault code and turn ignition switch to OFF position. After 5 seconds, turn ignition switch to the ON position
and check whether fault 88 is still active.

ECCU2 - 89 AUX 5 switched off because temperature is too high

Cause:
AUX 5 signals a temperature > 110°C.

The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. The temperature of the hydraulic fluid is > 110°C.
2. The temperature sensor in AUX 5 is defective.
NOTE: If an AUX is switched off because the temperature is too high, it will not automatically switch on again once
it has cooled down, but the ignition switch must be turned to the OFF position once (RESET).
Remedy:
Faults ECCU2 85, 86, 87 and 88 can also be active. If the temperature of several AUX is > 110°C, there is a mecha-
nical defect in the hydraulic system. (see workshop manual, Chapter 8)
Use monitor function AUX VALVE TEMPERATURE.
1. Cancel fault codes and turn ignition switch to the OFF position. After 5 seconds, turn ignition switch back to the
ON position and check whether fault 89 is still activated. If the fault is active again, read off the temperature of all
AUX units.
If the value of AUX 5 > 110°C and if the values of the other AUX are considerably lower, the temperature sensor
in AUX 5 is defective. Replace AUX 5.
2. Cancel fault code and turn ignition switch to OFF position. After 5 seconds, turn ignition switch to the ON position
and check whether fault 89 is still active.

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ECCU2 - 98 12 V supply voltage too high (>16V)

Cause:
Control unit detects an overvoltage of more than 16V at the voltage supply (CN1a PIN1, 2, 3).
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Voltage regulator of the alternator defective.
2. Temporary overvoltage as a result of incorrect use of a starting aid.
Remedy:
1. While the engine is running (charging indicator lamp off), check the alternator charging voltage and the battery
voltage. The charging voltage at different engine speeds should range between 13.8V and 14.5.

a) If the charging voltage is outside the specified range, the voltage regulator of the alternator must be replaced.

b) If the charging voltage is in the specified range, cancel the fault and switch the engine off. Start the engine
again after approx. 5 seconds. If the fault is activated again, replace ECCU2.

ECCU2 - 99 12 V supply voltage too low (<10V)

Cause:
Control unit detects an undervoltage below 10V at the supply input (CN1a PIN1, 2 and 3).
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Battery faulty or insufficiently charged.
2. Plus or (and) ground line between alternator or battery and ECCU2 defective.
3. Voltage regulator or alternator defective.
4. ECCU2 defective.
Remedy:
1. While the engine is running (charging indicator lamp off), check the alternator charging voltage and the battery
voltage. The charging voltage at different engine speeds should range between 13.8V and 14.5.
a) If the charging voltage is less than the specified range, the voltage regulator of the alternator must be replaced.
b) If the charging voltage is in the specified range, cancel the fault and switch the engine off. Start the engine after
approx. 5 seconds. If the fault is activated again, go to step 2.
2. Use a test adapter to check the supply voltage to ECCU2 at inputs CN1a PIN1, 2 and 3. (Engine has started)
a) If the supply voltage is higher than 10 V, replace ECCU2.
b) If the supply voltage is less than 10 V, the supply and ground lines must be checked and repaired if required.

Supply: CN1a PIN1, 2, 3 via X4/85/a,b PIN1, 2 to X24/2 PIN8, 9 (A12)

Ground:
Up to DBD100000:
CN1a PIN19, 25, 26 as well as CN2/E PIN21 and 26 to grounding point 16.
From DBD100001:
CN1a PIN19, 25, 26 as well as CN2/E PIN21 and 26 to grounding point 11.

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ECCU2 - 100 12 V supply voltage too high (>16V)

Cause:
Control unit detects an overvoltage of more than 16 V at the voltage supply (CN3b PIN25, 34).
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Voltage regulator of the alternator defective.
2. Temporary overvoltage as a result of incorrect use of a starting aid.
Remedy:
1. While the engine is running (charging indicator lamp off), check the alternator charging voltage and the battery
voltage. The charging voltage at different engine speeds should range between 13.8V and 14.5.

a) If the charging voltage is outside the specified range, the voltage regulator of the alternator must be replaced.

b) If the charging voltage is in the specified range, cancel the fault and switch the engine off. Start the engine
again after approx. 5 seconds. If the fault is activated again, replace ECCU2.

ECCU2 - 101 12 V supply voltage too low (<10V)

Cause:
Control unit detects an undervoltage below 10V at the supply input (CN3b PIN25 and 34).
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Battery faulty or insufficiently charged.
2. Plus or (and) ground line between alternator or battery and ECCU2 defective.
3. Voltage regulator or alternator defective.
4. ECCU2 defective.
Remedy:
1. While the engine is running (charging indicator lamp off), check the alternator charging voltage and the battery
voltage. The charging voltage at different engine speeds should range between 13.8V and 14.5.
a) If the charging voltage is less than the specified range, the voltage regulator of the alternator must be replaced.
b) If the charging voltage is in the specified range, cancel the fault and switch the engine off. Start the engine after
approx. 5 seconds. If the fault is activated again, go to step 2.
2. Use a test adapter to check the supply voltage to ECCU2 at inputs CN3b PIN25 and 34. (Engine has started)
a) If the supply voltage is higher than 10 V, replace ECCU2.
b) If the supply voltage is less than 10 V, the supply and ground lines must be checked and repaired if required.

Supply: CN3b PIN25, 34 via X4/85/a,b PIN1, 2 to X24/2 PIN8, 9 (A12)

Ground:
Up to DBD100000:
CN1a PIN19, 25, 26 as well as CN2/E PIN21 and 26 to grounding point 16.
From DBD100001:
CN1a PIN19, 25, 26 as well as CN2/E PIN21 and 26 to grounding point 11.

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ECCU2 - 110 Vehicle BUS OFF up to DBD100000

Cause:
The control unit detects an interruption of data transfer between ECCU2 and the vehicle bus.

The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Interruption or contact fault on the CAN bus lines CANH or CANL between ECCU2 and other bus users.
2. Short-circuit between CANH and CANL.
3. One of the CAN bus lines is shorted to plus or GND.
4. Bus termination fault (contact fault or terminating resistor defective).
5. Fault in the screening of the bus line.
6. Fault in the supply to ECCU2.
7. Hardware fault of ECCU2 or another bus user.
Remedy:
Use CONTROL modulE status Service Tool to check whether other bus users are offline, too.
Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine and check whether the
fault is still active.
NOTE: If only fault 110 is active, the fault is probably caused by ECCU2 or the CAN bus wiring (including screening)
between ECCU2 and the weld points to the vehicle bus.
1. Check the plus supply of ECCU2 (fuses at print A12). Also check the ground supply to ECCU2. See fault codes
ECCU2 99 and ECCU2 101. Afterwards, turn ignition switch to ON position. If only fault 110 is active, go to step 3.
If other CAN bus faults are also active or if other bus users are OFFLINE, check all CAN bus fuses. Go to step 2.
2. If other bus users on the vehicle bus are also OFFLINE, check the entire vehicle bus for short-circuits, interrupti-
ons or defective terminating resistors. In the event of a short-circuit, all bus users are OFFLINE.
In this case, disconnect one bus user after the other, starting with ECCU2. If the other bus users go ONLINE when
the bus user to be tested is disconnected, this bus user must be replaced.
3. Carry out checks (by measuring) at the vehicle bus:
Disconnect the plug of Service Tool DPA from diagnosis socket X9/17. Use switch S31 to select the vehicle bus
(switch in upper position). Turn ignition switch to ON position.

a) Check voltages - CAN H and CAN L at diagnosis socket X9/17con.

PINC (CANH, yellow ) and PIND (CANL, green) against PINA (GND).
If the voltages are in the specified range, you can assume that the data lines are neither shorted to GND (supply
or screening), nor to plus 12 V (supply or screening).
If the voltages strongly deviate from the setpoints, check the data lines one by one for contact faults (interruption)
or for short-circuits to ground or plus (see step b). Check the screening (see Schematic of CAN bus).

b) Check resistance values - CAN H against CAN L at diagnosis socket X9/17con. To do so, turn ignition switch
to OFF position.
PINC (CANH, yellow ) against PIND (CANL, green). Setpoint: 60 ohms +/- 10%.

If resistances and voltages at diagnosis plug X9/17 are ok, go to step 4.

If the resistance strongly deviates from the setpoint when CANH is measured against CANL, check the plug-in
contacts of plugs X3/10 and X70 and repair them if required. Afterwards, check the two terminating resistors one
by one.
One terminating resistor is integrated in plug X3/10 (AUX valve block). The second terminating resistor is integra-
ted in EEM A2.

c) Check the terminating resistor in plug housing X3/10. (Plug of the CAN wiring disconnected) PINA against
PINB = 120 ohms +/- 10%.

d) Check the resistance of the CAN lines including the terminating resistor in the EEM, at X3/10: (Terminating
resistor at X3/10 disconnected)
PINA against PINB = 120 ohms +/- 10%.
If the resistance strongly deviates from the setpoint, disconnect plug X70 from the EEM and check the terminating
resistor at the EEM, PIN18 against PIN42. (120 ohms +/- 10%)

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e) If the terminating resistor in the EEM is also ok, check the CAN lines. Connect the terminating resistor to
X3/10. Measure the resistance at plug X70 between PIN18 and PIN42. (120 ohms +/- 10%) If the resistance
strongly deviates, check and repair the CAN wiring.
4. Disconnect plug CN1a from ECCU2 and also measure resistances and voltages at the spur line (PIN15 against
PIN16). Localize the interruption or contact fault and repair the spur line.

ECCU2 - 110 Vehicle BUS OFF from DBD100001

Cause:
The control unit detects an interruption of data transfer between ECCU2 and the vehicle bus.

The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Interruption or contact fault on the CAN bus lines CANH or CANL between ECCU2 and other bus users.
2. Short-circuit between CANH and CANL.
3. One of the CAN bus lines is shorted to plus or GND.
4. Bus termination fault (contact fault or terminating resistor defective).
5. Fault in the supply to ECCU2.
6. Hardware fault of ECCU2 or another bus user.
Remedy:
Use "CONTROL module status" Service Tool to check whether other bus users are offline, too.
Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine and check whether the
fault is still active.
NOTE: If only fault 110 is active, the fault is probably caused by ECCU2 or the CAN bus wiring between ECCU2
and the weld points to the vehicle bus.
1. Check the plus supply of ECCU2 (fuses at print A12). Also check the ground supply to ECCU2. See fault codes
ECCU2 99 and ECCU2 101. Afterwards, turn ignition switch to ON position. If only fault 110 is active, go to step 3.
If other CAN bus faults are also active or if other bus users are OFFLINE, check all CAN bus fuses. Go to step 2.
2. If other bus users on the vehicle bus are also OFFLINE, check the entire vehicle bus for short-circuits, interrupti-
ons or defective terminating resistors. In the event of a short-circuit, all bus users are OFFLINE.
In this case, disconnect one bus user after the other, starting with ECCU2. If the other bus users go ONLINE when
the bus user to be tested is disconnected, this bus user must be replaced.
3. Carry out checks (by measuring) at the vehicle bus:
Disconnect the plug of Service Tool DPA from diagnosis socket X9/17. Turn ignition switch to ON position.

a) Check voltages - CAN H and CAN L at diagnosis socket X9/17con.

PINC (CANH) and PIND (CANL) against PINA (GND).
If the voltages are in the specified range, you can assume that the data lines are neither shorted to GND, nor to
plus 12 V.
If the voltages strongly deviate from the setpoints, check the data lines one by one for contact faults (interruption)
or for short-circuits to ground or plus (see step b).

b) Check resistance values - CAN H against CAN L at diagnosis socket X9/17con. To do so, turn ignition switch
to OFF position.
PINC (CANH) against PIND (CANL). Setpoint: 60 ohms +/- 10%.

If resistances and voltages at diagnosis plug X9/17 are ok, go to step 4.

If the resistance strongly deviates from the setpoint when CANH is measured against CANL, check the plug-in
contacts of plugs X3/10 and X89/1 and repair them if required. Afterwards, check the two terminating resistors
one by one.
One terminating resistor is integrated in plug X3/10 (AUX valve block). The second terminating resistor is integra-
ted in EEM3.

c) Check the terminating resistor in plug housing X3/10. (Plug of the CAN wiring disconnected) PINA against
PINB = 120 ohms +/- 10%.

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d) Check the resistance of the CAN lines including the terminating resistor in the EEM, at X3/10: (Terminating
resistor at X3/10 disconnected)
PINA against PINB = 120 ohms +/- 10%.
If the resistance strongly deviates from the setpoint, disconnect plug X89/1 from the EEM and check the termina-
ting resistor at the EEM, PIN34 against PIN35. (120 ohms +/- 10%)

e) If the terminating resistor in the EEM is also ok, check the CAN lines. Connect the terminating resistor to
X3/10. Measure the resistance at plug X89/1 between PIN34 and PIN35. (120 ohms +/- 10%) If the resistance
strongly deviates, check and repair the CAN wiring.
4. Disconnect plug CN1a from ECCU2 and also measure resistances and voltages at the spur line (PIN15 against
PIN16). Localize the interruption or contact fault and repair the spur line.

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ECCU2 - 120 ISO Bus OFF

Cause:
The control unit detects an interruption in data transfer between ECCU2 and the ISO bus.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Interruption or contact fault in the ISO bus lines CANH or CANL between ECCU2 and other devices (terminal,
implement).
2. Short-circuit between CANH and CANL.
3. One of the CAN bus lines is shorted to plus or GND.
4. Terminating resistor in the ISO bus socket or in the implement faulty.
5. Hardware fault in ECCU2 or another device. (Terminal, implement)
Remedy:
1. Cancel the fault, turn the engine off (ignition off), wait 5 seconds, start the engine and check whether the fault is
still active. If the fault is no longer active, then it was a brief data transmission failure. No additional measures are
necessary.
2. The fault is still active: Disconnect the ISO BUS connection to the implement. Cancel fault. Turn the ignition switch
to off, wait 5 seconds; start the engine and check whether the fault is still active. If the fault is no longer active,
then the implement's electronics are causing the problem. If the fault is active again even though no implement
is connected to the ISO bus socket, then the fault lies in the tractor's ISO bus (can include the ISO bus socket).
Go to step 3.
3. Do not connect an implement to the ISO bus socket. Check the resistance at the ISO bus socket (see ISO bus
schematic). Setpoint: 120 ohms +/-10%. If the setpoint value is not attained, go to step 4. Otherwise replace
ECCU2.
4. Do not connect an implement to the ISO bus socket. Check the wiring and terminating resistors at the ISO bus:
Disconnect the plug of Service Tool DPA from diagnosis socket X9/17.
a) Check the CAN H and CAN L voltages at diagnosis socket X9/17 con.
PINH (CANH) and PINJ (CANL) to PINA (GND).
If the voltages are in the 2.5V range, you can assume that the data lines are neither shorted to GND, nor to po-
sitive 12 V. Check the data lines individually for contact faults (interruption) or a short-circuit to ground or positive.

b) Check the resistance values CAN H to CAN L at diagnosis socket X9/17 con. To do so, turn the ignition switch
to the OFF position.
PINH (CANH) to PINJ (CANL). Setpoint: 60 ohms + / -10%.
If the resistance deviates substantially from the setpoint value when checking CANH to CANL, then both termi-
nating resistors must then be checked individually.

c) One terminating resistor is located in plug X3/85 (German, 4-pole), the other one is integrated in the ISO bus
socket. Disconnect the terminating resistor in plug X4/86. Repeat the resistance measurement as described in
step b. Setpoint: 120 ohms +/-10%. If the setpoint value is attained, then the terminating resistor in the ISO bus
socket is ok. If not, then the ISO bus socket must be replaced.

d) Check plug X3/85 and the terminating resistor: Pin assignment: see ISO bus schematic, setpoint = 120 ohms
+/- 10%. If the resistance deviates from the setpoint value, then the terminating resistor is defective. Replace the
terminating resistor in plug X3/85.

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ECCU2 - 130 Front external button "RAISE front hitch" -

signal permanently at +
Cause:
The signal at this input is permanently plus (12V), although it should be clocked (GSV4). The fault is stored.
GSV4 = 5.3 V / 50 Hz
Possible causes:
1. Signal line of button S15/3 is shorted to plus.
2. ECCU2 has an internal defect.
Remedy:
Faults ECCU2 14 to 38 or 131 to 137 can also be active. If some of these faults occur at the same time, the fault can
also be caused by the supply as they are also supplied by the same output (GSV4).
Check the supply line from CN1a PIN10 to the individual functions (see corresponding faults).
Use Service Tool monitor function: External button, RAISE front hitch
1. Do not press the RAISE button. If the data value of the monitor function is ON, there is a short-circuit to plus or
ECCU2 has an internal defect.
Disconnect plug CN3a from ECCU2 and read off the data value:
a) If the data value remains ON, ECCU2 has an internal defect and must be replaced.
b)
Up to DBD100000:
If the data value changes to OFF, the signal line is shorted to plus. Check signal line from plug CN3a PIN26 via ,
X23/2 PINC and X4/69 PIN1 to button S15/3 and repair if necessary.
From DBD100001:
If the data value changes to OFF, the signal line is shorted to plus. Check signal line from plug CN3a PIN26 via
X4/69 PIN1 to button S15/3 and repair if necessary.

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ECCU2 - 131 Front external button "LOWER front hitch" - signal

permanently at +
Cause:
The signal at this input is permanently plus (12V), although it should be clocked (GSV4). The fault is stored.
GSV4 = 5.3 V / 50 Hz
Possible causes:
1. Signal line of button S14/3 is shorted to plus.
2. ECCU2 has an internal defect.
Remedy:
Faults ECCU2 14 to 38 or 130 to 137 can also be active. If some of these faults occur at the same time, the fault can
also be caused by the supply as they are also supplied by the same output (GSV4).
Check the supply line from CN1a PIN10 to the individual functions (see corresponding faults).
Use Service Tool monitor function: External button, LOWER front hitch
1. Do not press the LOWER button. If the data value of the monitor function is ON, there is a short-circuit to plus or
ECCU2 has an internal defect.
2. Disconnect plug CN3a from ECCU2 and read off the data value:
a) If the data value remains ON, ECCU2 has an internal defect and must be replaced.
b)
Up to DBD100000:
If the data value changes to OFF, the signal line is shorted to plus. Check signal line from plug CN3a PIN23 via
X23/2 PIND and X4/69 PIN3 to button S14/3 and repair if necessary.
From DBD100001:
If the data value changes to OFF, the signal line is shorted to plus. Check signal line from plug CN3a PIN23 via
X4/69 PIN3 to button S14/3 and repair if necessary.

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ECCU2 - 132 Front external button "Raise auxiliary valve" - signal

permanently at +
Cause:
The signal at this input is permanently plus (12V), although it should be clocked (GSV4). The fault is stored.
GSV4 = 5.3 V / 50 Hz
Possible causes:
1. Signal line of button S19/2 is shorted to plus.
2. ECCU2 has an internal defect.
Remedy:
Faults ECCU2 14 to 38 or 130 to 137 can also be active. If some of these faults occur at the same time, the fault can
also be caused by the supply as they are also supplied by the same output (GSV4).
Check the supply line from CN1a PIN10 to the individual functions (see corresponding faults).
Use Service Tool monitor function:
FRONT EXTERNAL BUTTON, raise auxiliary valve
1. Do not press the RAISE button. If the data value of the monitor function is ON, there is a short-circuit to plus or
ECCU2 has an internal defect.
Disconnect plug CN3a from ECCU2 and read off the data value:
a) If the data value remains ON, ECCU2 has an internal defect and must be replaced.
b)
Up to DBD100000:
If the data value changes to OFF, the signal line is shorted to plus. Check signal line from plug CN3a PIN11 via
X23/2 PING and X4/72 PIN1 to button S19/2 and repair if necessary.
From DBD100001:
If the data value changes to OFF, the signal line is shorted to plus. Check signal line from plug CN3a PIN11 via
X4/72 PIN1 to button S19/2 and repair if necessary.

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ECCU2 - 133 Front external button "Lower auxiliary valve" - signal

permanently at +
Cause:
The signal at this input is permanently plus (12V), although it should be clocked (GSV4). The fault is stored.
GSV4 = 5.3 V / 50 Hz
Possible causes:
1. Signal line of button S19/1 is shorted to plus.
2. ECCU2 has an internal defect.
Remedy:
Faults ECCU2 14 to 38 or 130 to 137 can also be active. If one of these faults occurs at the same time, the fault can
also be caused by the supply as they are also supplied by the same output (GSV4).
Check the supply line from CN1a PIN10 to the individual functions (see corresponding faults).
Use Service Tool monitor function:
FRONT EXTERNAL BUTTON, LOWER auxiliary valve
1. Do not press the LOWER button. If the data value of the monitor function is ON, there is a short-circuit to plus or
ECCU2 has an internal defect.
Disconnect plug CN3a from ECCU2 and read off the data value:
a) If the data value remains ON, ECCU2 has an internal defect and must be replaced.
b)
Up to DBD100000:
If the data value changes to OFF, the signal line is shorted to plus. Check signal line from plug CN3a PIN10 via
X23/2 PINF and X4/72 PIN2 to button S19/1 and repair if necessary.
From DBD100001:
If the data value changes to OFF, the signal line is shorted to plus. Check signal line from plug CN3a PIN10 via
X4/72 PIN2 to button S19/1 and repair if necessary.

ECCU2 - 134 Rear external button "Raise auxiliary valve" - signal

permanently at +
Cause:
The signal at this input is permanently plus (12V), although it should be clocked (GSV4). The fault is stored.
GSV4 = 5.3 V / 50 Hz
Possible causes:
1. Signal line of button S18/2 is shorted to plus.
2. ECCU2 has an internal defect.
Remedy:
Faults ECCU2 14 to 38 or 130 to 137 can also be active. If some of these faults occur at the same time, the fault can
also be caused by the supply as they are also supplied by the same output (GSV4).
Check supply line from CN1a PIN10 to the individual functions (see corresponding faults).
Use Service Tool monitor function:
REAR EXTERNAL BUTTON, raise auxiliary valve
1. Do not press the RAISE button. If the data value of the monitor function is ON, there is a short-circuit to plus or
ECCU2 has an internal defect.
Disconnect plug CN3a from ECCU2 and read off the data value:
a) If the data value remains ON, ECCU2 has an internal defect and must be replaced.
b) If the data value changes to OFF, the signal line is shorted to plus. Check signal line from plug CN3a PIN13 to
button S18/2 and repair if necessary.

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ECCU2 - 135 Rear external button "Lower auxiliary valve" - signal

permanently at +
Cause:
The signal at this input is permanently plus (12V), although it should be clocked (GSV4). The fault is stored.
GSV4 = 5.3 V / 50 Hz
Possible causes:
1. Signal line of button S18/1 is shorted to plus.
2. ECCU2 has an internal defect.
Remedy:
Faults ECCU2 14 to 38 or 130 to 137 can also be active. If some of these faults occur at the same time, the fault can
also be caused by the supply as they are also supplied by the same output (GSV4).
Check the supply line from CN1a PIN10 to the individual functions (see corresponding faults).
Use Service Tool monitor function:
REAR EXTERNAL BUTTON, LOWER auxiliary valve
1. Do not press the LOWER button. If the data value of the monitor function is ON, there is a short-circuit to plus or
ECCU2 has an internal defect.
Disconnect plug CN3a from ECCU2 and read off the data value:
a) If the data value remains ON, ECCU2 has an internal defect and must be replaced.
b) If the data value changes to OFF, the signal line is shorted to plus. Check signal line from plug CN3a PIN12 to
button S18/1 and repair if necessary.

ECCU2 - 136 Hydraulic Master switch in EDC+AUX position - signal

permanently at +
Cause:
The signal at this input is permanently plus (12V), although it should be clocked (GSV4). The fault is stored.
GSV4 = 5.3 V / 50 Hz
Possible causes:
1. Signal line of switch S2/7/3 is shorted to plus.
2. ECCU2 has an internal defect.
Remedy:
Faults ECCU2 14 to 38 or 130 to 137 can also be active. If some of these faults occur at the same time, the fault can
also be caused by the supply as they are also supplied by the same output (GSV4).
Check the supply line from CN1a PIN10 to the individual functions (see corresponding faults).
Use Service Tool monitor function:
SWITCH FOR HYDRAULIC MASTER AUXILIARY VALVES AND EDC ON
1. Turn switch S2/7/3 to the OFF position. If the data value remains in the ON position, there is a short-circuit to plus
or ECCU2 has an internal defect.
Disconnect plug CN3a from ECCU2 and read off the data value:
a) If the data value remains ON, ECCU2 has an internal defect and must be replaced.
b) If the data value changes to OFF, the signal line is shorted to plus. Check signal line from CN3a PIN4 via
X10/9 PIN6 to switch S2/7/3 and repair if necessary.

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ECCU2 - 137 Engine speed reduction switch in ON position - signal

permanently at +
Cause:
The signal at this input is permanently plus (12V), although it should be clocked (GSV4). The fault is stored.
GSV4 = 5.3 V / 50 Hz
Possible causes:
1. Signal line of switch S2/15/7 is shorted to plus.
2. ECCU2 has an internal defect.
Remedy:
Faults ECCU2 14 to 38 or 130 to 136 can also be active. If some of these faults occur at the same time, the fault can
also be caused by the supply as they are also supplied by the same output (GSV4).
Check the supply line from CN1a PIN10 to the individual functions (see corresponding faults).
Use Service Tool monitor function: engine speed reduction SWITCH
1. Turn switch S2/15/7 to the OFF position. If the data value remains in the ON position, there is a short-circuit to
plus or ECCU2 has an internal defect.
Disconnect plug CN3a from ECCU2 and read off the data value:
a) If the data value remains ON, ECCU2 has an internal defect and must be replaced.
b) If the data value changes to OFF, the signal line is shorted to plus. Check signal line from CN3a PIN24 via
X24/5 PIN7 to switch S2/15/7 and repair if necessary.

ECCU2 - 200 A bulb in the left-hand indicator is

defective (implement)
Cause:
The implement sends information via the ISO bus.
The fault does not have any further effect.

The fault is stored and signalled on the instrument panel by a warning triangle.

Possible causes:
1. Fuse defective.
2. Bulb defective.
3. Interruption or contact fault in the lamp circuit.
4. Data communication on the bus was disturbed by electromagnetic interference.
Remedy:
1. Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine and check whether
the fault is active again. If this is the case, go to step 2.
If the fault is no longer active, data communication on the ISO bus was disturbed by electromagnetic interference.
2. Check fuse and replace if required. Check bulb and replace if required. If neither fuse nor bulb is defective, then
check that the bulb has good contact to the lamp socket and check the wiring for interruptions or contact faults.
Repair if necessary.

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ECCU2 - 201 A bulb in the stop lights is defective (implement)

Cause:
The implement sends information via the ISO bus.
The fault does not have any further effect.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Fuse defective.
2. Bulb defective.
3. Interruption or contact fault in the lamp circuit.
4. Data communication on the bus was disturbed by electromagnetic interference.
Remedy:
1. Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine and check whether
the fault is active again. If this is the case, go to step 2.
If the fault is no longer active, data communication on the ISO bus was disturbed by electromagnetic interference.
2. Check fuse and replace if required. Check bulb and replace if required. If neither fuse nor bulb is defective, then
check that the bulb has good contact to the lamp socket and check the wiring for interruptions or contact faults.
Repair if necessary.

ECCU2 - 202 A bulb in the stop lights is defective (implement)

Cause:
The implement sends information via the ISO bus.
The fault does not have any further effect.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Fuse defective.
2. Bulb defective.
3. Interruption or contact fault in the lamp circuit.
4. Data communication on the bus was disturbed by electromagnetic interference.
Remedy:
1. Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine and check whether
the fault is active again. If this is the case, go to step 2.
If the fault is no longer active, data communication on the ISO bus was disturbed by electromagnetic interference.
2. Check fuse and replace if required. Check bulb and replace if required. If neither fuse nor bulb is defective, then
check that the bulb has good contact to the lamp socket and check the wiring for interruptions or contact faults.
Repair if necessary.

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ECCU2 - 203 A bulb in the sidelights is defective (implement)

Cause:
The implement sends information via the ISO bus.
The fault does not have any further effect.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Fuse defective.
2. Bulb defective.
3. Interruption or contact fault in the lamp circuit.
4. Data communication on the bus was disturbed by electromagnetic interference.
Remedy:
1. Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine and check whether
the fault is active again. If this is the case, go to step 2.
If the fault is no longer active, data communication on the ISO bus was disturbed by electromagnetic interference.
2. Check fuse and replace if required. Check bulb and replace if required. If neither fuse nor bulb is defective, then
check that the bulb has good contact to the lamp socket and check the wiring for interruptions or contact faults.
Repair if necessary.

ECCU2 - 204 A bulb in the worklights is defective (implement)

Cause:
The implement sends information via the ISO bus.
The fault does not have any further effect.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Fuse defective.
2. Bulb defective.
3. Interruption or contact fault in the lamp circuit.
4. Data communication on the bus was disturbed by electromagnetic interference.
Remedy:
1. Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine and check whether
the fault is active again. If this is the case, go to step 2.
If the fault is no longer active, data communication on the ISO bus was disturbed by electromagnetic interference.
2. Check fuse and replace if required. Check bulb and replace if required. If neither fuse nor bulb is defective, then
check that the bulb has good contact to the lamp socket and check the wiring for interruptions or contact faults.
Repair if necessary.

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ECCU2 - 220 No communication with ARU

Cause:
The CAN module in the armrest has failed.

The fault is stored and signalled on the instrument panel by a warning triangle.

Possible causes:
1. Supply to CAN module in the armrest faulty.
2. Interruption or contact fault on the CAN bus lines CANH or CANL.
3. Terminating resistor at vehicle bus defective.
4. Data communication on the bus was disturbed by electromagnetic interference.
5. Another bus user is faulty.
Remedy:
Use "CONTROL modulE status" Service Tool monitor to check which bus users are offline.
1. Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine and check whether
the fault is active again. If this is the case, go to step 2.
NOTE: If fault ECCU2 - 110 (vehicle bus OFF) is also triggered, remedy this fault first.
2. If the armrest is "OFFLINE" go to fault code ARU 71. If the armrest is ONLINE, however, this was only a temporary
fault.

ECCU2 - 221 No communication with AUX 1

Cause:
AUX 1 has failed.

The fault is stored and signalled on the instrument panel by a warning triangle.

Possible causes:
1. Supply to AUX 1 faulty.
2. Interruption or contact fault on the CAN bus lines CANH or CANL.
3. Terminating resistor at vehicle bus defective.
4. Data communication on the bus was disturbed by electromagnetic interference.
5. Another bus user is faulty.
Remedy:
Use "CONTROL modulE status" Service Tool monitor to check which bus users are offline.
1. Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine and check whether
the fault is active again. If this is the case, go to step 2.
If AUX 1 is "ONLINE", however, this was only a temporary fault.
NOTE: If fault ECCU2 - 110 (vehicle bus OFF) is also triggered, remedy this fault first.
2. If AUX 1 is "OFFLINE", use the CAN BUS diagram to check the supply and the data lines to AUX 1. Repair if
necessary.

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ECCU2 - 222 No communication with EDC

Cause:
The EDC has failed.

The fault is stored and signalled on the instrument panel by a warning triangle.

Possible causes:
1. Supply to EDC is faulty.
2. Interruption or contact fault on the CAN bus lines CANH or CANL.
3. Terminating resistor at vehicle bus defective.
4. Data communication on the bus was disturbed by electromagnetic interference.
5. Another bus user is faulty.
Remedy:
Use "CONTROL modulE status" Service Tool monitor to check which bus users are offline.
1. Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine and check whether
the fault is active again. If this is the case, go to step 2.
NOTE: If fault ECCU2 - 110 (vehicle bus OFF) is also triggered, remedy this fault first.
2. Check supply to EDC. For details, refer to fault code EDC 33.

ECCU2 - 223 No communication with the EEM up to DBD100000

Cause:
The engine control unit has failed.

The fault is stored and signalled on the instrument panel by a warning triangle.

Possible causes:
1. Supply to EEM is faulty.
2. Interruption or contact fault on the CAN bus lines CANH or CANL.
3. Terminating resistor at vehicle bus defective.
4. Fault in the screening of the bus line.
5. Data communication on the bus was disturbed by electromagnetic interference.
6. Another bus user is faulty.
Remedy:
Use "CONTROL module status" Service Tool monitor to check which bus users are offline.
1. Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine and check whether
the fault is active again. If this is the case, go to step 2.
NOTE: If fault ECCU2 - 110 (vehicle bus OFF) is also triggered, remedy this fault first.
2. If the EEM is "OFFLINE" go to fault code EEM 141. If the EEM is "ONLINE", however, this was only a temporary
fault.

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ECCU2 - 223 No communication with the EEM from DBD100001

Cause:
The engine control unit has failed.

The fault is stored and signalled on the instrument panel by a warning triangle.

Possible causes:
1. Supply to EEM is faulty.
2. Interruption or contact fault on the CAN bus lines CANH or CANL.
3. Terminating resistor at vehicle bus defective.
4. Data communication on the bus was disturbed by electromagnetic interference.
5. Another bus user is faulty.
Remedy:
Use "CONTROL modulE status" Service Tool monitor to check which bus users are offline.
1. Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine and check whether
the fault is active again. If this is the case, go to step 2.
NOTE: If fault ECCU2 - 110 (vehicle bus OFF) is also triggered, remedy this fault first.
2. If the EEM is "OFFLINE" go to fault code EEM 141. If the EEM is "ONLINE", however, this was only a temporary
fault.

ECCU2 - 224 No communication with the FMGR

Cause:
The vehicle controller (FMGR) has failed.

The fault is stored and signalled on the instrument panel by a warning triangle.

Possible causes:
1. The supply to the FMGR is faulty.
2. Interruption or contact fault on the CAN bus lines CANH or CANL.
3. Terminating resistor at vehicle bus defective.
4. Data communication on the bus was disturbed by electromagnetic interference.
5. Another bus user is faulty.
Remedy:
Use "CONTROL modulE status" Service Tool monitor to check which bus users are offline.
1. Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine and check whether
the fault is active again. If this is the case, go to step 2.
NOTE: If fault ECCU2 - 110 (vehicle bus OFF) is also triggered, remedy this fault first.
2. If the FMGR is "OFFLINE" go to fault code FMGR 255. If the FMGR is ONLINE, however, this was only a tem-
porary fault.

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ECCU2 - 225 No communication with ICU

Cause:
The display on the A Column (ICU) has failed.

The fault is stored and signalled on the instrument panel by a warning triangle.

Possible causes:
1. The supply to the ICU is faulty.
2. Interruption or contact fault on the CAN bus lines CANH or CANL.
3. Terminating resistor at vehicle bus defective.
4. Data communication on the bus was disturbed by electromagnetic interference.
5. Another bus user is faulty.
Remedy:
Use "CONTROL modulE status" Service Tool monitor to check which bus users are offline.
1. Cancel fault. Turn ignition switch to OFF position. After at least 5 seconds, start the engine and check whether
the fault is active again. If this is the case, go to step 2.
NOTE: If fault ECCU2 - 110 (vehicle bus OFF) is also triggered, remedy this fault first.
2. If the ICU is "OFFLINE" go to fault code ICU 2. If the ICU is "ONLINE", however, this was only a temporary fault.

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COMPONENTS SUMMARY
(11) Ground point engine device carrier, rear up to DBD100000..............................................................Fig. 1
(11) Ground point engine cable carrier, rear from DBD100001 ................................................................Fig. 2
(16) Ground point starter...........................................................................................................................Fig. 3
ARU Armrest ..............................................................................................................................................Fig. 4
AUX1 1st remote control valve ....................................................................................................................Fig. 4
AUX2 2nd remote control valve ...................................................................................................................Fig. 4
AUX3 3rd remote control valve ....................................................................................................................Fig. 4
AUX4 4th remote control valve ....................................................................................................................Fig. 4
AUX5 5th remote control valve ....................................................................................................................Fig. 4
A2 EEM2 control unit up to DBD100000.................................................................................................Fig. 5
A3 EEM3 control unit from DBD100001 .................................................................................................Fig. 6
A4 FMGR ................................................................................................................................................Fig. 7
A55 EDC control unit ................................................................................................................................Fig. 8
A60 ECCU2 ..............................................................................................................................................Fig. 9
B7 Rear PTO speed sensor .................................................................................................................Fig. 10
B8 Front PTO speed sensor ................................................................................................................. Fig. 11
B19 Angle of rotation sensor [LAGESENSOR VO]..................................................................................Fig. 12
CN1a ECCU2 plug connection ..................................................................................................................Fig. 13
CN2/E ECCU2 plug connection ..................................................................................................................Fig. 13
CN3a ECCU2 plug connection ..................................................................................................................Fig. 14
CN3b ECCU2 plug connection ..................................................................................................................Fig. 14
G2/2 Generator, Magneton 120A up to DBD100000................................................................................Fig. 15
G2/2 Generator, Bosch 120A from DBD100001 ......................................................................................Fig. 15
G2/2/2 2nd Generator, Magneton 95A ........................................................................................................Fig. 16
G2/3 Generator, Denso 140A up to DBD100000 .....................................................................................Fig. 16
K5/16 Relay, reverse fan up to DBD100000 ..............................................................................................Fig. 17
P8 ICU ..................................................................................................................................................Fig. 18
P8 Plug connection ICU........................................................................................................................Fig. 19
S2/7/3 Switch, hydraulic master [MASTER]................................................................................................Fig. 20
S2/15/6 Switch, HTS [HTS]...........................................................................................................................Fig. 21
S2/15/7 Switch, reducing speed [DREHZAHLABSENKUNG] ......................................................................Fig. 21
S2/56 Switch, differential lock management [DIFF HI]...............................................................................Fig. 22
S2/70/1 Switch, front PTO [PTO VO] ............................................................................................................Fig. 23
S2/70/2 Switch, rear PTO [PTO HI]...............................................................................................................Fig. 23
S2/71 Switch, rear PTO management [PTO M] .........................................................................................Fig. 23
S14/3 External button, front power lift, LOWER.........................................................................................Fig. 24
S15/3 External button, front power lift, RAISE ...........................................................................................Fig. 24
S17/1 External button, PTO rear left .........................................................................................................Fig. 25
S17/2 External button, PTO rear right........................................................................................................Fig. 26

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S18/1 External button, AUX BLUE, pressure in - [ATS] ............................................................................ Fig. 27

S18/2 External button, AUX BLUE, pressure in + [ATH] ........................................................................... Fig. 27
S19/1 External button, AUX BROWN, pressure in - ................................................................................. Fig. 28
S19/2 External button, AUX BROWN, pressure in +................................................................................. Fig. 28
S28/1 Button, front power lift management ............................................................................................... Fig. 29
S31 Changeover switch, CAN SGR/FMGR up to DBD100000.............................................................. Fig. 30
X1/31/1 Screw connection, engine print, potential 31 from DBD100001 ..................................................... Fig. 31
X2/25 Plug connection, reverse fan [LU] up to DBD100000 ..................................................................... Fig. 32
X3/10 Plug connection, terminal resistance .............................................................................................. Fig. 33
X3/21 Plug connection, speed sensor, PTO front ..................................................................................... Fig. 34
X3/22 Plug connection, angle of rotation sensor....................................................................................... Fig. 35
X3/85 Plug connection, terminating resistor ISO-BUS ............................................................................. Fig. 36
X4/66 Plug connection, reverse fan from DBD100001 ............................................................................. Fig. 37
X4/69 Plug connection, external button, front power lift ............................................................................ Fig. 38
X4/72 Plug connection, external button, front AUX brown ....................................................................... Fig. 39
X4/85/a Plug connection, cab wiring harness, right - ISO BUS preparation ............................................... Fig. 40
X4/85/b Plug connection, cab wiring harness, right - ISO BUS preparation ............................................... Fig. 40
X4/86 Plug connection, socket LBS ISO-BUS ......................................................................................... Fig. 41
X6/2 Plug connection, engine print, supply EDC [2] from DBD100001................................................... Fig. 42
X9/17 Socket, diagnosis service tool ....................................................................................................... Fig. 43
X10/9 Plug connection, wiring harness, cab right - control panel ............................................................. Fig. 44
X18/4 Plug connection, cab wiring harness, right - armrest ...................................................................... Fig. 45
X23/1 Plug connection, instruments wiring harness - engine wiring harness up to DBD100000.............. Fig. 46
X23/2 Plug connection, wiring harness, cab right - engine wiring harness up to DBD100000.................. Fig. 47
X24/2 Plug connection, wiring harness, cab right ..................................................................................... Fig. 48
X24/3 Plug connection, instruments wiring harness - cab wiring harness on right [3] .............................. Fig. 49
X24/5 Plug connection, wiring harness, cab, right - control panel [5]........................................................ Fig. 44
X70 Plug connection, engine control unit EEM2 up to DBD100000 ...................................................... Fig. 50
X85 Socket, LBS, ISO-BUS ................................................................................................................... Fig. 51
X89/1 Plug connection, EEM3 engine control unit - engine wiring harness from DBD100001 ................. Fig. 52
Y4 Solenoid valve, front PTO [PTO VO]............................................................................................... Fig. 53
Y5 Solenoid valve, rear PTO [PTO]...................................................................................................... Fig. 54
Y8 Heating valve .................................................................................................................................. Fig. 55
Y10 Differential lock solenoid valve [DIFF]............................................................................................. Fig. 54

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ECCU2 4011-227

Fig. 1 up to DBD100000 Fig. 5 up to DBD100000

Fig. 2 from DBD100001 Fig. 6 from DBD100001

Fig. 3 Fig. 7

Fig. 4 Fig. 8

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Fig. 9 Fig. 11 from DBD100001

Fig. 10 up to DBD100000 Fig. 12 up to DBD100000

Fig. 10 from DBD100001 Fig. 12 from DBD100001

Fig. 11 up to DBD100000

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ECCU2 4011-229

Fig. 13 up to DBD100000

Fig. 14 up to DBD100000

Fig. 13 from DBD100001

Fig. 14 from DBD100001

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 4011-230

Fig. 15 Fig. 19

Fig. 16 Fig. 20

Fig. 17 up to DBD100000 Fig. 21

Fig. 18

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ECCU2 4011-231

Fig. 22 Fig. 24 from DBD100001

Fig. 23 Fig. 25 up to DBD100000

Fig. 25 from DBD100001

Fig. 24 up to DBD100000

Fig. 26

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Fig. 27 up to DBD100000 Fig. 29

Fig. 27 from DBD100001 Fig. 30 up to DBD100000

Fig. 28 up to DBD100000 Fig. 31 from DBD100001

Fig. 28 from DBD100001 Fig. 32 up to DBD100000

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ECCU2 4011-233

Fig. 33 Fig. 34 from DBD100001

Fig. 34 up to DBD100000

Fig. 35 up to DBD100000

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Fig. 35 from DBD100001 Fig. 38 up to DBD100000

Fig. 36 Fig. 38 from DBD100001

Fig. 37

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ECCU2 4011-235

Fig. 39 up to DBD100000 Fig. 40

Fig. 41 up to DBD100000

Fig. 39 from DBD100001

Fig. 41 from DBD100001

Fig. 42 from DBD100001

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Fig. 43 up to DBD100000 Fig. 44 up to DBD100000

Fig. 43 from DBD100001

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ECCU2 4011-237

Fig. 44 from DBD100001 Fig. 45 up to DBD100000

Fig. 45 from DBD100001

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Fig. 46 up to DBD100000 Fig. 48 up to DBD100000

Fig. 48 from DBD100001

Fig. 47 up to DBD100000

Fig. 49 up to DBD100000

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ECCU2 4011-239

Fig. 49 from DBD100001 Fig. 51

Fig. 52 from DBD100001

Fig. 50 up to DBD100000

Fig. 53

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 4011-240

Fig. 54

Fig. 55 up to DBD100000

Fig. 55 from DBD100001

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ECCU2 4011-241

FUNCTIONAL SCHEMATIC DIAGRAM FOR ECCU2 UP TO DBD100000

A1 ADIC X24/2 A12
F50 25A
A12 Central print 8 +15/1
A13 Roof print
A14 Engine print 9
F10 5A
A60 ECCU2
X4/85a 1 2 22 +30
X10/12 A13 X10/11 X14/15 A12
A62 Reverse fan unit F45 5A
CN1a 26-pin plug connection
D+
X4/85b 1 2 6 7 12 +15/1

CN2/E 26-pin plug connection

CN3 26-pin plug connection
CN3a 26-pin plug connection
CN3b 34-pin plug connection X14/14 X10/14 X23/1 X20/1 A14
K5/16 Relay, reverse fan 2 25 34 1 2 3 14 21 26 25 26 19 F93 5A
(16) 4 7 Q 8 +30
P8 ICU CN3a CN3b CN1a CN2/E CN1a
P8 10-pin plug connection A60 ECCU2
P8/1 4-pin plug connection
P8/2 4-pin plug connection
S2/15/6 Switch, HTS A60_GND (7)
Supply P8 7 5 3 (8)
S2/15/7 Switch, speed reduction
S2/56 Switch for differential lock P8/1 P8 ICU
S2/74 Reverse fan pushbutton CAN H

CN1a
15 3 P8/2 CN3 A1 ADIC
CAN L CAN H
16 4 3 26
CAN L
4 25
X10/9 CN1a
GSV4
2 10

S2/56 Y10
CN3b
Differential lock 12 V
0 5 1
1
2
X24/5 CN3b
5 2 24 Management
3 2
1 1 23 Differential lock ON
S2/15/6
(16)
0
1
X24/5 CN3a HTS
2

7 22 18 RECORD
3
1 24 19 PLAY
S2/15/7

OFF
ON A62
Speed reduction
X24/5 CN3a
X4/66
2 1 7 24
3 M
A14
S2/74
F95 15A
X1/17
+30
A12 Reversible fan
OFF

X24/1 ON
X24/3 CN3a 1
F29 10A K5/16
+15/2 4 1 3 22 3 12 V 4
3 5 2
CN3b X24/3 X23/1 X2/25
12 V 1 2
8 16 H 1 4
X1/17 Plug connection X23/1 23-pin plug connection
X2/25 2-pin plug connection X24/1 24-pin plug connection
X4/66 4-pin plug connection X24/2 24-pin plug connection X2/25 2
X4/85a 4-pin plug connection X24/3 24-pin plug connection
X4/85b 4-pin plug connection X24/5 24-pin plug connection
X10/9 10-pin plug connection Y8 Heating valve CN3b
X10/11 10-pin plug connection Y10 Solenoid valve, differential lock 12 V
X10/12 10-pin plug connection (7) Ground point, roof hood, left 16 1
X10/14 10-pin plug connection (8) Ground point, roof hood, right (11)
Heating valve Y8
X14/14 14-pin plug connection (11) Ground point, engine device carrier
X14/15 14-pin plug connection (16) Ground point, starter 2
X20/1 20-pin plug connection

(16)

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ECCU2 4011-243

A60 ECCU2

X10/9 CN1a
GSV4
2 10

S2/70/1
Front PTO

ON

OFF
X24/5 CN3b
1 17 31 6.4 V when ON
3
7 18 30 6.4 V when OFF
CN2/E Y4
12 V**
7 1
X3/21 CN3b
(11) GND
n C 3 X23/2 CN3b 225 Hz at 900 rpm 6 2
B8 B 2 N 22 490 Hz at 1900 rpm
f A 1 570 Hz at 2300 rpm
A12
F32 10A
X24/2 **) Activation for approx. 6 sec. with 3 V, then 12 V
+15/2 7

n 3 CN2/E 150 Hz at 900 rpm

B7 2 20 330 Hz at 1900 rpm CN3b Y5
f 400 Hz at 2300 rpm 12 V**
1 14 1

GND
S2/70/2 18 2
(16)
ON

OFF
X24/5 CN3b
1 A12 Central print
14 33 6.4 V when ON A60 ECCU2
3
7 15 32 6.4 V when OFF B7 Rear PTO speed sensor
B8 Front PTO speed sensor
S2/71 CN1a 26-pin plug connection
Rear PTO CN2/E 26-pin plug connection
OFF
CN3a 26-pin plug connection
ON
CN3b 34-pin plug connection
S2/70/1 Switch for front PTO
X24/5 CN3a S2/70/2 Switch for rear PTO
5 1 16 20 6.4 V with management ON S2/71 Switch for rear PTO, management
S17/1 External pushbutton, PTO shaft, rear left
S17/1 S17/2 External pushbutton, PTO shaft, rear right
X3/21 3-pin plug connection
OFF
X10/9 10-pin plug connection
ON X23/2 23-pin plug connection
CN3a X24/2 24-pin plug connection
1 2 21 6.4 V with pushbutton pressed X24/5 24-pin plug connection
22 Ω Y4 Solenoid valve, front PTO
S17/2 Y5 Solenoid valve, rear PTO
(11) Ground point, engine device carrier
OFF
(16) Ground point, starter
ON
CN3a
1 2 22 6.4 V with pushbutton pressed
22 Ω

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BLANK PAGE

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ECCU2 4011-245

FUNCTIONAL SCHEMATIC DIAGRAM FOR ECCU2 FROM DBD100001

A1 ADIC X24/2 A12 F50 25A
A12 Central print 8 +15/1
X14/15
A13 Roof print F45 5A

A14 Engine print 9 +15/1 12

F10 5A
A60 ECCU2 X4/85/a 1 2 22 +30
A62 Reverse fan unit
CN1a 26-pin plug connection X4/85/b 1 2
D+
CN2/E 26-pin plug connection
CN3 26-pin plug connection
CN3a 26-pin plug connection
CN3b 34-pin plug connection 2 25 34 1 2 3 14 21 26 25 26 19
K5/FAN Relay, reverse fan (11) X10/12 A13 X10/11
P8 ICU
CN3a CN3b CN1a CN2/E CN1a
A60 ECCU2 6 7
P8 10-pin plug connection
P8/1 4-pin plug connection
P8/2 4-pin plug connection A60_GND
S2/15/6 Switch, HTS Supply
S2/15/7 Switch, speed reduction
S2/56 Switch for differential lock CAN H

CN1a
15
S2/74 Reverse fan pushbutton CAN L (7)
X1/31/1 Screw connection 16 P8 7 5 3 (8)
X4/64 4-pin plug connection P8 ICU A1 ADIC
X10/9 CN1a P8/1 P8/2 CN3
GSV4 CAN H
2 10 3 3 26
CAN L
4 4 25
S2/56
0 Differential lock
1
X24/5 CN3b
2

5 24 Management CN3b Y10 X14/14 4

2 12 V
3 5 1
1 1 23 Differential lock ON
S2/15/6
2 X10/14 7
0
1
X24/5 CN3a HTS
2
(11)
7 22 18 RECORD
3
1 24 19 PLAY
S2/15/7 X10/3 6
A14
F212 5A
OFF +30 A62
ON
Speed reduction K5/FAN X4/64 X4/66
X24/5 CN3a 4
5 1 7 24 F211 10A 3 5 4 3 M
+30

1 2 3
CN3b 1
S2/74 X6/2
12 V 2
Reverse fan 8 3 1
A12
OFF

F29 10A
X24/1 ON
X24/3 CN3a X1/31/1
+15/2 4 1 3 22 3 12 V 2
GND
4

(11)
X4/66 4-pin plug connection X14/15 14-pin plug connection
X4/85/a 4-pin plug connection X24/1 24-pin plug connection
X4/85/b 4-pin plug connection X24/2 24-pin plug connection
X6/2 6-pin plug connection X24/3 24-pin plug connection
X10/3 10-pin plug connection X24/5 24-pin plug connection
X10/9 10-pin plug connection Y8 Heating valve CN3b
X10/11 10-pin plug connection Y10 Solenoid valve, differential lock 12 V
16 1
X10/12 10-pin plug connection (7) Ground point, roof hood, left
X10/14 10-pin plug connection (8) Ground point, roof hood, right
Y8
Heating valve
X14/14 14-pin plug connection (11) Ground point, engine cable carrier, rear 2

(11)

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ECCU2 4011-247

A60 ECCU2

X10/9 CN1a
GSV4
2 10

S2/70/1
Front PTO

ON

OFF
X24/5 CN3b
1 17 31 6.4 V when ON
3
7 18 30 6.4 V when OFF
CN2/E Y4
12 V**
7 1
X3/21 CN3b
(11) GND
n C 3 CN3b 225 Hz at 900 rmp 6 2
B8 B 2 22 490 Hz at 1900 rmp
f A 1 570 Hz at 2300 rmp
A12
F32 10A
X24/2 **) Activation approx. 6 sec. with 3 V, then 12 V
+15/2 7

n 3 CN2/E 150 Hz at 900 rmp

B7 2 20 330 Hz at 1900 rmp CN3b Y5
f 400 Hz at 2300 rmp 12 V**
1 14 1

GND
S2/70/2 18 2
(11)
ON

OFF
X24/5 CN3b
1 14 33 6.4 V when ON
3
7 15 32 6.4 V when OFF A12 Central print
S2/71 A60 ECCU2
Rear PTO B7 Rear PTO speed sensor
B8 Front PTO speed sensor
OFF
ON
CN1a 26-pin plug connection
CN2/E 26-pin plug connection
X24/5 CN3a CN3a 26-pin plug connection
5 1 16 20 6.4 V with management ON CN3b 34-pin plug connection
S17/1 S2/70/1 Switch for front PTO
S2/70/2 Switch for rear PTO
S2/71 Switch for rear PTO, management
OFF
S17/1 External pushbutton for PTO, rear left
ON
CN3a S17/2 External pushbutton for PTO, rear right
1 2 21 6.4 V with pushbutton pressed X3/21 3-pin plug connection
22 Ω X10/9 10-pin plug connection
S17/2 X24/2 24-pin plug connection
X24/5 24-pin plug connection
OFF Y4 Solenoid valve, front PTO
ON
CN3a Y5 Solenoid valve, rear PTO
(11) Ground point, engine cable carrier, rear
1 2 22 6.4 V with pushbutton pressed
22 Ω

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ECCU2 4011-249

FUNCTIONAL SCHEMATIC DIAGRAM FOR REMOTE CONTROL VALVES - ADDITIONAL FUNCTIONS UP TO DBD100000

A60 ECCU2 CN1a X4/83 X4/90 AUX 1

CN1a CAN H CAN H
GSV4 15 3 3
10 CAN L CAN L
16 4 2
S2/7/3 CAN + CAN +
1 1
CAN - CAN -
0
17 2 4
1
3

3 X10/9 CN3a
X4/91 AUX 2
X10/9 6 1 8 1 6.4 V with EDC ON CAN H
3
2 8 2 6 4 6.4 V with EDC and AUX ON CAN L
2
A12 CAN +
X24/2 1
ARMREST F47 5A CAN -
+15/1 24 4
2
X5/1
S28/1 0
X18/4 CN3a 31
X4/92 AUX 3
X18/4 1
RAISE CAN H
1 6 17 6.4 V with pushbutton pressed 3
12 3 LOWER X14/15 CAN L
7 7 16 6.4 V with pushbutton pressed F45 5A 2
+15/1 12 CAN +
1
S18/1 CAN -
4

CAN H

CAN +
CAN L

CAN -
OFF
ON CN3a X4/93 AUX 4
1 2 A13 X10/11 CAN H
3
12 6.4 V with pushbutton pressed
22 Ω 7 CAN L
S18/2 2
CAN +
X10/12 6 1
CAN -
P8/1 3 4 1 2 4
OFF
ON
P8 ICU P8
1 2 13 6.4 V with pushbutton pressed
22 Ω 7 X14/14 X10/14 X4/94 AUX 5
S19/1 CAN H
5 4 7 3
CAN L
OFF
3 2
(7) CAN +
X23/2 X4/72 ON
X4/72 X23/2 1
(8) CAN -
K 3 1 2 2 F 10 6.4 V with pushbutton pressed 4
22 Ω
S19/2 A14 X20/1 X23/1
F93 5A A X3/10 B
+30 8 Q
OFF

X4/72 ON
X4/72 X23/2 120 Ω

4 1 2 1 G 11 6.4 V with pushbutton pressed A12 Central print X4/72 4-pin plug connection
A X23/2 22 Ω
A13 Roof print X4/83 4-pin plug connection
S14/3
A14 Engine print X4/90 4-pin plug connection
A60 ECCU2 X4/91 4-pin plug connection
2 X4/69 X4/92 4-pin plug connection
OFF B19 Angle of rotation sensor for front power lift
ON
X4/69 CN1a 26-pin plug connection X4/93 4-pin plug connection
X23/2 X4/94 4-pin plug connection
CN3a 26-pin plug connection
1 2 2 D 23 6.4 V with pushbutton pressed
CN3b 34-pin plug connection X5/1 Plug connection
22 Ω
S15/3 P8 ICU X10/9 10-pin plug connection
P8 10-pin plug connection X10/11 10-pin plug connection
P8/1 4-pin plug connection X10/12 10-pin plug connection
OFF S2/7/3 Switch, hydraulic master X10/14 10-pin plug connection
ON
X4/69 X23/2 S14/3 External pushbutton, front power lift LOWER X14/14 14-pin plug connection
S15/3 External pushbutton, front power lift RAISE X14/15 14-pin plug connection
1 2 1 C 26 6.4 V with pushbutton pressed S18/1 External push button, AUX BLUE pressure in - X18/4 18-pin plug connection
22 Ω
S18/2 External push button, AUX BLUE pressure in + X20/1 20-pin plug connection
CN3b S19/1 External push button, AUX BROWN X23/1 23-pin plug connection
X3/22 X23/2 12 (up to DBD... YELOW) pressure in - X23/2 23-pin plug connection
8V S19/2 External push button, AUX BROWN X24/2 24-pin plug connection
3 3 S CN3a (7) Ground point, roof hood, left
(up to DBD... YELOW) pressure in +
B19 2 2 T 8 2.5 to 4.7 V S28/1 Switch, front power lift management (8) Ground point, roof hood, right
U GND X3/10 3-pin plug connection
1 1 R CN1a X3/22 3-pin plug connection
23 X4/69 4-pin plug connection

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ECCU2 4011-251

FUNCTIONAL SCHEMATIC DIAGRAM FOR REMOTE CONTROL VALVES - ADDITIONAL FUNCTIONS FROM DBD100001

A60 ECCU2 CN1a X4/83 X4/90 AUX 1

CN1a CAN H
3
CAN H
3
GSV4 15
10 CAN L CAN L
16 4 2
S2/7/3 CAN + CAN +
1 1
CAN - CAN -
0
1
2 4
2

3 X10/9 CN3a
X4/91 AUX 2
X10/9 6 1 8 1 6.4 V with EDC ON
A12 CAN H
X24/2 3
2 8 2 6 4 6.4 V with EDC and AUX ON F47 5A CAN L
+15/1 24 (11) 2
CAN +
1
ARMREST X14/15 CAN -
F45 5A 4
+15/1 12
2

S28/1 0
X18/4 CN3a X4/92 AUX 3
X18/4 1
RAISE CAN H
1 6 17 6.4 V with pushbutton pressed 3
12 3 LOWER CAN L
7 7 16 6.4 V with pushbutton pressed 2
A13 X10/11 CAN +
1
S18/1 7 CAN -
4
OFF
X10/12 6 A14
CN3a X10/14 X10/3
ON
F212 5A X4/93 AUX 4
7 6 +30
CAN H
1 2 12 6.4 V with pushbutton pressed 3
22 Ω CAN L
S18/2 2
CAN +
4 X14/14 1
CAN -
OFF
ON
4

1 2 13 6.4 V with pushbutton pressed (7)

22 Ω
P8 7 5 3 (8) X4/94 AUX 5
S19/1 P8 ICU CAN H
P8/1 3
CAN L CAN L
OFF
4 2
CAN H CAN +
X4/72 ON
X4/72 3 1
CAN -
3 1 2 2 10 6.4 V with pushbutton pressed 4
22 Ω
S19/2
A X3/10 B
OFF

X4/72 ON
X4/72 120 Ω
4 1 2 1 11 6.4 V with pushbutton pressed
22 Ω
A12 Central print X4/69 4-pin plug connection
S14/3 A13 Roof print X4/72 4-pin plug connection
A14 Engine print X4/83 4-pin plug connection
2 X4/69 OFF A60 ECCU2 X4/90 4-pin plug connection
ON
X4/69 B19 Angle of rotation sensor for front power lift X4/91 4-pin plug connection
CN1a 26-pin plug connection X4/92 4-pin plug connection
1 2 3 23 6.4 V with pushbutton pressed CN3a 26-pin plug connection X4/93 4-pin plug connection
22 Ω
S15/3 CN3b 34-pin plug connection X4/94 4-pin plug connection
P8 ICU X10/3 10-pin plug connection
P8 10-pin plug connection X10/9 10-pin plug connection
OFF P8/1 4-pin plug connection X10/11 10-pin plug connection
ON
X4/69 S2/7/3 Switch, hydraulic master X10/12 10-pin plug connection
1 2 1 26 6.4 V with pushbutton pressed S14/3 External pushbutton, front power lift LOWER X10/14 10-pin plug connection
22 Ω S15/3 External pushbutton, front power lift, RAISE X14/14 14-pin plug connection
CN3b S18/1 External pushbutton, AUX BLUE pressure in - X14/15 14-pin plug connection
12 S18/2 External pushbutton, AUX BLUE pressure in + X18/4 18-pin plug connection
X3/22 S19/1 External pushbutton, AUX BROWN pressure in - X24/2 24-pin plug connection
8V
3 3 CN3a S19/2 External pushbutton, AUX BROWN pressure in + (7) Ground point, roof hood, left
B19 2 2 8 2.5 to 4.7 V S28/1 Switch for front power lift management (8) Ground point, roof hood, right
GND X3/10 3-pin plug connection (11) Ground point, engine cable carrier, rear
U 1 1 CN1a X3/22 3-pin plug connection
23

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FAULTCODES EDC
EDC - 11 Valve solenoid Y6 RAISE is not activated ......................................................................................... 255
EDC - 12 Valve solenoid Y7 LOWER is not activated ...................................................................................... 256
EDC - 15 The signal of the RAISE/LOWER buttons is outside the permissible range ..................................... 257
EDC - 16 Stabilised supply voltage for sensors and control elements is faulty ................................................ 259
EDC - 17 Supply voltage too high (> 18 V) ....................................................................................................... 260
EDC - 18 The signal of the TRANSPORT, CONTROL and QUICK-DROPkey functions is outside
the permissible range up to DBD094270 .......................................................................................................... 261
EDC - 18 The signal of the TRANSPORT, CONTROL and QUICK-DROP key functions is outside
the permissible range from DBD094271 ........................................................................................................... 263
EDC - 21 The signal of the EMERGENCY-STOP key is outside the permissible range up to DBD094270 ..... 265
EDC - 21 The signal of the EMERGENCY-STOP key is outside the permissible range from DBD094271 ...... 266
EDC - 22 Angle of rotation sensor signal is faulty ............................................................................................. 268
EDC - 23 The signal of SETPOINT potentiometer R6/1 is outside the permissible range ................................ 269
EDC - 24 The signal of LIFT LIMITER potentiometer R6/2 is outside the permissible range ........................... 270
EDC - 31 Signal from force sensor, right, B10/2 is faulty .................................................................................. 272
EDC - 32 Signal from force sensor, left, B10/1 is faulty .................................................................................... 273
EDC - 33 Supply voltage too low (< 11.5 V) ..................................................................................................... 275
EDC - 34 The signal of LOWERING SPEED potentiometer R6/4 is outside the permissible range ................. 276
EDC - 36 The signal of MIXED CONTROL potentiometer R6/3 is outside the permissible range .................... 277
EDC - 41 Signal of radar sensor B16 is faulty or not present up to DBD100000 .............................................. 279
EDC - 41 Signal of radar sensor B16 is faulty or not present from DBD100001 ............................................... 280
EDC - 42 Theoretical driving speed signal is faulty or not present ................................................................... 282
EDC - 44 The signal of SLIP LIMIT potentiometer R6/5 is outside the permissible range ................................ 283
COMPONENTS SUMMARY ............................................................................................................................. 285
FUNCTIONAL SCHEMATIC DIAGRAM FOR EDC UP TO DBD100000 ......................................................... 295
FUNCTIONAL SCHEMATIC DIAGRAM FOR EDC FROM DBD100001 .......................................................... 299

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EDC - 11 Valve solenoid Y6 RAISE is not activated

Cause:
No current in the electrical circuit of valve solenoid Y6.
The fault is output as a flashing code by the diagnosis LED.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Fuse (supply +30 to EDC Box) is defective.
2. Supply (+30) to EDC Box A55 not present.
3. Interruption in the cabling to the solenoid or contact resistance too high.
4. Interruption in solenoid coil Y6.
5. Output stage in EDC Box A55 is defective.
Remedy:
Use monitor function "MOVING DIRECTION OF HITCH".
Indicators: NONE / UP / DOWN.
1. Check fuse (supply +30 to EDC Box). If the fuse is ok, go to step 2.
2. Check the supply voltage (+30) at EDC Box A55. Disconnect plug X55 and connect adapter 380000074 in bet-
ween. PIN29 (min. 12V) against PIN28 (GND).
3. Disconnect the two-pin plug from solenoid coil Y6 and check the plug-in contacts. Connect adapter 380000066
in between. Check the resistance of solenoid coil Y6.
Setpoint: 1.6 - 2.2 ohms. Replace the solenoid coil if it is defective.
NOTE: During operation, the solenoid current is controlled by pulse-width modulation in the EDC Box. Direct activa-
tion with 12 V is not permitted, since the current would be too high and destroy the solenoid coil (solenoid coil tem-
perature too high).
4. If the solenoid coil is ok, connect the two-pin plug, then disconnect plug X55 from EDC Box A55.
Only connect adapter 380000074 with the cable harness.
Between PIN55 and PIN35 check the resistance of the solenoid coil including the lines: If the resistance
is > 1.6 - 2.2 ohms, check the lines individually and repair them if required.
5. If you cannot detect a fault in steps 1 to 4, the RAISE output stage is defective.
Replace EDC Box A55.

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EDC - 12 Valve solenoid Y7 LOWER is not activated

Cause:
No current in the electrical circuit of valve solenoid Y7.
The fault is output as a flashing code by the diagnosis LED.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Fuse (supply +30 to EDC Box) is defective.
2. Supply (+30) to EDC Box A55 not present.
3. Interruption in the cabling to the solenoid or contact resistance too high.
4. Interruption in solenoid coil Y7.
5. Output stage in EDC Box A55 is defective.
Remedy:
Use monitor function "MOVING DIRECTION OF HITCH".
Indicators: NONE / UP / DOWN
1. Check fuse (supply +30 to EDC Box). If the fuse is ok, go to step 2.
2. Check the supply voltage (+30) at EDC Box A55. Disconnect plug X55 and connect measuring adapter
380000074 in between. PIN29 (min. 12V) against PIN28 (GND).
3. Disconnect the two-pin plug from solenoid coil Y7 and check the plug-in contacts. Connect adapter 380000066
in between. Check the resistance of solenoid coil Y6.
Setpoint: 1.6 - 2.2 ohms. Replace the solenoid coil if it is defective.
NOTE: During operation, the solenoid current is controlled by pulse-width modulation in the EDC Box. Direct activa-
tion with 12 V is not permitted, since the current would be too high and destroy the solenoid coil (solenoid coil tem-
perature too high).
4. If the solenoid coil is ok, connect the two-pin plug, then disconnect plug X55 from EDC Box A55.
Only connect adapter 380000074 with the cable harness.
Between PIN19 and PIN53 check the resistance of the solenoid coil including the lines: If the resistance
is >1.6 - 2.2 ohms, check the lines individually and repair them if required.
5. If you cannot detect a fault in steps 1 to 4, the LOWER output stage is defective.
Replace EDC Box A55.

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EDC - 15 The signal of the RAISE/LOWER buttons is outside the

permissible range
Cause:
When the button is operated, the signal voltage must be within 3.45V +/- 0.5V.
When the button is not operated, the signal voltage must be approx. 0V.
The fault is output as a flashing code by the diagnosis LED.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. One of the right-hand RAISE/LOWER external buttons S15/2, S14/2 is faulty.
2. One of the left-hand RAISE/LOWER external buttons S15/1, S14/1 is faulty.
3. RAISE/LOWER button S2/15/5 is faulty.
4. Interruption or high contact resistance in the signal line.
5. Interruption or high contact resistance in the supply line.
6. Signal line is shorted to other plus lines.
7. Signal line is shorted to ground (GND).
8. EDC Box A55 is faulty.
Remedy:
Connect the Service Tool to diagnosis plug X9/17.
Use monitor function "RAISE/LOWER HITCH BUTTON".
Delete fault. Turn ignition switch to OFF position. Start engine after 5 seconds.
Turn HYDRAULIK MASTER switch to EDC position. Monitor display: "OFF".
Operate a RAISE button and hold: Monitor display "RAISE".
Release button: Monitor display "OFF".
Operate a LOWER button and hold: Monitor display "LOWER".
Release button: Monitor display "OFF".
If the monitor display does not agree with the button which was operated and if fault 15 is active again, carry out fault
diagnostics as follows:
Turn ignition switch to OFF position. Detach plug X55 from EDC Box A55 and connect measuring adapter 380000074
in between. Turn ignition switch to ON position.
1. Check stabilised supply voltage, signal voltage and RAISE/LOWER button.
NOTE: When no button is operated, the buttons’ supply voltage at PIN9 is approx. 5V. When one or several buttons
are operated, the supply voltage at PIN9 has the same value as the signal voltage (see steps b, c and d).
a) Do not operate a RAISE/LOWER button.
PIN9 (plus supply for all buttons) against PIN28 (GND): Setpoint approx. 5V.
PIN17 (RAISE signal) against PIN28 (GND): Setpoint approx. 0V.
PIN36 (LOWER signal) against PIN28 (GND): Setpoint approx. 0V.
If the setpoints are met, go to steps b, c and d.
If the setpoints are not met, go to step 2.

b) Operate a RAISE button.

PIN17 (RAISE signal) against PIN28 (GND): Setpoint 3.45V +/- 0.5V.
PIN36 (LOWER signal) against PIN28 (GND): Setpoint approx. 0V.
PIN9 (plus supply for all buttons) against PIN28 (GND): Setpoint 3.45V +/- 0.5V.

c) Operate a LOWER button.

PIN36 (LOWER signal) against PIN28 (GND): Setpoint 3.45V +/- 0.5V.
PIN17 (RAISE signal) against PIN28 (GND): Setpoint approx. 0V.
PIN9 (plus supply for all buttons) against PIN28 (GND): Setpoint 3.45V +/- 0.5V.

d) Operate a RAISE and a LOWER button at the same time.

PIN17 (RAISE signal) against PIN28 (GND): Setpoint 2.65V +/- 0.5V.
PIN36 (LOWER signal) against PIN28 (GND): Setpoint 2.65V +/- 0.5V.
PIN9 (plus supply for all buttons) against PIN28 (GND): Setpoint 2.65V +/- 0.5V.
NOTE: If the setpoints are not met in step b, or c or d, go to step 3.

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2. Check the supply voltage of the buttons without load:
Disconnect plug X55 from adapter 380000074. Measure the supply voltage at EDC Box A55, PIN9. PIN9 (set-
point approx. 5V) against PIN28 (GND).
a) If the setpoint is not met, the fault is outside the EDC Box. Go to step 3.
b) If the setpoint is not met, the fault is in the EDC Box. Replace EDC Box A55.
3. Check wiring and buttons:
Reconnect X55 to adapter 380000074.
a) If no button is operated and the supply voltage at PIN9 still deviates significantly from 5V, the buttons must then
be disconnected from the wiring one after the other. As soon as the voltage changes to 5V, reconnect the other
buttons that were disconnected one after the other. If the voltage stays at 5V, the defective button has been found.
Replace the defective button.

b) If the voltage does not change although all buttons are disconnected, the wiring between EDC Box and buttons
must be checked. The wiring must not be shorted to other lines (plus or ground, or to components). The two signal
lines (RAISE and LOWER) and the supply line must not be shorted. Repair the wiring if necessary.

c) If the supply is ok and if the voltage does not change when a button is operated, the button is defective or the
supply or signal line to the next weld point is defective. Replace the button or repair the line.

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EDC - 16 Stabilised supply voltage for sensors and control

elements is faulty
Cause:
The supply voltage is < 9.8V, but > 0V.

The fault is output as a flashing code by the diagnosis LED.

The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Short-circuit or conductive connection to other lines or components on the tractor.
2. Contact fault in the wiring (loose contacts or oxidation).
3. Potentiometer (R6/1, R6/2, R6/3, R6/4 or R6/5) is faulty.
4. Sensor (B9/1, B10/1 or B10/2) is faulty.
5. EDC print A16 is faulty.
6. EDC box A55 is defective.
General:
The EDC Box supplies the potentiometers (R6/1 to R6/5), the sensors (B9/1 to B10/2) as well as the resistors (R3,
R5, R8, R10 and R14 on print A16) with a stabilised voltage of 10V ± 2.5 %.
NOTE: A safety circuit prevents damage in the event of a short-circuit. This results in the following behaviour:
Depending on the degree of overload (load resistance too low = current too high), the voltage drops.
Remedy:
Delete fault. Turn ignition switch to OFF position, turn back to ON position after min. 5 seconds. If fault 16 is active
again, go to step 1.
NOTE: If fault codes EDC 33 or EDC 17 (12V supply to EDC Box faulty) are also activated, remedy those faults
first.
1. Delete fault and turn ignition switch to OFF position. Disconnect the plug from one of the sensors and then turn
the ignition switch to the ON position.
a) If fault 16 is activated again, carry out the same test step for the other sensors. If fault 16 still remains active,
go to steps 2, 3 and 4.
b) If fault 16 is not activated again, the faulty sensor must be replaced.
2. Turn ignition switch to OFF position. Detach plug X55 from EDC Box A55 and connect adapter 380000074 to plug
X55 (the EDC Box is disconnected).
3. Carry out a resistance measurement at the potentiometer supply and measure the resistors (on print A16):
PIN2 (10V) against PIN20 (GND). Setpoint: > 330 ohms.
If the resistance is > 330 ohms, go to step 4.
If the resistance is < 330 ohms, the fault must be localised by checking individual components.
a) The wiring of the supply (10V) between plug X55 and the five potentiometers as well as the resistors on print
A16 must not be shorted to other lines.
b) Resistance of one potentiometer (R6/1, R6/2, R6/3, R6/4, R6/5): 4.7 kilo ohms ± 20%.
c) Resistance value at print A16 (plugs X14/4 and X10/4 disconnected),
potentiometers (R6/1 to R6/5) disconnected):
Plug X14/4 PIN14 (10V) against PIN12 (GND). Setpoint 2 kilo ohms ±10%.
If the resistance value < setpoint, print A16 is faulty. Replace print A16.
4. Carry out a resistance measurement at the supply to the sensors (The sensors must be connected to the wiring
for this test):
PIN39 (10V) against PIN38 or PIN41 (GND). Setpoint: > 20 ohms.
a) If the resistance is < 20 ohms, the fault is in the wiring between EDC Box A55 or in the sensors. In case of
doubt, the current consumption of the sensors can also be measured.
b) Current consumption of a force sensor (B10/1 or B10/2): Setpoint < 100 mA.
c) Current consumption of the angle of rotation sensor (B9/1): Setpoint< 40 mA.
NOTE: If a resistance > 330 ohms is measured in step 3 and a resistance > 20 ohms is measured in step 4, the
faulty EDC Box must be replaced. If the total supply current to the three sensors is > 240 mA, the faulty sensor must
be replaced.
5. Delete fault. Turn ignition switch to OFF position, turn back to ON position after min. 5 seconds. Check that
fault 16 is not activated again.

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EDC - 17 Supply voltage too high (> 18 V)

Cause:
The supply voltage is > 18V.

The fault is output as a flashing code by the diagnosis LED.

The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Voltage regulator of the alternator defective.
2. Alternator defective.
3. Ground connection to EDC Box faulty.
4. External starting aid not suitable (voltage too high, e.g. 24V).
5. EDC Box A55 faulty.
Remedy:
Delete fault and turn ignition switch to OFF position.
Start engine without starting aid and make sure that the charging indicator lamp is off.
If fault 17 is no longer active, the voltage was too high (> 18V) while an inadequate starting aid was being used, for
instance.
If fault 17 is active again, carry out fault diagnostics as follows:
1. While the engine is running (charging indicator lamp off), check the alternator charging voltage and the battery
voltage.
Setpoint at different engine speeds and loads: 13.8V to 14.5V.
If the charging voltage is ok, continue fault diagnostics with step 2.
If the charging voltage is considerably higher, go to step 3.
2. Check the ground connection from the alternator via the battery up to EDC Box A55.
NOTE: If the wiring and the supply voltage at the EDC Box is ok, but fault 17 comes up again when the engine is
restarted, the fault is caused by the EDC Box. Replace the EDC Box.
3. If the charging voltage is above the values specified, the voltage regulator of the alternator or the alternator (with
integrated regulator) must be replaced.
4. While the engine is running (charging indicator lamp off), check the charging voltage and check that fault 17 is no
longer active.

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EDC - 18 The signal of the TRANSPORT, CONTROL and QUICK-

DROPkey functions is outside the permissible range
up to DBD094270
Cause:
The signal voltage is > 9.5V or < 0.5V.
The fault is output as a flashing code by the diagnosis LED.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Interruption or high contact resistance in the signal line.
2. Print A16 is faulty (resistor circuit defective).
3. Signal line is shorted to other plus lines.
4. Signal line is shorted to ground (GND).
5. EDC Box A55 is faulty
6. Plug module A28 in the armrest is faulty.
The signal voltage is tapped off from a resistor circuit at print A16. There are three voltage levels, depending on the
key operation.
Remedy:
Connect the Service Tool to diagnosis socket X9/17.
Use Service Tool monitor function: "EDC STATUS".
1. Delete fault. Turn ignition switch to OFF position.
a) Start engine. (charging indicator lamp off) and turn HYDRAULIK MASTER switch to EDC position.
Monitor display: "INTERLOCKED"; therefore: The diagnosis LED of the EDC is lit.
b) Carry out the following operations to test the reactions of the EDC.
Activate the EDC. Subsequently, the diagnosis LED goes out, since the EDC is activated and the TRANSPORT
indicator on the multi-controller II is lit.
The monitor display is now either "TRANSPORT" or "CONTROL", depending on the mode which was active be-
fore the engine was switched off.
c) Press the TRANSPORT / CONTROL button S60/7 on the multi-controller II once.
The modus must change and the lifting cylinders and the RAISE or LOWER indicator lamps must react. Subse-
quently, select the "CONTROL" mode so that the "QUICK-DROP" function can be checked.
NOTE: If there is no reaction of the lifting cylinders in step "c", it must be checked whether the "D+" (12V) signal is
present at the EDC Box, PIN13 when the engine is running (see schematic 1 EDC, fault code EDC 33).
Use monitor function "QUICK-DROP KEY / EMERGENCY STOP KEY".

d) Press the QUICK-DROP button S2/72 on the armrest and hold it down.
Monitor display: "QUICK-DROP".
e) Release the QUICK-DROP button.
Monitor display: "NONE".
NOTE: If a fault is active, the EDC control valve is not activated. As a result, the lifting cylinders do not move.
If the engine function does not change from step b) to e) and if the fault is active, go to step 2.
2. Turn ignition switch to OFF position. Detach plug X55 from EDC Box A55 and connect adapter 380000074 in bet-
ween. Start the engine.
3. Check the signal voltage at the EDC Box: PIN21 (signal) against PIN28 (GND).
TRANSPORT mode. Setpoint: 6.7V +/- 0.5V.
CONTROL mode. Setpoint 5.1V +/- 0.5V.
QUICK-DROP mode. Setpoint: 3.4V +/- 0.5V.
a) If the signal voltage is 10.5V +/- 0.4V, the signal line is interrupted. Go to step 4.
b) If the signal voltage is > 9.5V (up to 14V), the signal line is shorted to plus. Go to step 5.
c) If the signal voltage is < 0.5V, the signal line is shorted to GND or is interrupted.
Go to step 6.
4. Check signal line between plug X55 PIN 21 and plug X10/4 PIN8 at print A16 for correct continuity
(resistance < 1 ohm). Repair if necessary.
Connect both plugs and check the signal voltage as described in step 3.

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5. a) Check whether the signal line between plug X55 PIN 21 and plug X10/4 PIN8 is shorted to plus. Remedy the
fault and check the signal voltage as described in step 3.
b) If no fault is detected in the signal line, print A16 can be faulty. Go to steps 6 and 7.
6. a) Check the stabilised supply voltage at EDC Box A55.
To do so, turn ignition switch to ON position.
PIN2 (plus) against PIN28 (GND): Setpoint 10V +/- 0.25V.
PIN20 (GND) against PIN28 (GND-EDC Box): Setpoint 0 to 0.1V.
NOTE: If the voltage is outside the setpoint range, see fault code EDC 16.
b) Check the stabilised supply voltage at print A16.
To do so, disconnect plugs X14/4 and X10/4 and connect adapter 380000075
to the pcb. Only connect plug X14/4 to the adapter.
X14/4 PIN14 (10V +/- 0.25V) against PIN12 (GND).
7. Check the signal voltage at print A16:
X10/4 PIN8 (signal) against X14/4 PIN12 (GND).
a) The signal voltage should now correspond to CONTROL mode (5.1V +/- 0.5V).
If the CONTROL mode signal voltage is ok, go to step b.
NOTE: If the signal voltage is outside the setpoint range, the faulty print A16 must be replaced.
b) Check the TRANSPORT mode signal voltage at print A16, plug X10/4 as follows:
Connect PIN8 (signal) with PIN9 via a jumper. Setpoint: 6.7V +/- 0.5V.
c) Check QUICK-DROP signal voltage at print A16, plug X10/4 as follows:
Remove jumper (step b). Connect PIN8 (signal) with PIN5 via a jumper. Setpoint: 3.4V +/- 0.5V.
If the signal voltage corresponds to each of the three modes, the resistor circuit on print A16 is ok.
8. Check the QUICK-DROP key ("CONTROL" mode must be active for this):
Connect plug X10/4 and turn ignition switch to ON position.
Service Tool monitor function QUICK-DROP KEY / EMERGENCY STOP KEY.
a) QUICK-DROP button not operated. Monitor display: "NONE".
b) Press the QUICK-DROP key and hold it down. Monitor display: QUICK-DROP.
NOTE: If the monitor display stays at "NONE", check the wiring to the "quick-drop" key in the armrest and repair if
necessary. If the wiring is ok, replace the faulty "quick-drop" key.
9. Check the TRANSPORT / CONTROL key and the holding circuit for "TRANSPORT".
Use monitor function "EDC STATUS".
a) On starting the engine, the "INTERLOCKED" monitor display must appear.
b) Press the TRANSPORT / CONTROL button twice. The monitor display must toggle between the "TRANS-
PORT" and "CONTROL" modes each time.
If the monitor display stays at "INTERLOCKED", go to step 10.
10. Check signal change-over without keyboard: Remove the fixing screw and take the keyboard out of the multi-
controller II. Disconnect plug X21 from the keyboard. Turn ignition switch to ON position. Measure PIN3 (signal)
against PIN2 (GND).
a) Monitor display: "INTERLOCKED" = CONTROL mode: 5.1V +/- 0.5V.
b) On plug X21 connect PIN3 with PIN4.
Monitor display: TRANSPORT = TRANSPORT mode: 6.7V +/- 0.5V.
c) Disconnect the connection again.
Monitor display: "CONTROL" = CONTROL mode: 5.1V +/- 0.5V.
If the level change does not work, the wiring between print A16 and keyboard must be repaired. If there is a line
fault in plug module in the armrest, the module must be replaced. If the level change works without keyboard, go
to step 11.
11. Check the function of the keyboard: Connect the keyboard to the wiring (X21).
a) Check the supply voltage to the holding circuit in the keyboard:
X21, PIN1 (5V) against PIN2 (GND).
b) Check the key function as described in step 9.
NOTE: If the supply voltage to the keyboard is ok and the change-over still does not work, the keyboard is faulty
and must be replaced.

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EDC - 18 The signal of the TRANSPORT, CONTROL and QUICK-

DROP key functions is outside the permissible range
from DBD094271
Cause:
The signal voltage is > 9.5V or < 0.5V.

The fault is output as a flashing code by the diagnosis LED.

The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Interruption or high contact resistance in the signal line.
2. Print A16 is faulty (resistor circuit defective).
3. Signal line is shorted to other plus lines.
4. Signal line is shorted to ground (GND).
5. EDC Box A55 is faulty
6. Print ARU A30 in the armrest is faulty.
The signal voltage is tapped off from a resistor circuit at print A16. There are three voltage levels, depending on the
key operation.
Remedy:
Connect the Service Tool to diagnosis socket X9/17.
Use Service Tool monitor function: "EDC STATUS".
1. Delete fault. Turn ignition switch to OFF position.
a) Start engine. (charging indicator lamp off) and turn HYDRAULIK MASTER switch to EDC position.
Monitor display: "INTERLOCKED"; therefore: The diagnosis LED of the EDC is lit.
b) Carry out the following operations to test the reactions of the EDC.
Activate the EDC. Subsequently, the diagnosis LED goes out, since the EDC is activated and the TRANSPORT
indicator on the multi-controller II is lit.
The monitor display is now either "TRANSPORT" or "CONTROL", depending on the mode which was active be-
fore the engine was switched off.
c) Press the TRANSPORT / CONTROL button S60/7 on the multi-controller II once.
The modus must change and the lifting cylinders and the RAISE or LOWER indicator lamps must react. Subse-
quently, select the "CONTROL" mode so that the "QUICK-DROP" function can be checked.
NOTE: f there is no reaction of the lifting cylinders in step "c", it must be checked whether the "D+" (12V) signal is
present at the EDC Box, PIN13 when the engine is running (see schematic 1 EDC, fault code EDC 33).
Use monitor function "QUICK-DROP KEY / EMERGENCY STOP KEY".

d) Press the QUICK-DROP button S2/72 on the armrest and hold it down.
Monitor display: "QUICK-DROP".
e) Release the QUICK-DROP button.
Monitor display: "NONE".
NOTE: If a fault is active, the EDC control valve is not activated. As a result, the lifting cylinders do not move.
If the engine function does not change from step b) to e) and if the fault is active, go to step 2.
2. Turn ignition switch to OFF position. Detach plug X55 from EDC Box A55 and connect adapter 380000074 in bet-
ween. Start the engine.
3. Check the signal voltage at the EDC Box: PIN21 (signal) against PIN28 (GND).
TRANSPORT mode. Setpoint: 6.7V +/- 0.5V.
CONTROL mode. Setpoint 5.1V +/- 0.5V.
QUICK-DROP mode. Setpoint: 3.4V +/- 0.5V.
a) If the signal voltage is 10.5V +/- 0.4V, the signal line is interrupted. Go to step 4.
b) If the signal voltage is > 9.5V (up to 14V), the signal line is shorted to plus. Go to step 5.
c) If the signal voltage is < 0.5V, the signal line is shorted to GND or is interrupted.
Go to step 6.
4. Check signal line between plug X55 PIN21 and plug X10/4 PIN8 at print A16 for correct continuity
(resistance < 1 ohm). Repair if necessary.
Connect both plugs and check the signal voltage as described in step 3.

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5. a) Check whether the signal line between plug X55 PIN21 and plug X10/4 PIN8 is shorted to plus. Remedy the
fault and check the signal voltage as described in step 3.
b) If no fault is detected in the signal line, print A16 can be faulty. Go to steps 6 and 7.
6. a) Check the stabilised supply voltage at EDC Box A55.
To do so, turn ignition switch to ON position.
PIN2 (plus) against PIN28 (GND): Setpoint 10V +/- 0.25V.
PIN20 (GND) against PIN28 (GND-EDC Box): Setpoint 0 to 0.1V.
NOTE: If the voltage is outside the setpoint range, see fault code EDC 16.
b) Check the stabilised supply voltage at print A16.
To do so, disconnect plugs X14/4 and X10/4 and connect adapter 380000075
to the pcb. Only connect plug X14/4 to the adapter.
X14/4 PIN14 (10V +/- 0.25V) against PIN12 (GND).
7. Check the signal voltage at print A16:
X10/4 PIN8 (signal) against X14/4 PIN12 (GND).
a) The signal voltage should now correspond to CONTROL mode (5.1V +/- 0.5V).
If the CONTROL mode signal voltage is ok, go to step b.
NOTE: If the signal voltage is outside the setpoint range, the faulty print A16 must be replaced.
b) Check the TRANSPORT mode signal voltage at print A16, plug X10/4 as follows:
Connect PIN8 (signal) with PIN9 via a jumper. Setpoint: 6.7V +/- 0.5V.
c) Check QUICK-DROP signal voltage at print A16, plug X10/4 as follows:
Remove jumper (step b). Connect PIN8 (signal) with PIN5 via a jumper. Setpoint: 3.4V +/- 0.5V.
If the signal voltage corresponds to each of the three modes, the resistor circuit on print A16 is ok.
8. Check the QUICK-DROP key ("CONTROL" mode must be active for this):
Connect plug X10/4 and turn ignition switch to ON position.
Service Tool monitor function QUICK-DROP KEY / EMERGENCY STOP KEY.
a) QUICK-DROP button not operated. Monitor display: "NONE".
b) Press the QUICK-DROP key and hold it down. Monitor display: QUICK-DROP.
NOTE: If the monitor display stays at "NONE", check the wiring to the "quick-drop" key in the armrest and repair if
necessary. If the wiring is ok, replace the faulty "quick-drop" key.
9. Check the TRANSPORT / CONTROL key and the holding circuit for "TRANSPORT".
Use monitor function "EDC STATUS".
a) On starting the engine, the "INTERLOCKED" monitor display must appear.
b) Press the TRANSPORT / CONTROL button twice. The monitor display must toggle between the "TRANS-
PORT" and "CONTROL" modes each time.
If the monitor display stays at "INTERLOCKED", go to step 10.
10. Check signal change-over without keyboard: Remove the fixing screw and take the keyboard out of the multi-
controller II. Disconnect plug X21 from the keyboard. Turn ignition switch to ON position. Measure PIN3 (signal)
against PIN2 (GND).
a) Monitor display: "INTERLOCKED" = CONTROL mode: 5.1V +/- 0.5V.
b) On plug X21 connect PIN3 with PIN4.
Monitor display: TRANSPORT = TRANSPORT mode: 6.7V +/- 0.5V.
c) Disconnect the connection again.
Monitor display: "CONTROL" = CONTROL mode: 5.1V +/- 0.5V.
If the level change does not work, the wiring between print A16 and keyboard must be repaired. If there is a line
fault in Print ARU in the armrest, the module must be replaced. If the level change works without keyboard, go to
step 11.
11. Check the function of the keyboard: Connect the keyboard to the wiring (X21).
a) Check the supply voltage to the holding circuit in the keyboard:
X21, PIN1 (5V) against PIN2 (GND).
b) Check the key function as described in step 9.
NOTE: If the supply voltage to the keyboard is ok and the change-over still does not work, the keyboard is faulty
and must be replaced.

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EDC - 21 The signal of the EMERGENCY-STOP key is outside the

permissible range up to DBD094270
Cause:
The signal voltage is > 6.5V or < 2V.
The fault is output as a flashing code by the diagnosis LED.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Interruption or high contact resistance in the signal line.
2. Print A16 is faulty (resistor circuit defective).
3. Signal line is shorted to other plus lines.
4. Signal line is shorted to ground (GND).
5. EDC Box A55 is faulty.
6. Plug module A28 in the armrest is faulty.
The signal voltage is tapped off from a resistor circuit at print A16.
Remedy:
Connect the Service Tool to diagnosis socket X9/17.
Use monitor function "QUICK-DROP KEY / EMERGENCY-STOP KEY".
Delete fault. Turn ignition switch to OFF position. Start engine after 5 seconds.
Turn HYDRAULIK MASTER switch to EDC position. Monitor display: "NONE".
Press the EMERGENCY-STOP key and hold it down: Monitor display "EMERGENCY-STOP".
Release key: Monitor display "NONE".
If the monitor display does not agree with the button which was operated and if fault 21 is active again, carry out fault
diagnostics as follows:
Turn ignition switch to OFF position. Detach plug X55 from EDC Box A55 and connect measuring adapter 380000074
in between. Turn ignition switch to ON position.
1. Check signal voltage: PIN5 (signal) against PIN28 (GND).
Button S33 not pressed, setpoint: 5.1V 0.5V.
Button S33 pressed, setpoint: 3.4V 0.5V.
a) If the signal voltage is 10.5V 0.4V, the signal line is interrupted. Go to step 2.
b) If the signal voltage is > 6.5V (up to 14V), the signal line is shorted to plus. Go to step 3.
c) If the signal voltage is < 2.0V, the signal line is shorted to GND or print A16 or the EDC Box is defective.
Go to step 4.
2. Check signal line between plug X55 PIN 5 and plug X10/4 PIN3 at print A16 for correct continuity
(resistance < 1 ohm). Repair if necessary.
Connect both plugs and check the signal voltage as described in step 1.
3. a) Check whether the signal line between plug X55 PIN 5 and plug X10/4 PIN3 is shorted to plus. Remedy the
fault and check the signal voltage as described in step 1.
b) If no fault is detected in the signal line, print A16 can be faulty. Go to steps 5 and 6.
4. a) Check whether the signal line between plug X55 PIN 5 and plug X10/4 PIN3 is shorted to GND. Remedy the
fault and check the signal voltage as described in step 1.
b) If no fault is detected in the signal line, go to steps 5 and 6.
5. a) Check the stabilised supply voltage at EDC Box A55.
To do so, turn ignition switch to ON position.
PIN2 (plus) against PIN28 (GND): Setpoint 10V 0.25V.
PIN20 (GND) against PIN28 (GND-EDC Box): Setpoint 0 to 0.1V.
NOTE: If the voltage is outside the setpoint range, see fault code EDC 16.
b) Check the stabilised supply voltage at print A16.
To do so, disconnect plugs X14/4 and X10/4 and connect adapter 380000075
to the pcb. Only connect plug X14/4 to the adapter.
X14/4 PIN14 (10V 0.25V) against PIN12 (GND).
6. Check the signal voltage at print A16:
X10/4 PIN3 (signal) against X14/4 PIN12 (GND).
a) Setpoint 5.1V 0.5V corresponds to "EMERGENCY-STOP" key not operated.
Monitor display "NONE".
NOTE: If the signal voltage is outside the setpoint range, the faulty print A16 must be replaced.

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b) Connect X10/4 PIN6 with X14/4 PIN12 via a jumper (substitutes "EMERGENCY-STOP" key).
Setpoint 3.4V 0.5V corresponds to "EMERGENCY-STOP" key pressed.
Monitor display "EMERGENCY-STOP".
NOTE: If the signal voltages correspond to the setpoints specified in a) and b), the resistor circuit on print A16 is ok.
If plug X10/4 is connected and the signal voltages changes to < 2.9 V or > 5.6 V, the faulty EDC Box must be repla-
ced.
7. Check the signal voltage at plug module:
On plug X18/4, connect PIN4 to PIN5. Setpoint 3.4V 0.5V (corresponds to "EMERGENCY-STOP" key pressed).
Monitor display "EMERGENCY-STOP".
Then interrupt the connection again. Monitor display: "NONE".
If the voltage does not change, repair lines between A16 and A28.
On plug X28/14, connect PIN1 to PIN2. Setpoint 3.4V 0.5V (corresponds to "EMERGENCY-STOP" key pressed).
Monitor display "EMERGENCY-STOP". Then interrupt the connection again. Monitor display: "NONE". If the
voltage does not change, the fault is caused by plug module A28. It must be replaced.
8. Check the EMERGENCY STOP key:
Connect plug X10/4 and turn ignition switch to ON position.
Service Tool monitor function "QUICK-DROP KEY / EMERGENCY STOP KEY".
a) EMERGENCY-STOP key S33 not operated. Monitor display: "NONE".
b) Press the EMERGENCY-STOP key and hold it down. Monitor display: "EMERGENCY-STOP".
NOTE: If the monitor display does not change, check the wiring to the "EMERGENCY-STOP" key in the armrest
and repair if necessary. If the wiring is ok, replace the faulty "EMERGENCY-STOP" key.

EDC - 21 The signal of the EMERGENCY-STOP key is outside the

permissible range from DBD094271
Cause:
The signal voltage is > 6.5V or < 2V.

The fault is output as a flashing code by the diagnosis LED.

The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Interruption or high contact resistance in the signal line.
2. Print A16 is faulty (resistor circuit defective).
3. Signal line is shorted to other plus lines.
4. Signal line is shorted to ground (GND).
5. EDC Box A55 is faulty.
6. Print ARU A30 in the armrest is faulty.
The signal voltage is tapped off from a resistor circuit at print A16.
Remedy:
Connect the Service Tool to diagnosis socket X9/17.
Use monitor function "QUICK-DROP KEY / EMERGENCY-STOP KEY".
Delete fault. Turn ignition switch to OFF position. Start engine after 5 seconds.
Turn HYDRAULIK MASTER switch to EDC position. Monitor display: "NONE".
Press the EMERGENCY-STOP key and hold it down: Monitor display "EMERGENCY-STOP".
Release key: Monitor display "NONE".
If the monitor display does not agree with the button which was operated and if fault 21 is active again, carry out fault
diagnostics as follows:
Turn ignition switch to OFF position. Detach plug X55 from EDC Box A55 and connect measuring adapter 380000074
in between. Turn ignition switch to ON position.
1. Check signal voltage: PIN5 (signal) against PIN28 (GND).
Button S33 not pressed, setpoint: 5.1V +/- 0.5V.
Button S33 pressed, setpoint: 3.4V +/- 0.5V.
a) If the signal voltage is 10.5V +/- 0.4V, the signal line is interrupted. Go to step 2.
b) If the signal voltage is > 6.5V (up to 14V), the signal line is shorted to plus. Go to step 3.
c) If the signal voltage is < 2.0V, the signal line is shorted to GND or print A16 or the EDC Box is defective.
Go to step 4.

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2. Check signal line between plug X55 PIN5 and plug X10/4 PIN3 at print A16 for correct continuity
(resistance < 1 ohm). Repair if necessary.
Connect both plugs and check the signal voltage as described in step 1.
3. a) Check whether the signal line between plug X55 PIN5 and plug X10/4 PIN3 is shorted to plus. Remedy the
fault and check the signal voltage as described in step 1.
b) If no fault is detected in the signal line, print A16 can be faulty. Go to steps 5 and 6.
4. a) Check whether the signal line between plug X55 PIN5 and plug X10/4 PIN3 is shorted to GND. Remedy the
fault and check the signal voltage as described in step 1.
b) If no fault is detected in the signal line, go to steps 5 and 6.
5. a) Check the stabilised supply voltage at EDC Box A55.
To do so, turn ignition switch to ON position.
PIN2 (plus) against PIN28 (GND): Setpoint 10V +/- 0.25V.
PIN20 (GND) against PIN28 (GND-EDC Box): Setpoint 0 to 0.1V.
NOTE: If the voltage is outside the setpoint range, see fault code EDC 16.
b) Check the stabilised supply voltage at print A16.
To do so, disconnect plugs X14/4 and X10/4 and connect adapter 380000075
to the pcb. Only connect plug X14/4 to the adapter.
X14/4 PIN14 (10V +/- 0.25V) against PIN12 (GND).
6. Check the signal voltage at print A16:
X10/4 PIN3 (signal) against X14/4 PIN12 (GND).
a) Setpoint 5.1V +/- 0.5V corresponds to "EMERGENCY-STOP" key not operated.
Monitor display "NONE".
NOTE: If the signal voltage is outside the setpoint range, the faulty print A16 must be replaced.
b) Connect X10/4 PIN6 with X14/4 PIN12 via a jumper (substitutes "EMERGENCY-STOP" key).
Setpoint 3.4V +/- 0.5V corresponds to "EMERGENCY-STOP" key pressed.
Monitor display "EMERGENCY-STOP".
NOTE: If the signal voltages correspond to the setpoints specified in a) and b), the resistor circuit on print A16 is ok.
If plug X10/4 is connected and the signal voltages changes to < 2.9 V or > 5.6 V, the faulty EDC Box must be repla-
ced.
7. Check the signal voltage at Print ARU :
On plug X18/4, connect PIN4 to PIN5. Setpoint 3.4V +/- 0.5V (corresponds to "EMERGENCY-STOP" key pres-
sed). Monitor display "EMERGENCY-STOP".
Then interrupt the connection again. Monitor display: "NONE".
If the voltage does not change, repair lines between A16 and A30.
On plug X30/14, connect PIN1 to PIN2. Setpoint 3.4V +/- 0.5V (corresponds to "EMERGENCY-STOP" key pres-
sed). Monitor display "EMERGENCY-STOP". Then interrupt the connection again. Monitor display: "NONE". If
the voltage does not change, the fault is caused by Print ARU A30. It must be replaced.
8. Check the EMERGENCY STOP key:
Connect plug X10/4 and turn ignition switch to ON position.
Service Tool monitor function "QUICK-DROP KEY / EMERGENCY STOP KEY".
a) EMERGENCY-STOP key S33 not operated. Monitor display: "NONE".
b) Press the EMERGENCY-STOP key and hold it down. Monitor display: "EMERGENCY-STOP".
NOTE: If the monitor display does not change, check the wiring to the "EMERGENCY-STOP" key in the armrest
and repair if necessary. If the wiring is ok, replace the faulty "EMERGENCY-STOP" key.

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EDC - 22 Angle of rotation sensor signal is faulty

Description:
The signal voltage of the angle of rotation sensor B9/1 on the rear lifting gear is outside the valid range.
(< 2.15 V or > 7.7 V)
Possible Cause:
1. Connector or cabling faulty
2. Angle of rotation sensor is not adjusted correctly
3. Angle of rotation sensor is faulty
4. The EDC Box A55 is faulty
Reaction:
The error is output as a flashing code by the diagnosis LCD. The error is stored and signalled at the ADIC with a
warning triangle.
Remedy:
NOTE: During this trouble shooting and during the adjustment of the angle of rotation sensor no built-on device is to
be mounted on the lifting gear.
1. Check the connector B9/1 and the connector X55 of the EDC box.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right positions and the
connectors are secure. If necessary, undertake repair or replacement.
b) If the connectors are okay, continue to step 2.
2. Check the supply voltage of the sensor using test adapter 380000067.
a) Connect the test adapter to connector B9/1. (Sensor unplugged) Start the engine and measure the supply
voltage between plug:
B9/1 PIN3 and PIN1.
The displayed voltage must be 10 volts ( 0.25 V). If the voltage is not reached, go to step 3.
b) If the supply voltage is correct. go to step 4.
3. Check the cabling to the sensor for short-circuit against ground and for disconnection.
a) Disconnect the connector X55 from the EDC box. Check between connector:
B9/1 PIN3 and ground
B9/1 PIN2 and ground
B9/1 PIN3 and X55 PIN39
B9/1 PIN2 and X55 PIN6
If a short-circuit to ground or a disconnect is displayed, you must repair or replace the cable.
b) If the cabling is OK, go to step 4.
4. Check the sensor signal voltage.
a) Connect the test adapter on the sensor and the connector X55 to the EDC box. Start the engine and lower the
lifting gear to the lower mechanical stop with the RAISE / LOWER pushbutton. Measure the signal voltage bet-
ween connector:
B9/1 PIN2 and PIN1.
The displayed voltage must be about 2.7 volts.
Raise the lifting gear to the maximum lifting height (overlift) with the RAISE / LOWER pushbutton. The displayed
voltage must be about 7.4 volts.
b) If no signal voltage is measured, then test the signal cable for short-circuit against ground and for disconnec-
tion. (see step 3) If the signal cable is OK, the sensor must be replaced. (see Chapter 8005)
c) If the signal voltage is above or below the limit value (< 2.15 V or > 7.7 V), the sensor must be set. (Step 5)
d. If the signal voltage is correct and the fault continues to be active, you must replace the EDC box.
5. Setting the sensor:
The angle of rotation sensor B9/1 is mounted on the left-hand bearing block of the lifting shaft. The adjustment is
done by elongated holes in the sensor housing. Ensure that the bearing of the lifting shaft and the lifting cylinder
as well as the sensor fastening are in order.

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• Apply the test adapter 380000067 in the plug-in connector on sensor B9/1.
• Start the engine and lower the lifting gear with the RAISE/LOWER pushbutton as far as the lower mechani-
cal stop. If the lifting gear does not go to the lower mechanical stop, use the emergency LOWER operation.
• Loosen the sensor fastening screws until it can be twisted easily.
• Measure the signal voltage between PIN2 and PIN1. Twist the sensor until a signal voltage of 2.7 volts ( 0.02
V) is displayed. Tighten the fixing screws.
• Raise the lifting gear using the RAISE/LOWER pushbutton up to the maximum lift height and check the
signal voltage. (approx. 7.4 V)
Check that sufficient clearance (3 - 5 mm lifting cylinder piston travel) is given to the upper mechanical stop.
To do this use the emergency RAISE operation.
IMPORTANT: If the clearance of 3 - 5 mm to the upper mechanical stop is not achieved, the setting by twisting the
rotation angle sensor must be correspondingly corrected.

EDC - 23 The signal of SETPOINT potentiometer R6/1 is outside the

permissible range
Cause:
The signal voltage is > 10.3V.
The signal voltage must be within a certain range (0 to 10V).
The fault is output as a flashing code by the diagnosis LED.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Interruption or high contact resistance in the signal line.
2. The potentiometer is defective.
3. Print A16 is faulty.
4. The signal line is shorted to other plus lines.
5. EDC Box A55 is faulty.
Remedy:
Connect the Service Tool to diagnosis socket X9/17.
Use monitor function "SETPOINT POTENTIOMETER POSITION".

The monitor displays the value in "%". The following assignment applies:
a) Potentiometer R6/1 in position "0": Monitor display "5 %" = 0 V.
b) Potentiometer R6/1 in position "10": Monitor display "95%" = 10 V.
Delete fault. Turn ignition switch to OFF position. Start engine after 5 seconds.
Turn HYDRAULIK MASTER switch to EDC position.
Turn the adjustment wheel on potentiometer R6/1 and check whether the percentage in the monitor function has
changed.
If fault 23 is active again, carry out the fault diagnostics as follows:
Turn ignition switch to OFF position. Detach plug X55 from EDC Box A55 and connect adapter 380000074 in bet-
ween. Turn ignition switch to ON position.
1. a) Check the stabilised supply voltage at EDC Box A55.
To do so, turn ignition switch to ON position.
PIN2 (plus) against PIN28 (GND): Setpoint 10V +/- 0.25V.
PIN20 (GND) against PIN28 (GND-EDC Box): Setpoint 0 to 0.1V.
NOTE: If the voltage is outside the setpoint range, see fault code EDC 16.
b) Check the signal voltage of potentiometer R6/1 at EDC Box A55:
PIN22 (signal) against PIN28 (GND).
Setpoint 0V to 10V, corresponds to monitor display 5 % to 95 %.
If the signal voltage is outside the setpoint range, go to step 2.
2. a) Check the stabilised supply voltage at print A16.
Disconnect plug X14/4 and connect adapter 380000075 in between.
PIN14 (plus) against PIN12 (GND): Setpoint 10V +/- 0.25V.
If the voltage does not meet the setpoint, the wiring between EDC Box A55 and print A16 must be repaired.
If the supply voltage is ok, go to step b.

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b) Check the signal voltage of potentiometer R6/1 at the output of print A16:
X14/4 PIN13 (signal) against X14/4 PIN12 (GND).
Setpoint 0V to 10V, corresponds to monitor display 5 % to 95 %.
If the supply voltage does not meet the setpoint, go to step c).

c) Check the signal voltage of potentiometer R6/1 at the input of print A16:
To do so, disconnect plug X5/6.
X5/6 PIN3 (signal) against X14/4 PIN12 (GND).
Setpoint 0V to 10V, corresponds to monitor display 5 % to 95 %.
If the signal voltage at plug X5/6 PIN3 is ok, the faulty print A16 must be replaced.
If the signal voltage at plug X5/6 does not meet the setpoint, go to step 3.
3. a) Check the stabilised supply voltage to potentiometer R6/1 at print A16.
X5/6 PIN2 (plus) against X14/4 PIN12 (GND): Setpoint 10V +/- 0.25V.
X5/6 PIN1 (GND) against X14/4 PIN12 (GND): Setpoint 0 to 0.1V.
If the voltage does not meet the setpoint, the faulty print A16 must be replaced. If, subsequently, the supply volta-
ge is ok, repeatedly check the signal voltage at plug X5/6 (see step 2c).
If the signal voltage at plug X5/6 does not meet the setpoint, go to step b):

b) Check potentiometer R6/1 at plug X5/6:

Disconnect plug X5/6. Check wiring and plug-in contacts.
Perform the following resistance measurements:
PIN1 against PIN2: Setpoint 4.7 kohms +/- 20%.
PIN1 against PIN3 and PIN2 against PIN3: Setpoint 0 ohms to 4.7 kohms +/- 20%,
depending on the position of the adjuster wheel.
Replace the faulty potentiometer.
4. Delete fault 23. Turn ignition switch to OFF position, turn back to ON position after min. 5 seconds. Check that
fault 23 is not displayed any longer.

EDC - 24 The signal of LIFT LIMITER potentiometer R6/2 is outside

the permissible range
Cause:
The signal voltage is > 10.3V.
The signal voltage must be within a certain range (0 to 9.5V).

The fault is output as a flashing code by the diagnosis LED.

The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Interruption or high contact resistance in the signal line.
2. The potentiometer is defective.
3. Print A16 is faulty (series resistor defective).
4. The signal line is shorted to other plus lines.
5. EDC Box A55 is faulty.
Remedy:
Connect the Service Tool to diagnosis socket X9/17.
Use monitor function "UPPER LIMIT POSITION POTENTIOMETER POSITION".

The monitor displays the value in "%". The following assignment applies:
a) Potentiometer R6/2 in position "0": Monitor display "5 %" = 0 V.
b) Potentiometer R6/2 in position "10": Monitor display "95%" = 9.5 V.
Delete fault. Turn ignition switch to OFF position. Start engine after 5 seconds.
Turn HYDRAULIK MASTER switch to EDC position.
Turn the adjustment wheel on potentiometer R6/2 and check whether the percentage in the monitor function has
changed.
If fault 24 is active again, carry out the fault diagnostics as follows:
Turn ignition switch to OFF position. Detach plug X55 from EDC Box A55 and connect adapter 380000074 in bet-
ween. Turn ignition switch to ON position.

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1. a) Check the stabilised supply voltage at EDC Box A55.
To do so, turn ignition switch to ON position.
PIN2 (plus) against PIN28 (GND): Setpoint 10V +/- 0.25V.
PIN20 (GND) against PIN28 (GND-EDC Box): Setpoint 0 to 0.1V.
NOTE: If the voltage is outside the setpoint range, see fault code EDC 16.
b) Check the signal voltage of potentiometer R6/2 at EDC Box A55:
PIN3 (signal) against PIN28 (GND).
Setpoint 0V to 9.5V, corresponds to monitor display 5 % to 95 %.
If the signal voltage is outside the setpoint range, go to step 2.
2. a) Check the stabilised supply voltage at print A16.
Disconnect plug X14/4 and connect adapter 380000075 in between.
PIN14 (plus) against PIN12 (GND): Setpoint 10V +/- 0.25V.
If the voltage does not meet the setpoint, the wiring between EDC Box A55 and print A16 must be repaired.
If the supply voltage is ok, go to step b.

b) Check the signal voltage of potentiometer R6/2 at the output of print A16:
X14/4 PIN6 (signal) against X14/4 PIN12 (GND).
Setpoint 0V to 9.5V, corresponds to monitor display 5 % to 95 %.
If the supply voltage does not meet the setpoint, go to step c).

c) Check the signal voltage of potentiometer R6/2 at the input of print A16:
To do so, disconnect plug X3/17.
X5/17 PIN3 (signal) against X14/4 PIN12 (GND).
Setpoint 0V to 9.5V, corresponds to monitor display 5 % to 95 %.
If the signal voltage at plug X3/17 is ok, the faulty print A16 must be replaced.
If the signal voltage at plug X3/17 does not meet the setpoint, go to step 3.
3. a) Check the stabilised supply voltage to potentiometer R6/2 at print A16.
X3/17 PIN1 (plus) against X14/4 PIN12 (GND): Setpoint 9.5V +/- 0.25V.
X3/17 PIN2 (GND) against X14/4 PIN12 (GND): Setpoint 0 to 0.1V.
If the voltage is outside the setpoint range, go to step b.

b) Check series resistor R10 of the potentiometer supply at print A16.

Turn ignition switch to OFF position.
Disconnect plug X3/17 (wiring to pot R6/2) from print A16.
Resistance measurement at plug X14/4 PIN14 against plug X3/17 PIN1:
Setpoint 261 ohms +/- 10 %.
If the setpoint is not met, the faulty print A16 must be replaced.
If, subsequently, the supply voltage is ok, repeatedly check the signal voltage at plug X3/17 (see step 2c).
If the signal voltage at plug X3/17 does not meet the setpoint, go to step c):

c) Check potentiometer R6/2 at plug X3/17:

Disconnect plug X3/17. Check wiring and plug-in contacts.
Perform the following resistance measurements:
PIN1 against PIN2: Setpoint 4.7 kohms +/- 20%.
PIN1 against PIN3 and PIN2 against PIN3: Setpoint 0 ohms to 4.7 kohms +/- 20%,
depending on the position of the adjuster wheel.
Replace the faulty potentiometer.
4. Delete fault 24. Turn ignition switch to OFF position, turn back to ON position after min. 5 seconds. Check that
fault 24 is not displayed any longer.

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EDC - 31 Signal from force sensor, right, B10/2 is faulty

Cause:
The signal voltage is (or was briefly) < 2.15 VDC or > 7.7 VDC.

The fault is output as a flashing code by the diagnosis LED.

The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. The signal line is interrupted.
2. The signal line is shorted to the plus or GND supply.
3. Interruption or contact fault in the plus or GND supply line.
4. Force sensor B10/2 is (was briefly) overloaded, but not damaged.
5. The force sensor is faulty (e.g. the permissible overload was exceeded).
6. The EDC Box A55 is faulty.
Remedy:
Force sensor B10/2 is at the same time the bearing bolt for the right-hand lower linkage.
NOTE: During fault diagnostics and fault rectification, no implement may be fitted to the hitch linkage.
User monitor function "DRAFT, FORCE SENSOR REAR RIGHT"

The monitor display is in "N" (Newton). The following assignment applies:

a) Force sensor not loaded: Monitor display 0 N to max. 500 N = signal voltage approx. 5 Volt.
b) Force sensor loaded at nominal tractive load (60 kN): Monitor display 60000 N = signal voltage approx. 2.5 Volt.
c) Force sensor loaded at nominal thrust load (- 60 kN): Monitor display approx. - 60000 N = signal voltage
approx. 7.5 Volt.
1. Start fault diagnostics as follows:
a) Apply the parking brake, start the engine and engage the parking interlock.
b) Turn hydraulic master to EDC position. Use the rear button to lower the hitch linkage.
c) Delete fault, then turn ignition switch to OFF position, then turn back to ON position.
d) If fault 31 is activated again, although the monitor display is within the permissible range (- 60000 N to 60000
N), the faulty EDC Box A55 must be replaced.
If fault 31 is not activated again, still continue fault diagnostics (go to step e).
If fault 31 is activated again and if the monitor display is outside the permissible range of - 60000 N to 60000 N,
go to step 2).
e) Move the cable to the plug-in connection at the force sensor. If the % value on the monitor changes or if fault 31
is activated again, continue fault diagnostics as follows:
Turn the ignition switch to the OFF position. Disconnect the plugs on the power sensor. Check the condition of
the plug-in contacts. Repair the cable connection in the plug or plug-in connection.
2. Check the supply voltage to force sensor B10/2:
a) Turn the ignition switch to the OFF position.
b) On the plug of force sensor B10/2, connect adapter 380000067 in between.
c) Turn the ignition switch to the ON position.
d) Check the supply (stabilised d.c. voltage) to the force sensor:
PIN3 (10V +/- 0.2V) against PIN1 (GND).
If the setpoint is met, go to step 3.
If the setpoint is not met, temporarily disconnect the sensor cable on the adapter. If, subsequently, the supply
voltage is ok, the plug-in connection or the cable or the sensor is defective. Replace the defective sensor.
If the setpoint is still not reached after disconnecting the sensor, see fault code 16 (stabilised supply voltage faul-
ty).
3. Check the signal voltage of force sensor B10/2:
PIN2 (signal) against PIN1 (GND): Setpoint (sensor not loaded) Monitor display 0 N to max. 500 N = signal volta-
ge approx. 5 VDC.
If the signal voltage considerably deviates from the setpoint, the cause must be narrowed down step by step.
a) Disconnect the plug of the sensor cable from adapter 380000067. If the signal voltage changes erratically, go
to step b. If the voltage of the signal line does not change, the signal line up to EDC Box A55 must be checked:
The signal line must not be shorted to other lines.
Use an ohmmeter to check signal line continuity from the sensor’s cable plug up to plug-in connection X55 at the
ECD Box. The resistance must be < 1 ohm.
b) Reconnect the plug of the sensor cable to the adapter. Start the engine and use the rear button to raise and
lower the hitch linkage. The signal voltage may only slightly change.
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c) Turn the ignition switch to the OFF position. Check the sensor for mechanical influences or damage. For in-
stance, the ball of the lower linkage joint has become rusted into the sensor or (and) the lower linkage, or the
sensor was bent by overload or the sensor has been fitted under tension due to incorrect assembly. Remedy the
fault or replace the faulty sensor.
d) If the signal line is ok, but if the monitor display or the signal voltage considerably deviates from the setpoint
when a new or other intact sensor is connected, the fault is caused by a faulty EDC Box A 55 (cause: load resi-
stance < 10 kOhms). Replace the EDC Box.
4. Delete fault 31. Turn ignition switch to OFF position, turn back to ON position after min. 5 seconds. Check that
fault 31 is not displayed any longer.

EDC - 32 Signal from force sensor, left, B10/1 is faulty

Cause:
The signal voltage is (or was briefly) < 2.15 VDC or > 7.7 VDC.
The fault is output as a flashing code by the diagnosis LED.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. The signal line is interrupted.
2. The signal line is shorted to the plus or GND supply.
3. Interruption or contact fault in the plus or GND supply line.
4. The force sensor is (was briefly) overloaded, but not damaged.
5. The force sensor is faulty (e.g. the permissible overload was exceeded).
6. EDC Box A55 is faulty.
Remedy:
Force sensor B10/1 is at the same time the bearing bolt for the left-hand lower linkage.
NOTE: During fault diagnostics and fault rectification, no implement may be fitted to the hitch linkage.
User monitor function "DRAFT, FORCE SENSOR REAR LEFT"

The monitor display is in "N" (Newton). The following assignment applies:

a) Force sensor not loaded: Monitor display 0 N to max. 500 N = signal voltage approx. 5 Volt.
b) Force sensor loaded at nominal tractive load (60 kN): Monitor display 60000 N = signal voltage approx. 2.5 Volt.
c) Force sensor loaded at nominal thrust load (- 60 kN): Monitor display approx. - 60000 N = signal voltage approx.
7.5 Volt.
1. Start fault diagnostics as follows:
a) Apply the parking brake, start the engine and engage the parking interlock.
b) Turn hydraulic master to EDC position. Use the rear button to lower the hitch linkage.
c) Delete fault, then turn ignition switch to OFF position, then turn back to ON position.
d) If fault 32 is activated again, although the monitor display is within the permissible range
(- 60000 N to 60000 N), the faulty EDC Box must be replaced.
If fault 32 is not activated again, still continue fault diagnostics (go to step e).
If fault 32 is activated again and if the monitor display is outside the permissible range of - 60000 N to 60000 N,
go to step 4 and note the check with respect to ECCU2. If the resulting signal value does not change, go to step 2).
e) Move the cable to the plug-in connection at the force sensor. If the % value on the monitor changes or if fault
32 is activated again, continue fault diagnostics as follows:
Turn the ignition switch to the OFF position. Disconnect the plugs on the power sensor. Check the condition of
the plug-in contacts. Repair the cable connection in the plug or plug-in connection.
2. Check the supply voltage to force sensor B10/1:
a) Turn the ignition switch to the OFF position.
b) On the plug of force sensor B10/1, connect adapter 380000067 in between.
c) Turn the ignition switch to the ON position.
d) Check the supply (stabilised d.c. voltage) to the force sensor:
PIN3 (10V +/- 0.2V) against PIN1 (GND).
If the setpoint is met, go to step 3.
If the setpoint is not met, temporarily disconnect the sensor cable on the adapter. If, subsequently, the supply
voltage is ok, the plug-in connection or the cable or the sensor is defective. Replace the defective sensor.
If the setpoint is still not reached after disconnecting the sensor, see fault code 16
(stabilised supply voltage faulty).

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3. Check the signal voltage of force sensor B10/1:
PIN2 (signal) against PIN1 (GND): Setpoint (sensor not loaded)
Monitor display 0 N to max. 500 N = signal voltage approx. 5 VDC.
If the signal voltage considerably deviates from the setpoint, the cause must be narrowed down step by step.
a) Disconnect the plug of the sensor cable from adapter 380000067. If the signal voltage changes erratically, go
to step b. If the voltage of the signal line does not change, the signal line up to EDC Box A55 must be checked:
The signal line must not be shorted to other lines.
Use an ohmmeter to check signal line continuity from the sensor’s cable plug up to plug-in connection X55 at the
ECD Box. The resistance must be < 1 ohm.
b) Reconnect the plug of the sensor cable to the adapter. Start the engine and use the rear button to raise and
lower the hitch linkage. The signal voltage may only slightly change.
c) Turn the ignition switch to the OFF position. Check the sensor for mechanical influences or damage. For in-
stance, the ball of the lower linkage joint has become rusted into the sensor or (and) the lower linkage, or the
sensor was bent by overload or the sensor has been fitted under tension due to incorrect assembly. Remedy the
fault or replace the faulty sensor.
d) If the signal line is ok, but if the monitor display or the signal voltage considerably deviates from the setpoint
when a new or other intact sensor is connected, the fault is caused by a faulty EDC Box A 55 (cause: load resi-
stance < 10 kOhms). Replace the EDC Box.
4. Delete fault 32. Turn ignition switch to OFF position, turn back to ON position after min. 5 seconds. Check that
fault 32 is not displayed any longer.

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EDC - 33 Supply voltage too low (< 11.5 V)

Cause:
The supply voltage is < 11.5V.
The fault is output as a flashing code by the diagnosis LED.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Battery faulty or insufficiently charged.
2. Plus or (and) ground line between alternator or battery and EDC Box damaged.
3. Voltage regulator or alternator defective.
4. EDC Box A55 faulty.
Remedy:
Use monitor function "EDC FAULT ACTIVE - YES / NO".

Turn ignition switch to OFF position.

Start engine and make sure that the charging indicator lamp is off.
If fault 33 is active again, carry out fault diagnostics as follows:
1. a)
Up to DBD100000:
Check the fuses for the EDC plus supply F91 (+30) 7.5A, F49 (+15/1) 7.5A, F21 (D+) 5A.
From DBD100001:
Check the fuses for the EDC plus supply F210 (+30) 7.5A, F49 (+15/1) 7.5A, F21 (D+) 5A.
b) While the engine is running (charging indicator lamp off), check the alternator charging voltage and the battery
voltage.
Charging voltage setpoint at different engine speeds and loads: 13.8V to 14.5V.
If the charging voltage of the alternator is ok, continue fault diagnostics with step 2.
If the alternator charging voltage is < 13.8V, go to step 3.
2. Check ground connection and plus supply lines from the generator via the battery up to EDC Box A55:
Disconnect plug X55 and connect adapter 380000074 in between.
Check supply voltage (+30) at PIN29 against PIN28 and 46 (GND). Start the engine.
The voltage should be min. 12.5 to 14V.
Check supply voltage (+15/1 ) at PIN24 against PIN28 and 46 (GND). The voltage should be 12.5 to 14V.
While the engine is running, make sure that the charging indicator lamp is off.
Check the (D+) voltage at PIN13.
If the wiring and the supply voltage at the EDC Box is ok, but fault 33 comes up again when the engine is restarted,
the EDC Box must be replaced.
3. Replace the voltage regulator of the alternator or the alternator.
4. While the engine is running (charging indicator lamp off), repeatedly check the charging voltage and check that
fault 33 is no longer active.

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EDC - 34 The signal of LOWERING SPEED potentiometer R6/4 is

outside the permissible range
Cause:
The signal voltage is > 10.3V.
The signal voltage must be within a certain range (0 to 10V).
The fault is output as a flashing code by the diagnosis LED.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Interruption or high contact resistance in the signal line.
2. The potentiometer is defective.
3. Print A16 is faulty.
4. The signal line is shorted to other plus lines.
5. The EDC Box A55 is faulty.
Remedy:
Connect the Service Tool to diagnosis socket X9/17.
Use monitor function "LOWERING THROTTLE POTENTIOMETER POSITION".

The monitor displays the value in "%". The following assignment applies:
a) Potentiometer R6/4 in position "0": Monitor display "5 %" = 0 V.
b) Potentiometer R6/4 in position "10": Monitor display "95%" = 10 V.
Delete fault. Turn ignition switch to OFF position. Start engine after 5 seconds.
Turn HYDRAULIK MASTER switch to EDC position.
Turn the adjustment wheel on potentiometer R6/4 and check whether the percentage in the monitor function has
changed.
If fault 34 is active again, carry out the fault diagnostics as follows:
Turn ignition switch to OFF position. Detach plug X55 from EDC Box A55 and connect measuring adapter 380000074
in between. Turn ignition switch to ON position.
1. a) Check the stabilised supply voltage at EDC Box A55.
To do so, turn ignition switch to ON position.
PIN2 (plus) against PIN28 (GND): Setpoint 10V +/- 0.25V.
PIN20 (GND) against PIN28 (GND-EDC Box): Setpoint 0 to 0.1V.
NOTE: If the voltage is outside the setpoint range, see fault code EDC 16.
b) Check the signal voltage of potentiometer R6/4 at EDC Box A55:
PIN23 (signal) against PIN28 (GND).
Setpoint 0V to 10V, corresponds to monitor display 5 % to 95 %.
If the signal voltage is outside the setpoint range, go to step 2.
2. a) Check the stabilised supply voltage at print A16.
Disconnect plug X14/4 and connect measuring adapter 380000075 in between.
PIN14 (plus) against PIN12 (GND): Setpoint 10V +/- 0.25V.
If the voltage does not meet the setpoint, the wiring between EDC Box A55 and print A16 must be repaired.
If the supply voltage is ok, go to step b.

b) Check the signal voltage of potentiometer R6/4 at the output of print A16:
X14/4 PIN4 (signal) against X14/4 PIN12 (GND).
Setpoint 0V to 10V, corresponds to monitor display 5 % to 95 %.
If the supply voltage does not meet the setpoint, go to step c).

c) Check the signal voltage of potentiometer R6/4 at the input of print A16:
To do so, disconnect plug X3/16.
X5/16 PIN3 (signal) against X14/4 PIN12 (GND).
Setpoint 0V to 10V, corresponds to monitor display 5 % to 95 %.

If the signal voltage at plug X3/16 is ok, the faulty print A16 must be replaced.
If the signal voltage at plug X3/16 does not meet the setpoint, go to step 3.

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3. a) Check the stabilised supply voltage to potentiometer R6/4 at print A16.
X3/16 PIN1 (plus) against X14/4 PIN12 (GND): Setpoint 10V +/- 0.25V.
X3/16 PIN2 (GND) against X14/4 PIN12 (GND): Setpoint 0 to 0.1V.
If the voltage does not meet the setpoint, the faulty print A16 must be replaced. If, subsequently, the supply volta-
ge is ok, repeatedly check the signal voltage at plug X3/16 (see step 2c).
If the signal voltage at plug X3/16 does not meet the setpoint, go to step b):

b) Check potentiometer R6/4 at plug X3/16:

Disconnect plug X3/16. Check wiring and plug-in contacts.
Perform the following resistance measurements:
PIN1 against PIN2: Setpoint 4.7 kohms +/- 20%.
PIN1 against PIN3 and PIN2 against PIN3: Setpoint 0 ohms to 4.7 kohms +/- 20%,
depending on the position of the adjuster wheel.
Replace the faulty potentiometer.
4. Delete fault 34. Turn ignition switch to OFF position, turn back to ON position after min. 5 seconds. Check that
fault 34 is not displayed any longer.

EDC - 36 The signal of MIXED CONTROL potentiometer R6/3 is

outside the permissible range
Cause:
The signal voltage is > 10.3V.
The signal voltage must be within a certain range (0 to 10V).
The fault is output as a flashing code by the diagnosis LED.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Interruption or high contact resistance in the signal line.
2. The potentiometer is defective.
3. Print A16 is faulty (resistor circuit defective).
4. The signal line is shorted to other plus lines.
5. EDC Box A55 is faulty.
Remedy:
Connect the Service Tool to diagnosis socket X9/17.
Use monitor function "POSITION/TRACTIVE FORCE
CONTROL POTENTIOMETER POSITION".

The monitor displays the value in "%". The following assignment applies:
a) Potentiometer R6/3 in position "0": Monitor display "5 %" = 0 V.
b) Potentiometer R6/3 in position "10": Monitor display "95%" = 10 V.
Delete fault. Turn ignition switch to OFF position. Start engine after 5 seconds.
Turn HYDRAULIK MASTER switch to EDC position.
Turn the adjustment wheel on potentiometer R6/3 and check whether the percentage in the monitor function has
changed.
If fault 36 is active again, carry out the fault diagnostics as follows:
Turn ignition switch to OFF position. Detach plug X55 from EDC Box A55 and connect measuring adapter 380000074
in between. Turn ignition switch to ON position.
1. a) Check the stabilised supply voltage at EDC Box A55.
To do so, turn ignition switch to ON position.
PIN2 (plus) against PIN28 (GND): Setpoint 10V +/- 0.25V.
PIN20 (GND) against PIN28 (GND-EDC Box): Setpoint 0 to 0.1V.
NOTE: If the voltage is outside the setpoint range, see fault code EDC 16.
b) Check the signal voltage of potentiometer R6/3 at EDC Box A55:
PIN4 (signal) against PIN28 (GND).
Setpoint 0V to 10V, corresponds to monitor display 5 % to 95 %.
If the signal voltage is outside the setpoint range, go to step 2.

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2. a) Check the stabilised supply voltage at print A16.
Disconnect plug X14/4 and connect measuring adapter 380000075 in between.
PIN14 (plus) against PIN12 (GND): Setpoint 10V +/- 0.25V.
If the voltage does not meet the setpoint, the wiring between EDC Box A55 and print A16 must be repaired.
If the supply voltage is ok, go to step b.

b) Check the signal voltage of potentiometer R6/3 at the output of print A16:
X14/4 PIN11 (signal) against X14/4 PIN12 (GND).
Setpoint 0V to 10V, corresponds to monitor display 5 % to 95 %.
If the supply voltage does not meet the setpoint, go to step c).

c) Check the signal voltage of potentiometer R6/3 at the input of print A16:
To do so, disconnect plug X3/18.
X3/18 PIN3 (signal) against X14/4 PIN12 (GND).
Setpoint 0V to 10V, corresponds to monitor display 5 % to 95 %.

If the signal voltage at plug X3/18 is ok, the faulty print A16 must be replaced.
If the signal voltage at plug X3/18 does not meet the setpoint, go to step 3.
3. a) Check the stabilised supply voltage to potentiometer R6/3 at print A16.
X3/18 PIN1 (plus) against X14/4 PIN12 (GND): Setpoint 10V +/- 0.25V.
X3/18 PIN2 (GND) against X14/4 PIN12 (GND): Setpoint 0 to 0.1V.
If the voltage does not meet the setpoint, the faulty print A16 must be replaced. If, subsequently, the supply volta-
ge is ok, repeatedly check the signal voltage at plug X3/18 (see step 2c).
If the signal voltage at plug X3/18 does not meet the setpoint, go to step b):

b) Check potentiometer R6/3 at plug X3/18:

Disconnect plug X3/18. Check wiring and plug-in contacts.
Perform the following resistance measurements:
PIN1 against PIN2: Setpoint 4.7 kohms +/- 20%.
PIN1 against PIN3 and PIN2 against PIN3: Setpoint 0 ohms to 4.7 kohms +/- 20%,
depending on the position of the adjuster wheel.
Replace the faulty potentiometer.
4. Delete fault 36. Turn ignition switch to OFF position, turn back to ON position after min. 5 seconds. Check that
fault 36 is not displayed any longer.

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EDC - 41 Signal of radar sensor B16 is faulty or not present

up to DBD100000
Cause:
The signal of the radar sensor (actual driving speed) is faulty or not present at the EDC Box.
NOTE: The fault is only displayed when the tractor is moving and the "theoretical driving speed" signal arrives at the
EDC Box. The slip controll must be activated.
The fault is output as a flashing code by the diagnosis LED.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Interruption or contact fault in the signal line.
2. The signal line is shorted to the plus or GND supply.
3. Fuse (supply +15/2) has blown or has a contact fault.
4. Interruption in the plus supply line (of print A12).
5. Interruption in the ground supply line (of ECCU2).
6. Radar sensor B16 is faulty.
7. Print A12 is faulty.
8. EDC Box A55 is faulty.
9. ECCU2 is faulty.
Remedy:
WARNING: Do not look into the radar sensor when the ignition switch is not in the OFF position (risk of permanent
eye damage)!
Delete fault 41, then turn ignition switch to OFF position.
1. Check 5 A fuse F31 (+15/2) at print A12, replace if necessary.
2. Check the signal of radar sensor B16:
a) Disconnect plug X4/12 on radar sensor B16 and connect adapter 380000062 in between.

b) Connect a multi-meter to PIN3 (signal) and ground connection.

Check the signal voltage at a driving speed of 5 km/h. The average voltage of the digital signal (square-wave) is
approx. 6 VDC.

c) Measure the signal frequency: Setpoint: approx. 180 Hz (standard: 130 pulses/metre or 505 Hz/14 km/h).
NOTE: The voltage remains constant, irrespective of the driving speed.
If the frequency is not displayed while driving, the supply to radar sensor B16 must be checked. Go to step 3.
If the signal at plug X4/12 is ok, continue checking the signal at the input of EDC Box A55. Go to step d).
d) Detach plug X55 from EDC Box A55 and
connect adapter 380000074 in between. Connect a multi-meter between PIN10 (signal) and PIN28 (ground EDC
Box). Check as described in steps 2b and 2c.
If the signal is not ok, check the signal line between radar sensor and EDC Box, repair if necessary.
3. Check the supply to radar sensor B16.
a) Check the plus supply: Start the engine.
At plug X4/12 PIN1 (12.5V to 14V), measure against ground. If the setpoint is not reached, subsequently check
the voltage at plug X3/1 at print A12, and if necessary also at the output of the fuse (supply +15/2). Check plug-
in contacts and line, repair if necessary. If necessary, replace damaged print A12.

b) Check the ground supply:

At plug X4/12 PIN2 (ground input at radar sensor), measure against ground. If the voltage drop is > 0.5V, subse-
quently check the ground output at ECCU2.
Measure plug CN2/E PIN8 (ground output) against ground. If the voltage drop is < 0.5 V, the ground line between
ECCU and radar sensor must be checked and repaired if necessary. If, however, the ground line mentioned is ok,
the supply to the ECCU must then be checked. Go to fault codes ECCU99 and ECCU101.
4. Continue checking the signal from the radar sensor:
a) Check signal repeatedly at plug X4/12 (see steps 2b and 2c).
If the signal is not ok, release PIN3 in the plug housing (temporarily interrupt signal line) and repeat the signal
check. If the signal is ok, go to step b).

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b) Check the signal line to the EDC Box and to the ECCU for interruptions or short-circuits to other lines or ground.
If the signal line is ok (also via print A12, plug X3/1, PIN2), go to step c).

c) At ECCU2, plug CN3b, PIN21, interrupt the signal line (release pin). Repeat signal check as described in
step 2c. If the signal is ok, replace the faulty ECCU. If the signal is not ok, go to step d).

d) At the EDC Box, plug X55, PIN10, interrupt the signal line (release pin). Repeat signal check as described in
step 2c. If the signal is ok, replace the faulty EDC Box.
5. Delete fault 41 and turn ignition switch to OFF position. After at least 5 seconds, start engine, drive tractor and
check that fault 41 is no longer active.

EDC - 41 Signal of radar sensor B16 is faulty or not present

from DBD100001
Cause:
The signal of the radar sensor (actual driving speed) is faulty or not present at the EDC Box.
NOTE: The fault is only displayed when the tractor is moving and the "theoretical driving speed" signal arrives at the
EDC Box. The slip controll must be activated.
The fault is output as a flashing code by the diagnosis LED.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Interruption or contact fault in the signal line.
2. The signal line is shorted to the plus or GND supply.
3. Fuse (supply +15/2) has blown or has a contact fault.
4. Interruption in the plus supply line (of print A12).
5. Interruption in the ground supply line (of ECCU2).
6. Radar sensor B16 is faulty.
7. Print A12 is faulty.
8. EDC Box A55 is faulty.
9. ECCU2 is faulty.
Remedy:
WARNING: Do not look into the radar sensor when the ignition switch is not in the OFF position (risk of permanent
eye damage)!
Delete fault 41, then turn ignition switch to OFF position.
1. Check 5 A fuse F31 (+15/2) at print A12, replace if necessary.
2. Check the signal of radar sensor B16:
a) Disconnect plug X3/2 on radar sensor B16 and connect adapter 380000062 in between.

b) Connect a multi-meter to PIN3 (signal) and ground connection.

Check the signal voltage at a driving speed of 5 km/h. The average voltage of the digital signal (square-wave) is
approx. 6 VDC.

c) Measure the signal frequency: Setpoint: approx. 180 Hz (standard: 130 pulses/metre or 505 Hz/14 km/h).
NOTE: The voltage remains constant, irrespective of the driving speed.
If the frequency is not displayed while driving, the supply to radar sensor B16 must be checked. Go to step 3.
If the signal at plug X3/2 is ok, continue checking the signal at the input of EDC Box A55. Go to step d).
d) Detach plug X55 from EDC Box A55 and
connect adapter 380000074 in between. Connect a multi-meter between PIN10 (signal) and PIN28 (ground EDC
Box). Check as described in steps 2b and 2c.
If the signal is not ok, check the signal line between radar sensor and EDC Box, repair if necessary.
3. Check the supply to radar sensor B16.
a) Check the plus supply: Start the engine.
At plug X3/2 PIN1 (12.5V to 14V), measure against ground. If the setpoint is not reached, subsequently check
the voltage at plug X3/1 at print A12, and if necessary also at the output of the fuse (supply +15/2). Check plug-
in contacts and line, repair if necessary. If necessary, replace damaged print A12.

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b) Check the ground supply:
At plug X3/2 PIN2 (ground input at radar sensor), measure against ground. If the voltage drop is > 0.5V, subse-
quently check the ground output at ECCU2.
Measure plug CN2/E PIN8 (ground output) against ground. If the voltage drop is < 0.5 V, the ground line between
ECCU and radar sensor must be checked and repaired if necessary. If, however, the ground line mentioned is ok,
the supply to the ECCU must then be checked. Go to fault codes ECCU99 and ECCU101.
4. Continue checking the signal from the radar sensor:
a) Check signal repeatedly at plug X3/2 (see steps 2b and 2c).
If the signal is not ok, release PIN3 in the plug housing (temporarily interrupt signal line) and repeat the signal
check. If the signal is ok, go to step b).

b) Check the signal line to the EDC Box and to the ECCU for interruptions or short-circuits to other lines or ground.
If the signal line is ok (also via print A12, plug X3/1, PIN2), go to step c).

c) At ECCU2, plug CN3b, PIN21, interrupt the signal line (release pin). Repeat signal check as described in
step 2c. If the signal is ok, replace the faulty ECCU. If the signal is not ok, go to step d).

d) At the EDC Box, plug X55, PIN10, interrupt the signal line (release pin). Repeat signal check as described in
step 2c. If the signal is ok, replace the faulty EDC Box.
5. Delete fault 41 and turn ignition switch to OFF position. After at least 5 seconds, start engine, drive tractor and
check that fault 41 is no longer active.

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EDC - 42 Theoretical driving speed signal is faulty or not present

Cause:
The "theoretical driving speed" signal is faulty or not present at the EDC Box.
NOTE: The fault is only displayed when the tractor is moving and the radar sensor signal arrives at the EDC Box.
The slip controll must be activated.
The fault is output as a flashing code by the diagnosis LED.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Interruption or contact fault in the signal line.
2. The signal line is shorted to plus or ground.
3. The FMGR is faulty.
4. EDC Box A55 is faulty.
5. No calibration in FMGR.
Remedy:
NOTE: If no other fault codes are displayed or the driving speed is displayed, the "theoretical driving speed" infor-
mation is ensured up to the FMGR. If, however, fault codes related to the SGR or FMGR are also displayed, these
must be remedied first.
If the driving speed is not displayed, go to step 1.
1. a) Connect Service Tool to diagnosis socket X9/17.
b) Turn ignition switch to ON position.
c) Go to "VEHICLE CONFIGURATION".
d) Check or carry out driving speed calibration.
e) After successful calibration (if required), delete fault 42 and turn ignition switch to ON position.
f) Drive the tractor. If the driving speed is displayed and if fault 41 is active again, check the signal at EDC Box
A55. Go to step 2.
2. Signal check at EDC Box A55:
a) Disconnect plug X55 and connect adapter 380000074 in between. Connect the multi-meter between PIN11
(signal) and PIN28 (ground - EDC Box).
b) Drive the tractor and check the signal voltage. The average voltage of the digital signal (square-wave) is ap-
prox. 6 VDC.
c) Measure the signal frequency. Standard: 130 pulses/metre (180 Hz/5 km/h or 505 Hz/14 km/h). If the signal at
the input of the EDC Box is faulty or not present, go to step d).
d) Disconnect the EDC Box from the adapter. Repeat the signal check (see steps 2b) and 2c). If the signal is ok,
replace the faulty EDC Box A55. If the signal is not ok, go to step 3.
3. Signal check at FMGR A4:
a) Disconnect plug A4/2 and connect adapter 380000076 in between.
b) Connect the multi-meter between PIN9 and ground.
c) Check the signal as described in steps 2b) and 2c). If the signal at the output of the FMGR is ok, check the
signal line between FMGR and EDC, repair if necessary. If the signal at the output of the FMGR is not ok, interrupt
the signal line and repeat the signal check. If the signal is ok during this check, the fault is in the signal line. If the
signal is not ok, replace the faulty FMGR.
4. Delete fault 42 and turn ignition switch to OFF position. After at least 5 seconds, start engine, drive tractor and
check that fault 42 is no longer active.

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EDC - 44 The signal of SLIP LIMIT potentiometer R6/5 is outside the

permissible range
Cause:
The signal voltage is > 10.3V.
The signal voltage must be within a certain range (2.5V to 7.4 V).
The fault is output as a flashing code by the diagnosis LED.
The fault is stored and signalled on the instrument panel by a warning triangle.
Possible causes:
1. Interruption or high contact resistance in the signal line.
2. The potentiometer is defective.
3. Print A16 is faulty (series resistors defective).
4. The signal line is shorted to other plus lines.
5. EDC Box A55 is faulty.
Remedy:
Connect the Service Tool to diagnosis socket X9/17.
Use monitor function "SLIP POTENTIOMETER POSITION".
The monitor displays the value in "%". The following assignment applies:
a) Potentiometer R6/5 in position "0": Monitor display "5 %" = 2.5 V.
b) Potentiometer R6/5 in position "10": Monitor display "95%" = 7.4 V.
Delete fault. Turn ignition switch to OFF position. Start engine after 5 seconds.
Turn HYDRAULIK MASTER switch to EDC position.
Turn the adjustment wheel on potentiometer R6/5 and check whether the percentage in the monitor function has
changed.
If fault 44 is active again, carry out the fault diagnostics as follows:
Turn ignition switch to OFF position. Detach plug X55 from EDC Box A55 and connect measuring adapter 380000074
in between. Turn ignition switch to ON position.
1. a) Check the stabilised supply voltage at EDC Box A55.
To do so, turn ignition switch to ON position.
PIN2 (plus) against PIN28 (GND): Setpoint 10V +/- 0.25V.
PIN20 (GND) against PIN28 (GND-EDC Box): Setpoint 0 to 0.1V.
NOTE: If the voltage is outside the setpoint range, see fault code EDC 16.
b) Check the signal voltage of potentiometer R6/5 at EDC Box A55:
PIN25 (signal) against PIN28 (GND).
Setpoint 2.5V to 7.4V, corresponds to monitor display 5 % to 95 %.
If the signal voltage is outside the setpoint range, go to step 2.
2. a) Check the stabilised supply voltage at print A16.
Disconnect plug X14/4 and connect measuring adapter 380000075 in between.
PIN14 (plus) against PIN12 (GND): Setpoint 10V +/- 0.25V.
If the voltage does not meet the setpoint, the wiring between EDC Box A55 and print A16 must be repaired.
If the supply voltage is ok, go to step 2b.

b) Check the signal voltage of potentiometer R6/5 at the output of print A16:
X14/4 PIN1 (signal) against X14/4 PIN12 (GND).
Setpoint 2.5V to 7.4V, corresponds to monitor display 5 % to 95 %.
If the supply voltage does not meet the setpoint, go to step c).

c) Check the signal voltage of potentiometer R6/5 at the input of print A16:
To do so, disconnect plug X3/19.
X3/19 PIN3 (signal) against X14/4 PIN12 (GND).
Setpoint 2.5V to 7.4V, corresponds to monitor display 5 % to 95 %.
If the signal voltage at plug X3/19 is ok, the faulty print A16 must be replaced.
If the signal voltage at plug X3/19 does not meet the setpoint, go to step 3.
3. a) Check the stabilised supply voltage to potentiometer R6/5 at print A16.
X3/19 PIN1 (plus) against X14/4 PIN12 (GND): Setpoint 7.4V +/- 0.25V.
X3/19 PIN2 (GND) against X14/4 PIN12 (GND): Setpoint 2.5V +/- 0.1V.
If the voltage is outside the setpoint range, go to step 3b.

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b) Check potentiometer R6/5 at plug X3/19:

Disconnect plug X3/19. Check wiring and plug-in contacts.
Perform the following resistance measurements:
PIN1 against PIN2: Setpoint 4.7 kohms +/- 20%.
PIN1 against PIN3 and PIN2 against PIN3: Setpoint 0 ohms to 4.7 kohms +/- 20%,
depending on the position of the adjuster wheel. Replace the faulty potentiometer.
If the resistance values of the potentiometer are ok, go to step 3c.

c) Check series resistors R14 and R13 of the potentiometer supply at print A16.
Turn ignition switch to OFF position.
Disconnect plug X3/19 (wiring to pot R6/5) from print A16.
Resistance measurement (R14) at plug X14/4 PIN14 against plug X3/19 PIN1:
Setpoint 2.5 kOhms +/- 10 %.
Resistance measurement (R13) at plug X14/4 PIN12 against plug X3/19 PIN2:
Setpoint 2.5 kOhms +/- 10 %.
If one of the setpoints is not met, the faulty print A16 must be replaced.
If, subsequently, the supply voltage to the potentiometer is ok, repeatedly check the signal voltage at plug X3/19
(see step 2c).
4. Delete fault 44. Turn ignition switch to OFF position, turn back to ON position after min. 5 seconds. Check that
fault 44 is not displayed any longer.

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COMPONENTS SUMMARY
ARU Armrest ..............................................................................................................................................Fig. 1
A4 FMGR ................................................................................................................................................Fig. 2
A4/2 FMGR plug connection - dark grey [2]...............................................................................................Fig. 3
A55 EDC control unit ................................................................................................................................Fig. 4
A60 ECCU2 ..............................................................................................................................................Fig. 5
B9/1 Rotary angle sensor EDC [LAGES] ...................................................................................................Fig. 6
B10/1 Power sensor, left ..............................................................................................................................Fig. 7
B10/2 Power sensor, right ...........................................................................................................................Fig. 8
B16 Radar sensor ....................................................................................................................................Fig. 9
CN2/E ECCU2 plug connection ..................................................................................................................Fig. 10
CN3b ECCU2 plug connection .................................................................................................................. Fig. 11
R6/1 Setpoint potentiometer ....................................................................................................................Fig. 12
R6/2 Lift limitation potentiometer..............................................................................................................Fig. 12
R6/3 Mixing potentiometer .......................................................................................................................Fig. 12
R6/4 Lowering speed potentiometer .......................................................................................................Fig. 12
R6/5 Slip control potentiometer ................................................................................................................Fig. 12
S2/15/5 Raise / Lower button [INNEN] .........................................................................................................Fig. 13
S2/72 Rapid retraction button .....................................................................................................................Fig. 9
S14/1 External button for LOWER, left [SENKEN].....................................................................................Fig. 14
S14/2 External button for LOWER, right [SENKEN] ..................................................................................Fig. 15
S15/1 External button for RAISE, left [HEBEN] .........................................................................................Fig. 14
S15/2 External button for RAISE, right [HEBEN] .......................................................................................Fig. 15
S33 EDC stop button ................................................................................................................................Fig. 9
S60/7 EDC Transport/control button ...........................................................................................................Fig. 1
X3/1 Plug connection, radar sensor ........................................................................................................Fig. 16
X3/2 Plug connection, radar sensor from DBD100001 ............................................................................Fig. 17
X3/16 Plug connection, potentiometer, lowering speed .............................................................................Fig. 18
X3/17 Plug connection, potentiometer, raising speed ...............................................................................Fig. 19
X3/18 Plug connection, EDC mixing potentiometer ..................................................................................Fig. 20
X3/19 Plug connection, slip control potentiometer ....................................................................................Fig. 21
X4/12 Plug connection, radar sensor up to DBD100000 ...........................................................................Fig. 22
X5/6 Plug connection, nominal value potentiometer ...............................................................................Fig. 23

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X9/17 Socket, diagnosis service tool ........................................................................................................ Fig. 24

X10/4 Plug connection, EDC print armrest (GSV) .................................................................................... Fig. 25
X14/4 Plug connection, EDC print - control panel ..................................................................................... Fig. 26
X18/4 Plug connection, wiring harness, cab right - armrest ...................................................................... Fig. 27
X21 Plug connection, multicontroller - print............................................................................................ Fig. 28
X28/14 Plug connection, ARU button, EDC stop up to DBD094270........................................................... Fig. 29
X30/14 Plug connection, ARU button, EDC stop from DBD094271 ........................................................... Fig. 30
X55 Plug connection, EDC box .............................................................................................................. Fig. 31
Y6 Solenoid valve, EDC, RAISE, grey [HEBEN].................................................................................. Fig. 32
Y7 Solenoid valve, EDC, LOWER, black [SENKEN] ........................................................................... Fig. 33

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Fig. 1

Fig. 3 from DBD100001

Fig. 2

Fig. 4

Fig. 3 up to DBD100000 Fig. 5

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Fig. 6 Fig. 10 up to DBD100000

Fig. 7

Fig. 10 from DBD100001

Fig. 8

Fig. 9

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Fig. 12

Fig. 11 up to DBD100000

Fig. 13

Fig. 14 up to DBD100000

Fig. 11 from DBD100001

Fig. 14 from DBD100001

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Fig. 15 Fig. 18

Fig. 16 up to DBD100000 Fig. 19

Fig. 16 from DBD100001 Fig. 20

Fig. 17 from DBD100001 Fig. 21

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Fig. 22 up to DBD100000 Fig. 25

Fig. 23

Fig. 26 up to DBD100000

Fig. 24 up to DBD100000

Fig. 26 from DBD100001

Fig. 24 from DBD100001

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Fig. 27 up to DBD100000 Fig. 28

Fig. 29 up to DBD094270

Fig. 27 from DBD100001

Fig. 30 from DBD094271

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Fig. 31 up to DBD100000 Fig. 32

Fig. 33

Fig. 31 from DBD100001

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BLANK PAGE

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*) see Note page 8

FUNCTIONAL SCHEMATIC DIAGRAM FOR EDC UP TO DBD100000
S2/7/3
A12 X24/2 X20/1 A14
ARMREST F49 7.5A S28
X24/2 +15/1 10 13 0
1
F19 5A F91 7.5A
*A28 PLUG MODULE 17 3 +30 3

*A30 PRINT ARU F20 5A

ON
3
S33 X14 X1 X18/4 18 +15/1 OFF

F16 5A 6 1
2 7 13 2 +15/2
X18/1 54c
5V (16) 1 O P X23/2 8 2
9 9 16

GSV4
1 GND D+

S2/72 X2 8 10
ARU + X5/1
2 X7 15 X24/3 1 54c
5V ARU - X2/12
1 2 16 1 X10/9 2 X10/9 6 8
CAN H (16)
A31 3 17
S60/7 X4 X11 CAN L CN3a 2 X55 13 24 29 47 28 46
12V 4 18 CAN H CN1a 10 CN3a 4 1
1 16 A60 ECCU2 15 A55 EDC
A60 ECCU2

6.4 V with EDC and AUX ON

6.4 V with EDC ON
X1 CAN L
Supply
16
X21 X11 13 4 CN1a
GND
2 9 6 5 15
5 2 16
X21 X11 4 3
4 7 12 1
38
5 14
41
3 15 15/1
5V 15/1 GND CONTROL
1 1
F45 5A A12
A16 X14/4 +15/1
*YA1 6 8 41 33 3 1 4 2 5 7
12
GND
20
X10/4
TRANSPORT 2k
X14/15 12
*YB1 6 8 41 33 3 1 4 2 5 7 9
14
10 V
2
2k 2k
* A27 CAN MODULE X10/4 X24/5 X10/11 7
2k
STOP A13
6 3 6 5 3.5 V with pushbutton pressed X10/12
2k
A1 ADIC X3/18 3-pin plug connection RAPID RETRACTION
Pushbutton
A12 Central print X3/19 3-pin plug connection
5 P8/1 3 4 6
A13 Roof print X4 4-pin plug connection P8 ICU P8
2k 2k
A14 Engine print X5/1 Plug connection 7
X24/5 6.75 V transport X14/14
A16 EDC print X5/6 5-pin plug connection
A27 CAN module ---> DBD..... X7 4-pin plug connection X5/6 8 9 21 5.17 V control 5 4
A28 Plug module ---> DBD..... X10/4 10-pin plug connection 2 3.50 V rapid retraction 3
A30 Print ARU DBD..... ---> X10/9 10-pin plug connection
A31 Multi controller X10/10 10-pin plug connection R6/1 1 X10/4 (7)
A55 EDC box X10/11 10-pin plug connection 3 13 22 0 to 10 V P8/2 3 4 (8)
A60 ECCU2 X10/12 10-pin plug connection
CN1a 26-pin plug connection X10/14 10-pin plug connection
X3/17 X10/14 7
CN3 26-pin plug connection X11 16-pin plug connection 2 Potentiometer
261Ω
CN3a 26-pin plug connection X14 2-pin plug connection R6/2 1
R6/1 Potentiometer, setpoint X14/4 14-pin plug connection
R6/2 Potentiometer, lift limitation X14/14 14-pin plug connection 3 6 3 0 to 9.5 V
A14 X20/1 X23/1
R6/3 Potentiometer, mixing X14/15 14-pin plug connection X3/18 F93 5A
R6/4 Potentiometer, lowering speed X18/4 18-pin plug connection +30 8 Q
2
R6/5 Potentiometer, slip control X18/1 18-pin plug connection
S2/7/3 Switch, hydraulic master X20/1 20-pin plug connection R6/3 1
S2/72 Rapid retraction pushbutton X21 14-pin plug connection 3 11 4 0 to 10 V
S28 Switch, stroke / pressure equipment X23/1 23-pin plug connection
S33 Stop pushbutton X23/2 23-pin plug connection X3/16
S60/7 EDC Transport/control button X24/2 24-pin plug connection 2
P8 ICU X24/3 24-pin plug connection
P8 10-pin plug connection X24/5 24-pin plug connection R6/4 1
P8/1 4-pin plug connection X55 55-pin plug connection 3 4 23 0 to 10 V CN3 A1 ADIC
P8/2 4-pin plug connection YA1 44-pin plug connection ---> DBD..... 2K5Ω CAN L
X3/19 25
X1 14-pin plug connection YB1 44-pin plug connection ---> DBD..... CAN H
X2 2-pin plug connection (7) Ground point, roof hood, left R6/5 2 26
2K5Ω
X2/12 2-pin plug connection (8) Ground point, roof hood, right 1
X3/16 3-pin plug connection (16) Ground point, starter
X3/17 3-pin plug connection 3 1 25 2.5 to 7.4 V

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BLANK PAGE

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A55 EDC
A4 FMGR X55
A4/2 18-pin plug connection 10 V
3 39
A12 Central print
A16 EDC print B9/1 2 6 2.5 to 7.5 V X55 Y6
A55 EDC box U GND
1 35 1
A60 ECCU2
B9/1 Angle of rotation sensor Sensors and
B10/1 Power sensor, left solenoid valves 0 to 5 V
B10/2 Power sensor, right F 3 55 2
B16 Radar sensor B10/1 2 7 approx. 5 V not loaded
CN2/E 26-pin plug connection U
CN3b 34-pin plug connection 1
H2/1 Diagnosis LED
H2/2 Slip LED
H2/3 RAISE LED F 3
H2/4 LOWER LED B10/2 2 26 approx. 5 V not loaded Y7
S2/15/5 RAISE/LOWER pushbutton GND GND
S2/73 Switch, slip control U 1 38 53 1
S14/1 External pushbutton, LOWER, left
S14/2 External pushbutton, LOWER, right 41
S15/1 External pushbutton, RAISE, left 0 to 5 V
19 2
S15/2 External pushbutton, RAISE, right
X3/1 3-pin plug connection 5V
X4/2 4-pin plug connection 9
X4/3 4-pin plug connection S14/1 S15/1
X4/12 4-pin plug connection
X10/4 10-pin plug connection
X10/9 10-pin plug connection OFF OFF

X14/4 14-pin plug connection ON ON A16

X24/2 24-pin plug connection X14/4 X4/3
X24/5 24-pin plug connection 1 2 1 2 1k H2/4
22 Ω 22 Ω 5 1
X55 55-pin plug connection
Y6 Solenoid valve, EDC, RAISE S14/2 2
S15/2 1k
Y7 Solenoid valve, EDC, LOWER
(16) Ground point, starter 37 3 4
OFF OFF
External pushbuttons 3
ON ON H2/3
and LEDs
1 2 1 2
22 Ω 22 Ω

X14/4 1k
X4/2
S2/15/5 H2/2
12 2 4
2 3
0
X24/5 31 7
1k
2
X24/5 1
1 20
LOWER
36 5 V with pushbutton pressed
19 3 RAISE 1
S2/73 7 21 17 5 V with pushbutton pressed H2/1

0
1

X10/9 X10/4 A16 X14/4

GND
9 1 5 7 12 20
58

14 GND

X14/4 9 X10/4 4
Slip control
X4/12 X3/1 A12 CN2/E A60 A4
F31 5A
1 1 +15/2 8 Potentiometer R6/5 is shown
v X24/2 on the previous page
B16 GND
2 3 5 CN3b (16)
f 3 2 15 21 9 A4/2 X24/2 19
Theoretical speed A12
11 505 Hz at 14 km/h F13 7.5A
+30
Real speed
10 505 Hz at 14 km/h

A60
Standard signal CN3b
Ground during transport
15 11

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FUNCTIONAL SCHEMATIC DIAGRAM FOR EDC FROM DBD100001

S2/7/3
0
A12 X24/2 A14 1
F49 7.5A S28
X24/2 +15/1 10 X6/2 3

ARMREST F19 5A 3
17 1
A30 PRINT ARU
F20 5A ON
F210 7.5A 6 1
18 +15/1
X18/1
OFF
4 +30
S33 X30/14 8 2
X30/1 X18/4 D+ 16 54c

GSV4
2 1
5V 7 13
1 X24/3 1
9 9
S2/72 X30/2 (11) 1 54c
8 10 A60 ECCU2 CN3a
2 X2/12 X10/9 2 6 8
5V X30/7 2
1 X55 13 24 29 47 28 46 (11)
2 16 CAN H
CAN H 50 A55 EDC
A31 3 17 CAN L
X4 X30/11 CAN L 52 Supply 10 4 1 CN3a
S60/7 4 18 CN1a
A60

6.4 V with EDC and

AUX ON
6.4 V with EDC ON
1 16
12V X30/1 15 ECCU2
X21 X30/11 13 4 16
2 GND 9 6 5
5 2
38
X21 X30/11 4 3
41
4 7 12 1
CONTROL
5 14
A12 F45 5A
3 15 15/1 A16 X14/4 +15/1
5V X10/9 4 5 7 GND
1 1 15/1 GND X10/4 12 20
2k
TRANSPORT
9 10 V X14/15 12
2k 2k 14 2
X10/4 X24/5
STOP 2k
X10/11 7
6 3 6 5 3.5 V with pushbutton pressed
A13
2k
RAPID RETRACTION
5 Pushbutton
2k 2k
X10/12 6
X24/5 6.75 V transport P8/1 3 4
A1 ADIC X3/18 3-pin plug connection 8 9 P8 ICU
A12 Central print X3/19 3-pin plug connection X5/6 21 5.17 V control P8
2 3.50 V rapid retraction
A13 Roof print X4 4-pin plug connection 7
A14 Engine print X5/6 5-pin plug connection c a
1 5
A16 EDC print X6/2 6-pin plug connection R6/1 X14/4
b
A30 Print ARU X10/3 10-pin plug connection 3 13 22 0 to 10 V 3
A31 Multi controller X10/4 10-pin plug connection
A55 EDC box X10/9 10-pin plug connection X3/17 (7)
A60 ECCU2 X10/11 10-pin plug connection 2 P8/2 3 4 (8)
261Ω
Potentiometer X14/14 4
CN1a 26-pin plug connection X10/12 10-pin plug connection c a
1
CN3 26-pin plug connection X10/14 10-pin plug connection R6/2
b
CN3a 26-pin plug connection X14/4 14-pin plug connection 3 6 3 0 to 9.5 V
R6/1 Potentiometer, setpoint X14/14 14-pin plug connection
R6/2 Potentiometer, lift limitation X14/15 14-pin plug connection X3/18
X10/14 7
R6/3 Potentiometer, mixing X18/1 18-pin plug connection 2
R6/4 Potentiometer, lowering speed X18/4 18-pin plug connection c a
1 A14
R6/5 Potentiometer, slip control X21 14-pin plug connection R6/3 X10/3
b F212 5A
S2/7/3 Switch, hydraulic master X24/2 24-pin plug connection 3 11 4 0 to 10 V +30 6
S2/72 Rapid retraction pushbutton X24/3 24-pin plug connection
S28 Switch, stroke / pressure equipment X24/5 24-pin plug connection X3/16
S33 Stop pushbutton X30/1 14-pin plug connection 2
S60/7 EDC Transport/control button X30/2 2-pin plug connection c a
1
P8 ICU X30/7 4-pin plug connection R6/4 A1 ADIC
b
P8 10-pin plug connection X30/11 16-pin plug connection 3 4 23 0 to 10 V CN3
P8/1 4-pin plug connection X30/14 2-pin plug connection 2K5Ω CAN L
X3/19 25
P8/2 4-pin plug connection X55 55-pin plug connection CAN H
X2/12 2-pin plug connection (7) Ground point, roof hood, left R6/5 2 26
2K5Ω
X3/16 3-pin plug connection (8) Ground point, roof hood, right c a
1
X3/17 3-pin plug connection (11) Ground point, engine cable carrier, rear b
3 1 25 2.5 to 7.4 V

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EDC 4011-301

A55 EDC
A4 FMGR X55
A4/2 18-pin plug connection 10 V
3 39
A12 Central print
B9/1 2 6 2.5 to 7.5 V X55 Y6
A16 EDC print
A55 EDC box U GND
1 35 1
A60 ECCU2 Sensors and
B9/1 Angle of rotation sensor
B10/1 Power sensor, left solenoid valves 0 to 5 V
F 3 55 2
B10/2 Power sensor, right
B10/1 2 7 approx. 5 V not loaded
B16 Radar sensor
CN2/E 26-pin plug connection U 1
CN3b 34-pin plug connection
H2/1 Diagnosis LED
H2/2 Slip LED 3 Y7
H2/3 RAISE LED
F
B10/2 GND
H2/4 LOWER LED 2 26 approx. 5 V not loaded 53 1
S2/15/5 RAISE/LOWER pushbutton U GND
1 38
S2/73 Switch, slip control 0 to 5 V
S14/1 External pushbutton, LOWER, left 41 19 2
S14/2 External pushbutton, LOWER, right
S15/1 External pushbutton, RAISE, left
S15/2 External pushbutton, RAISE, right 5V
9
X3/1 3-pin plug connection
X3/2 3-pin plug connection S14/1 S15/1
X4/2 4-pin plug connection
X4/3 4-pin plug connection
OFF OFF
X10/4 10-pin plug connection ON ON A16
X10/9 10-pin plug connection
X14/4 X4/3
X14/4 14-pin plug connection 1 2 1 2 1k H2/4
X24/2 24-pin plug connection 22 Ω 22 Ω 5 1
X24/5 24-pin plug connection S14/2 2
S15/2
X55 55-pin plug connection 1k
Y6 Solenoid valve, EDC RAISE 37 3 4
Y7 Solenoid valve, EDC LOWER OFF OFF
3
(11) Ground point, engine cable carrier, rear ON ON External pushbuttons H2/3
and LEDs
1 2 1 2
22 Ω 22 Ω

X14/4 1k
X4/2
S2/15/5 H2/2
12 2 4
2 3
0
X24/5 1k
X24/5 1
DOWN 31 7 2
1 20 36 5 V with pushbutton pressed
19 3 RAISE 1
7 21 17 5 V with pushbutton pressed H2/1
S2/73

0
1

X10/9 X10/4 A16 X14/4 58

GND
9 1 5 7 12 20

14 GND
X14/4 9 X10/4 4

Slip control
X3/2 X3/1 A12 CN2/E A60 A4
F31 5A
v 1 1 +15/2
X24/2 8 Potentiometer R6/5 is shown (11)
B16 GND
2 3 5 CN3b on the previous page X24/2 19
f 3 2 15 21 9 A4/2 A12
F13 7.5A
+30
Theoretical speed
11 505 Hz at 14 km/h
Real speed
10 505 Hz at 14 km/h
A60
Standard signal CN3b
Ground during transport
15 11

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FAULTCODES EEM2 UP TO DBD100000

EEM2 - 10 Power On self test ........................................................................................................................... 305
EEM2 - 11 Hardware Watchdog ....................................................................................................................... 305
EEM2 - 12 No valid EEM parameters ............................................................................................................... 305
EEM2 - 13 EEM parameters flash is full ........................................................................................................... 306
EEM2 - 14 Option mismatch ............................................................................................................................. 306
EEM2 - 15 Supply voltage 5 Vdc too low ( <4.6V) ............................................................................................ 307
EEM2 - 16 Supply voltage 5 Vdc too high (>5.2V) ............................................................................................ 308
EEM2 - 17 Battery voltage too low (<7.8V) ....................................................................................................... 309
EEM2 - 20 ECU temperature too high (>120°C) ............................................................................................... 310
EEM2 - 30 PCU EEPROM checksum defect .................................................................................................... 310
EEM2 - 31 PCU EEPROM hardware defect ..................................................................................................... 310
EEM2 - 32 PCU ADC defect ............................................................................................................................. 311
EEM2 - 33 Pump map defect ............................................................................................................................ 311
EEM2 - 34 PCU Internal bus defect .................................................................................................................. 311
EEM2 - 35 PCU Powerstage defect .................................................................................................................. 312
EEM2 - 37 Wrong pump CAN interface configuration ....................................................................................... 312
EEM2 - 39 PCU BIP not recognized ................................................................................................................. 313
EEM2 - 40 Solenoid valve final defect .............................................................................................................. 313
EEM2 - 41 Solenoid valve defect ...................................................................................................................... 314
EEM2 - 42 IAT final defect ................................................................................................................................ 314
EEM2 - 43 PCU Overtemperature .................................................................................................................... 315
EEM2 - 44 PCU Temperature sensor defect .................................................................................................... 315
EEM2 - 45 PCU Battery voltage measurement defectiv ................................................................................... 315
EEM2 - 46 Timing device defect ....................................................................................................................... 316
EEM2 - 48 PCU Speed sensor final defect ....................................................................................................... 316
EEM2 - 49 PCU CAN bus final defect ............................................................................................................... 317
EEM2 - 50 PCU reset while engine running (<6.0V) ......................................................................................... 318
EEM2 - 51 CAN connection to PCU defective .................................................................................................. 319
EEM2 - 52 Emergency shutdown signal (MAB) test dedects a defect .............................................................. 320
EEM2 - 53 PSG1 signal is missing ................................................................................................................... 321
EEM2 - 54 Injection control pulse width defect ................................................................................................. 322
EEM2 - 55 Pump speed deviation ..................................................................................................................... 323
EEM2 - 56 Pump supply voltage too low (< 6.8V) ............................................................................................ 323
EEM2 - 57 Pump supply voltage too high (>17.0V) .......................................................................................... 324
EEM2 - 66 Signal of speed sensor B20 faulty ................................................................................................... 325
EEM2 - 94 Engine overspeed (> 3000 rpm) ..................................................................................................... 325
EEM2 - 99 Oil pressure too low, alarm ............................................................................................................. 326
EEM2 - 100 Boost pressure signal out of range (too low) ................................................................................. 327
EEM2 - 101 Boost pressure signal out of range (too high) ............................................................................... 328
EEM2 - 102 Boost pressure too low .................................................................................................................. 329
EEM2 - 110 Coolant temperature signal out of range (too low) ........................................................................ 330
EEM2 - 111 Coolant temperature signal out of range (too high) ....................................................................... 331
EEM2 - 112 Coolant temperature too high, warning ......................................................................................... 332
EEM2 - 113 Coolant temperature too high, alarm ............................................................................................. 333
EEM2 - 114 Intake air temperature signal out of range (too low) ...................................................................... 334
EEM2 - 115 Intake air temperature signal out of range (too high) .................................................................... 335
EEM2 - 116 Intake air temperature too high ..................................................................................................... 336
EEM2 - 121 Water in fuel (dedecting optional) ................................................................................................. 336
EEM2 - 122 Fuel delivery pressure too low ...................................................................................................... 337
EEM2 - 123 Air in fuel system ........................................................................................................................... 338

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EEM2 - 141 CAN off (vehicle bus) .................................................................................................................... 339
EEM2 - 142 CAN off between EEM and PCU ................................................................................................... 341
EEM2 - 146 Requested speed (CAN) out of range (too low < 500 rpm) ........................................................... 342
EEM2 - 147 Requested speed (CAN) out of range (too high >3000 rpm) ........................................................ 342
EEM2 - 172 Upgrade protection fault ................................................................................................................ 343
EEM2 - 173 Power parameters too high ........................................................................................................... 343
EEM2 - 174 Absolute maximum power not set ................................................................................................. 343
EEM2 - 175 Injection pump serial number mismatch ........................................................................................ 344
COMPONENTS SUMMARY ............................................................................................................................. 344
FUNCTIONAL SCHEMATIC DIAGRAM FOR EEM2 ........................................................................................ 349

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EEM2 - 10 Power On self test

Description:
When ignition is switched ON, the EEM2 controller performs internal system checks. If any of these test fail, the sy-
stem reports the Power On self test defect. The engine will not start.
Reaction in EEM:
FC is stored and warning lamp is activated. The engine will not start.
Solution:
1. Delete the failure. Turn the ignition key off and after 5 sec. back on. If the fault code comes again, the EEM2 con-
troller has to be replaced.
Test current EEM2 controller functionality with another EEM2 controller.
NOTE: If EEM2 controller from another tractor is used, FC 175 will be activated, because of pump serial number
mismatch.
If FC 10 disappears, EEM2 controller was damaged. Replace the controller and couple current injection pump (serial
number) to the new EEM2 controller with CNH service tool.

EEM2 - 11 Hardware Watchdog

Description:
There has been a failure in the EEM2 program execution, caused by a hardware defect.
Reaction in EEM:
FC is stored and warning lamp is activated. The engine will stop immediately and may not start.
Solution:
1. Delete the failure. Turn the ignition key off and back on. If the fault code come again, the EEM2 controller has to
replace.
Test current EEM2 controller functionality with another EEM2 controller.
NOTE: If EEM2 controller from another tractor is used, FC 175 will be activated, because of pump serial number
mismatch.
If FC 11 disappears, EEM2 controller was damaged. Replace the controller and couple current injection pump (serial
number) to the new EEM2 controller with CNH service tool.

EEM2 - 12 No valid EEM parameters

Description:
Valid EEM2 parameters are not found on flash. Application starts to use default EEM2 parameters.
Reaction in EEM:
FC is stored and warning lamp is activated. Engine power will be reduced.
Solution:
1. Delete the failure. Turn the ignition key off and back on. If the fault code comes again, proceed to the next step.
2. Download a correct software in the EEM2 controller.
3. Turn the ignition key off and back on. If the fault code comes again, the EEM2 controller has to be replaced.
NOTE: If a EEM2 controller from another tractor is used temporary, FC 175 will be activated, because of pump
serial number mismatch.
4. If FC 12 disappears, the EEM2 controller was faulty. Replace the controller and couple the current injection pump
(serial number) to the new EEM2 controller with CNH service tool.

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EEM2 - 13 EEM parameters flash is full

Description:
EEM2 parameters area on flash is full. Application starts to use latest valid EEM2 parameters. Total amount of flash
memory entries are 385. A new entry will be used as an example after software download.
Reaction in EEM:
FC is stored and warning lamp is activated. Engine power will be reduced.
Solution:
1. Turn the ignition key off and back on. If the fault code comes again, the EEM2 controller has to be replaced.
NOTE: If a EEM2 controller from another tractor is used temporary, FC 175 will be activated, because of pump
serial number mismatch.
2. If FC 13 disappears, the EEM2 controller had a temporary fault. Delete the faiure and make a test-run.
If the failure appears again, the EEM2 controller has to be replaced and the the current injection pump (serial
number) has to be coupled to the new EEM2 controller with CNH service-tool.
If the failure does not appear again, nothing has to be done, because then it has just been a temporary problem.

EEM2 - 14 Option mismatch

Description:
Valid EEM2 parameters are not found on flash. Application starts to use default EEM2 parameters.
Reaction in EEM:
FC is stored and warning lamp is activated.
Solution:
1. Download correct software in the EEM2 controller.
2. If downloading correct software does not solve the problem, the EEM2 controller is faulty and has to be replaced.
NOTE: If a EEM2 controller from another tractor is used temporary, FC 175 will be activated, because of pump
serial number mismatch.
3. If FC 14 disappears, the EEM2 controller had a temporary fault. Delete the faiure and make a test-run.
If the failure appears again, the EEM2 controller has to be replaced and the the current injection pump (serial
number) has to be coupled to the new EEM2 controller with CNH service-tool.
If the failure does not appear again, nothing has to be done, because then it has just been a temporary problem.

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EEM2 - 15 Supply voltage 5 Vdc too low ( <4.6V)

Description:
Reference supply voltage for sensors is too low.
Reaction in EEM:
FC is stored and warning lamp is activated. The EEM2 controller see wrong values by the sensor and for that beha-
viour of the engine is not correct.
Solution:
The probably cause of the problem is the voltage drop during cranking. If the fault code is active (the fault count is
increased by 1 if it is not already 13) always when ignition is switched on, but engine is not running. Check following
paths:
1. Check the power supply lines
+12V continuous EEM2 (fuse F92 (+30) 10A)
• Measure the voltage from EEM2 PIN70 (+12 Vdc) to PIN69 (ground) of connector X70. If voltage is more
than 1 V below the battery voltage, check the wiring from EEM2 PIN70 of connector X70 to screw connec-
tion X1/10 of the engine print A14 to fuse F92.
+12V continuous, injection pump A2/1 (fuse F94 (+30) 25A)
• Measure the voltage from EEM2 PIN48 (+12 Vdc) to PIN46 (ground) of connector X70. If voltage is more
than 1 V below the battery voltage, check the wiring from EEM2 PIN48 of connector X70 to screw connec-
tion X1/14 of the engine print A14 to fuse F94.
+12V ignition key (fuse F97 (+15) 10A)
• Measure the voltage from EEM2 PIN21 (+12 Vdc) of connector X70. If voltage is more than 1 V below the
battery voltage, check the wiring from EEM2 PIN21 of connector X70 to connector X20/1 (Würth), X24/12
(Berifors), PIN7 of the engine print A14 to fuse F97.
2. Checking the ground lines
• Measure the ground line from EEM2 PIN69 of connector X70 to weld point X0/4/1 and up to
grounding point 11.
• Measure the ground line from EEM2 PIN46 of connector X70 to weld point X0/4/1 and up to
grounding point 11.
• Measure the ground line from the housing of the EEM2-controller to weld point X0/4/1 and up to
grounding point 11.
If the fuse or fuses are blown, replace it with a new fuse and switch the power on. If fuse or fuses blows again, check
the wiring from the fuses to the EEM2 pins 70, 48 and 21 for short circuit to tractor ground. If no short circuit is found
and voltages are correct, the controller is defective. Replace the controller and couple current injection pump (serial
number) to the new EEM2 controller with CNH service tool.
• Check boost pressure sensor B29 for short circuit via supply PIN3 on connector X4/71 and connector X4/71
PIN1 to ground.
• Check the GND wiring from the boost pressure sensor connector X4/71 PIN1 to the EEM2 controller PIN59
of connector X70.
• Check the supply (+5 V) wiring from the boost pressure sensor connector X4/71 PIN3 to the EEM2 controller
PIN11 of connector X70.
Test current EEM2 controller functionality with another EEM2 controller.
NOTE: If EEM2 controller from another tractor is used, FC 175 will be activated, because of pump serial number
mismatch.
If FC 15 disappears, EEM2 controller was damaged. Replace the controller and couple current injection pump(serial
number) to the new EEM2 controller with CNH service tool.

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EEM2 - 16 Supply voltage 5 Vdc too high (>5.2V)

Description:
Reference supply voltage for sensors is too high.
Reaction in EEM:
FC is stored and warning lamp is activated. The EEM2 controller see wrong values by the sensors and for that beha-
viour of the engine is not correct.
Solution:
1. Check the power supply lines
+12V continuous EEM (fuse F92 (+30) 10A)
• Measure the voltage from EEM2 PIN70 (+12 Vdc) to PIN69 (ground) of connector X70. If voltage is more
than 1 V below the battery voltage, check the wiring from EEM2 PIN70 of connector X70 to screw connec-
tion X1/10 of the engine print A14 to fuse F92.
+12V continuous, injection pump A2/1 (fuse F94 (+30) 25A)
• Measure the voltage from EEM2 PIN48 (+12 Vdc) to PIN46 (ground) of connector X70. If voltage is more
than 1 V below the battery voltage, check the wiring from EEM2 PIN48 of connector X70 to screw connec-
tion X1/14 of the engine print A14 to fuse F94.
+12V ignition key (fuse F97 (+15) 10A)
• Measure the voltage from EEM2 PIN21 (+12 Vdc) of connector X70. If voltage is more than 1 V below the
battery voltage, check the wiring from EEM2 PIN21 of connector X70 to connector X20/1 (Würth), X24/12
(Berifors), PIN7 of the engine print A14 to fuse F97.
2. Checking the ground lines
• Measure the ground line from EEM2 PIN69 of connector X70 to weld point X0/4/1 and up to
grounding point 11.
• Measure the ground line from EEM2 PIN46 of connector X70 to weld point X0/4/1 and up to
grounding point 11.
• Measure the ground line from the housing of the EEM2-controller to weld point X0/4/1 and up to
grounding point 11.
• Check boost pressure sensor for short circuit to +12V on PIN3 on connector X4/71. Normally there should
be + 5 V.
• Check the supply (+5 V) wiring from the boost pressure sensor B29 connector X4/71 PIN3 to the EEM2 con-
troller PIN11 of connector X70.
• If no short circuit is found, the voltage regulator of EEM2 controller is defective.
Test current EEM2 controller functionality with another EEM2 controller.
NOTE: If EEM2 controller from another tractor is used, FC 175 will be activated, because of pump serial number
mismatch.
If FC 16 disappears, EEM2 controller was damaged. Replace the controller and couple current injection pump(serial
number) to the new EEM2 controller with CNH service tool.

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EEM2 - 17 Battery voltage too low (<7.8V)

Description:
Supply voltage for EEM2 controller is too low. The probably cause of the problem is the voltage drop during cranking.
Reaction in EEM:
FC is stored and warning lamp is activated. If the failure occurs only a short time, it will not have any influence on the
engine behaviour.
Solution:
The probably cause of the problem is the voltage drop during cranking. If the fault code 17 is active continuously,
check following path:
• Check condition of the battery for too low voltage.
• Check working of the generator (13,8V to 14,5V).
1. Check the power supply lines
+12V continuous EEM2 (fuse F92 (+30) 10A)
• Measure the voltage from EEM2 PIN70 (+12 Vdc) to PIN69 (ground) of connector X70. If voltage is more
than 1 V below the battery voltage, check the wiring from EEM2 PIN70 of connector X70 to screw connec-
tion X1/10 of the engine print A14 to fuse F92.
+12V continuous, injection pump A2/1 (fuse F9 (+30) 25A)
• Measure the voltage from EEM2 PIN48 (+12 Vdc) to PIN46 (ground) of connector X70. If voltage is more
than 1 V below the battery voltage, check the wiring from EEM2 PIN48 of connector X70 to screw connec-
tion X1/14 of the engine print A14 to fuse F94.
+12V ignition key (fuse F97 (+15) 10A)
• Measure the voltage from EEM2 PIN21 (+12 Vdc) of connector X70. If voltage is more than 1 V below the
battery voltage, check the wiring from EEM2 PIN21 of connector X70 to connector X20/1 (Würth), X24/12
(Berifors), PIN7 of the engine print A14 to fuse F97.
2. Check the ground lines
• Measure the ground line from EEM2 PIN69 of connector X70 to weld point X0/4/1 and up to
grounding point 11.
• Measure the ground line from EEM2 PIN46 of connector X70 to weld point X0/4/1 and up to
grounding point 11.
• Measure the ground line from the housing of the EEM2-controller to weld point X0/4/1 and up to
grounding point 11.
If the fuse or fuses are blown, replace it with a new fuse and switch the power on. If fuse or fuses blows again, check
the wiring from the fuses to the EEM2 pins 70, 48 and 21 for short circuit to tractor ground. If no short circuit is found
and voltages are correct, the controller is defective. Replace the controller and couple current injection pump (serial
number) to the new EEM2 controller with CNH service tool.

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EEM2 - 20 ECU temperature too high (>120°C)

Description:
Temperature inside EEM2 controller is too high. The reason could be for example, when overheating has stopped the
engine and the cooling system does not work anymore. Due to radiating heat the temperature may rise inside the
EEM2 controller, because there is no cooling, for the air flow is missing.
Reaction in EEM:
FC is stored and warning lamp is activated.
Solution:
• If the failure IS ACTIVE CONTINUOUSLY, even the controller is cold. Test body temperature of the EEM2
controller by touching. If the controller is not hot, but the failure is still active. The EEM2 controller has to be
replaced. Replace the controller and couple current injection pump (serial number) to the new EEM2 control-
ler with CNH service tool.
• If the failure is NOT ACTIVE anymore, check failure codes 112 and 113 if one of these failure codes has
been active at the same time. Then problem has probably caused by engine overheating. You do not have to
take care about this failure code anymore.
If FC 112 or 113 has not been stored, the temperature element inside the EEM2 controller may be defective. Test
current EEM2 controller functionality with another EEM2 controller.
NOTE: If EEM2 controller from another tractor is used, FC 175 will be activated, because of pump serial number
mismatch.
Couple current injection pump(serial number) to the new EEM2 controller with CNH service tool.

EEM2 - 30 PCU EEPROM checksum defect

Description:
Cause of the problem is a incorrect check sum. At least one eeprom value can not be read in the pump control unit.
This means there are some problems with the PCU hardware or software. Engine power is reduced due this defect.
Reaction in EEM:
FC is stored and warning lamp is activated. Engine power will be reduced.
Solution:
The cause of the problem is a defective PCU.
Delete the fault code. Switch the ignition off (5 sec.) and back to on and start the engine. If the fault is still active, the
problem is a defective PCU A2/2 (Pump Control Unit). Contact the BOSCH service agency.

EEM2 - 31 PCU EEPROM hardware defect

Description:
Cause of the problem is a hardware error. All eeprom values can not be read in the pump control unit. This means
there are some problems with the PCU hardware. Engine power is reduced due this defect.
Reaction in EEM:
FC is stored and warning lamp is activated. Engine power will be reduced.
Solution:
The cause of the problem is a defective PCU.
Delete the fault code. Switch the ignition off (5 sec.) and back to on, if the fault is still active, the problem is a defective
PCU A2/2 (Pump Control Unit). Contact the BOSCH service agency.

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EEM2 - 32 PCU ADC defect

Description:
Incorrect analogy values (for instance fuel temperature) for fuel quantity correction. For example fuel temperature is
an important value for the Injection pump, which is used to calculate the correct injection quantity. Now one of those
analogy values is not correct, so the calculation of correct injection quantity is not correct anymore.
Reaction in EEM:
FC is stored and warning lamp is activated. Engine power will be reduced.
Solution:
The cause of the problem is defective PCU.
Delete the fault code. Switch the ignition off (5 sec.) and back to on, if the fault is still active, the problem is a defective
PCU A2/2 (Pump Control Unit). Contact the BOSCH service agency.

EEM2 - 33 Pump map defect

Description:
After power on, the pump control unit checks during self-test whether a pump map has been programmed and if it
operates correct. The engine may not start and emergency shutdown is activated by the EEM controller.
Reaction in EEM:
FC is stored and warning lamp is activated. The engine will not start and emergency shutdown is activated by the
EEM controller.
Solution:
The cause of the problem is a defective PCU.
Delete the fault code. Switch the ignition off (5 sec.) and back to on, if the fault is still active, the problem is a defective
PCU A2/2 (Pump Central Unit). Contact the BOSCH service agency.

EEM2 - 34 PCU Internal bus defect

Description:
Cause of the problem is a hardware error in the PCU. The pump control unit see wrong injection quantity.
Reaction in EEM:
FC is stored and warning lamp is activated. The engine will not start and emergency shutdown is activated by the
EEM controller.
Solution:
The cause of the problem is a defective PCU.
Delete the fault code. Switch the ignition off (5 sec.) and back to on, if the fault is still active, the problem is a defective
PCU A2/2 (Pump Central Unit). Contact the BOSCH service agency.

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EEM2 - 35 PCU Powerstage defect

Description:
Cause of the problem is a hardware error or solenoid valve voltage measurement error in the PCU.
Reaction in EEM:
FC is stored and warning lamp is activated. Engine power will be reduced.
Solution:
The cause of the problem is a defective PCU.
If there are additional fault codes, repair them first. Delete the fault code. Switch the ignition off (5 sec.) and back to
on, if the fault is still active, the problem is a defective PCU A2/2 (Pump Control Unit). Contact the BOSCH service
agency.

EEM2 - 37 Wrong pump CAN interface configuration

Description:
The EEM controller and pump control unit are not able to communicate because of wrong configuration, FC 33 also
set. Fault code may also activate if for example a wrong spare part injection pump has been installed.
Reaction in EEM:
FC is stored and warning lamp is activated. The engine will not start and emergency shutdown is activated by the
EEM controller.
Solution:
The cause of the problem is a defective PCU.
• Contact the BOSCH service agency, if the injection pump is correct for the Sisu Diesel engine.
If the injection pump A2/1 is correct, delete the fault code. Switch the ignition off (5 sec.) and back to on, if the fault is
still active, the problem is a defective PCU A2/2 (Pump Central Unit). Contact the BOSCH service agency.

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EEM2 - 39 PCU BIP not recognized

Description:
The pump control unit can not recognize begin of injection pulse. Injection timing and fuel amount are not correct then.
Reaction in EEM:
FC is stored and warning lamp is activated.
Solution:
Possible cause of the problem is too long/thin power supply line for the injection pump.
Impedance of the power supply line is too high or defective PCU.
• Check contacts through wiring from the battery to the injection pump A2/1 for bad contact at some connec-
tor. So, check the wiring from EEM2 PIN1 of connector X70 to PIN7 of the Injection pump connector X9/7.
• Check the ground wiring from EEM2 PIN23 of connector X70 to PIN6 of the Injection pump connector X9/7.
Power supply to the PCU A2/2 is provided by the EEM2 controller. Measure the voltage from EEM2 PIN48 (+12 Vdc)
to PIN46 (ground) of connector X70. If voltage is more than 1 V below the battery voltage, check the wiring from EEM2
PIN48 of connector X70 to screw connection X1/14 of the engine print A14 to fuse F94.
NOTE: battery voltage will drop during pre- or postheating period.
If the power supply to the EEM2 controller is correct, but PCU power supply is not OK. Replace the controller and
couple current injection pump (serial number) to the new EEM2 controller with CNH service tool.
If wirings and EEM2 controller are OK, the problem is a defective PCU (Pump Control Unit). Contact the BOSCH ser-
vice agency.

EEM2 - 40 Solenoid valve final defect

Description:
The Pump control unit monitors the solenoid valve current trace. When it recognizes that the solenoid valve is conti-
nuously energized the fault code is activated.
Reaction in EEM:
FC is stored and warning lamp is activated. The engine will not start and emergency shutdown is activated by the
EEM controller.
Solution:
The probably cause of the problem is a defective solenoid valve or a defective PCU A2/2.
Delete the fault code. Switch the ignition off (5 sec.) and back to on, if the fault is still active, the problem is a defective
PCU (Pump Control Unit). Contact the BOSCH service agency.

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EEM2 - 41 Solenoid valve defect

Description:
The Pump control unit monitors the solenoid valve current trace and the solenoid valve quick decay voltage. If both
of these variables are off the permitted range then a solenoid valve defect is recognized.
Reaction in EEM:
FC is stored and warning lamp is activated. Engine power will be reduced (also by the pump itself).
Solution:
The probably cause of the problem is a defective solenoid valve in the injection pump A2/1 or a defective PCU A2/2.
• If there are other failure codes active, for example 56, then repair those failures first.
Delete the fault code. Switch the ignition off (5 sec.) and back to on, if the fault is still active, the problem is a defective
PCU (Pump Control Unit). Contact the BOSCH service agency.

EEM2 - 42 IAT final defect

Description:
IAT is an angular reference for the cam-based control of the fuel quantity solenoid valve. If IAT pulse is missing then
the defect is activated. Fuel injection will be stopped as long as the fault 42 is active.
Reaction in EEM:
FC is stored and warning lamp is activated.
Solution1:
Possible cause of the problem is too low engine operating speed at starting. Check the vehicle battery and starter
motor condition.
• Check the wiring of the starter motor from the battery to the main switch (optional). From main switch to ter-
minal 30 of the starter motor.
• Check the wiring from terminal 50 of the starter motor to the connector X1/2 of the engine print A14. Check
the power on the relay K8/1 on PIN87. Check the power from the screw X1/12 and check the fuse F200.
• Check GND of the starter motor.
• Charge the Battery and check the water level of the battery.
Solution2:
The probably cause of the problem is air leak into fuel at the low pressure side or air in the fuel system.
• Check the tightness of all injection pump fuel lines.
Delete the fault code. Switch the ignition off (5 sec.) and back to on, if the fault is still active, the problem is a defective
PCU A2/2 (Pump Central Unit). Contact the BOSCH service agency.

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EEM2 - 43 PCU Overtemperature

Description:
The pump control unit recognizes overtemperature inside the injection pump A2/1. Reason for this could be for ex-
ample: engine overheating.
Reaction in EEM:
FC is stored and warning lamp is activated. Engine power will be reduced.
Solution:
Find cause for the overtemperature.
• If there are other failure code active, for example 112 or 113: Check those failures first.
• If fault codes 112 or 113 are not stored at the same time: Possible cause for the fault code is a defective
PCU.
Delete the fault code. Switch the ignition off (5 sec.) and back to on, if the fault is still active, the problem is a defective
PCU A2/2 (Pump Control Unit). Contact the BOSCH service agency.

EEM2 - 44 PCU Temperature sensor defect

Description:
Temperature sensing inside the injection pump does not work correctly. The pump control unit use a default value for
pump temperature.
Reaction in EEM:
FC is stored and warning lamp is activated. Engine power will be reduced.
Solution:
The cause of the problem is a defective PCU A2/2.
Delete the fault code. Switch the ignition off (5 sec.) and back to on, if the fault is still active, the problem is a defective
PCU (Pump Control Unit). Contact the BOSCH service agency.

EEM2 - 45 PCU Battery voltage measurement defectiv

Description:
Battery voltage measurement does not work correctly inside the injection pump A2/1 and the pump control unit use
a default value for battery voltage.
Reaction in EEM:
FC is stored and warning lamp is activated.
Solution:
The cause of the problem is a defective PCU A2/2.
• If there are other failure codes active, for example 56: Repair those failures first.
Delete the fault code. Switch the ignition off (5 sec.) and back to on, if the fault is still active, the problem is a defective
PCU (Pump Control Unit). Contact the BOSCH service agency.

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EEM2 - 46 Timing device defect

Description:
There is persistent governor deviation in injection timing or oscillating timing device piston.
Reaction in EEM:
FC is stored and warning lamp is activated. Engine power will be reduced.
Solution 1:
• Probable cause for persistent governor deviation is wrong mounting angle of the pump or a defective injec-
tion pump A2/1.
• Check the correct installation of the injection pump, according to the service manual.
• Delete the fault code. Switch the ignition off (5 sec.) and back to on, if the fault is still active continuously
when the engine is running, the problem can be a defective injection pump. Contact the BOSCH service
agency.
Solution 2:
The probably cause for the oscillation is air leak into fuel at low pressure side or air in the fuel system.
• Check the tightness of all injection pump fuel lines.
• Delete the fault code. Switch the ignition off (5 sec.) and back to on, if the fault is still active, the problem is
a defective PCU A2/2 (Pump Control Unit). Contact the BOSCH service agency.

EEM2 - 48 PCU Speed sensor final defect

Description:
The pump control unit cannot recognize reference pulses to the engine top dead center by the engine control unit.
Reaction in EEM:
FC is stored and warning lamp is activated. Engine power will be reduced and injection timing delayed.
Solution:
If defect 66 is also active at the same time then check cause for it first.
Other:
• Check "DZG" wiring between the pump and EEM controller. Check wiring between connector X9/7 PIN8 of
the injection pump to EEM2 controller connector X70 PIN19.
• If there are not other failures active at the same time, then delete the fault code. Switch the ignition off
(5 sec.) and back to on, if the fault is still active, problem is defective PCU A2/2 (Pump Central Unit) or
EEM2 controller.
Test PCU functionality with another EEM2 controller.
NOTE: If EEM2 controller from another tractor is used, FC 175 will be activated, because of pump serial number
mismatch. If FC 48disappears, EEM2 controller was damaged. Replace the controller and couple current injection
pump(serial number) to the new EEM2 controller with CNH service tool.
If FC 48 does not disappear with another EEM2 controller, injection pump A2/1 is damaged. Contact the Bosch ser-
vice agency.

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EEM2 - 49 PCU CAN bus final defect

Description:
There is problem at the CAN bus between the pump control unit and EEM controller. The pump control unit see con-
tinuously no message or impaired value range in the control message.
Reaction in EEM:
FC is stored and warning lamp is activated. Emergency shutdown will be activated by the EEM controller.
Solution:
1. Check CAN bus wiring from the injection pump (connector X9/7 PIN1 for CANL) to X70 PIN44 of the EEM2 con-
troller. For short circuit.
2. Check CAN bus wiring from the injection pump A2/1 (connector X9/7 PIN2 for CANH) to X70 PIN20 of the EEM2
controller. For short circuit.
3. Check contacts through wiring from the battery to the injection pump for bad contact at some connector. So, check
the wiring from EEM2 PIN1 of connector X70 to PIN7 of the Injection pump connector X9/7.
4. Check the ground wiring from EEM2 PIN23 of connector X70 to PIN6 of the Injection pump connector X9/7.
5. Measure the voltage from EEM2 PIN70 (+12 Vdc) to PIN69 (ground) of connector X70. If voltage is more than
1 V below the battery voltage, check the wiring from EEM2 PIN70 of connector X70 to screw connection X1/10
of the engine print A14 to fuse F92.
6. Measure the voltage from EEM2 PIN48 (+12 Vdc) to PIN46 (ground) of connector X70. If voltage is more than
1 V below the battery voltage, check the wiring from EEM2 PIN48 of connector X70 to screw connection X1/14
of the engine print A14 to fuse F94.
7. Measure the ground line from EEM2 PIN69 of connector X70 to weld point X0/4/1 and up to grounding point 11.
8. Measure the ground line from EEM2 PIN46 of connector X70 to weld point X0/4/1 and up to grounding point 11.
9. Measure the ground line from the housing of the EEM2 controller to weld point X0/4/1 and up to
grounding point 11.
10. Measure the terminating resistor of EEM2 controller of connector X70 PIN44 and PIN20
(resistance 120 Ohms ± 10%). Disconnect the connector X9/7 of the Injection pump first.
11. If the CAN bus between the injection pump and EEM2 controller and also power supply are OK. Possible causes
are defective EEM2 controller or defective PCU A2/2 (pump control unit).
12. Test PCU functionality with another EEM2 controller.
NOTE: If EEM2 controller from another tractor is used, FC 175 will be activated, because of pump serial number
mismatch.
If FC 49 disappears, EEM2 controller was damaged. Replace the controller and couple current injection pump(se-
rial number) to the new EEM2 controller with CNH service tool. If FC 49 does not disappear with another EEM2
controller, Bosch VP PCU is damaged. Take a contact to the Bosch service agency.
Delete the fault code. Switch the ignition off (5 sec.) and back to on and start the engine. If the fault is still active,
problem is defective PCU(Pump Central Unit). Take a contact to the BOSCH service agency.

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EEM2 - 50 PCU reset while engine running (<6.0V)

Description:
Supply voltage of the pump control unit drops below allowed voltage limit (< 6.0 V) during operation. If the supply
voltage returns back to allowed voltage range(< 200 ms), the engine continues normal operation. Otherwise engine
will stop. In every case the failure code has been stored.
Reaction in EEM:
FC is stored and warning lamp is activated. No fuel injection during PCU reset time.
Solution:
1. Check condition of the battery for too low voltage (<11.5V).
2. Check working of the generator (13,8 to 14,5V).
3. Check contacts through wiring from the battery to the injection pump for bad contact at some connector
(see FC 17). So, check the wiring from EEM2 PIN1 of connector X70 to PIN7 of the injection pump A2/1
connector X9/7.
4. Check the ground wiring from EEM2 PIN23 of connector X70 to PIN6 of the Injection pump connector X9/7.
Power supply to the PCU is provided by the EEM2 controller. Measure the voltage from EEM2 PIN48 (+12 Vdc) to
PIN46 (ground) of connector X70. If voltage is more than 1 V below the battery voltage, check the wiring from EEM2
PIN48 of connector X70 to screw connection X1/14 of the engine print A14 to fuse F94. Check also ground connection
from PIN46 to grounding point 11.
If the power supply to the EEM2 controller is correct, but PCU A2/2 power supply is not OK. Replace the controller
and couple current injection pump (serial number) to the new EEM2 controller with CNH service tool.
NOTE: FC 50 may activate if power supply to the EEM2 has been switched off irregular.

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EEM2 - 51 CAN connection to PCU defective

Description:
The EEM controller is not able to communicate with injection pump.
Reaction in EEM:
FC is stored and warning lamp is activated. Limp home function is activated in the injection pump. The engine will run
at constant speed 1400 rpm with reduced power. If power supply is missing the engine will not start.
Solution:
1. Check CAN bus wiring from the injection pump A2/1 (connector X9/7 PIN1 for CANL) to X70 PIN44 of the EEM2
controller. For short circuit.
2. Check CAN bus wiring from the injection pump (connector X9/7 PIN2 for CANH) to X70 PIN20 of the EEM2 con-
troller. For short circuit.
3. Check contacts through wiring from the battery to the injection pump for bad contact at some connector. So, check
the wiring from EEM2 PIN1 of connector X70 to PIN7 of the Injection pump connector X9/7.
4. Check the ground wiring from EEM2 PIN23 of connector X70 to PIN6 of the Injection pump connector X9/7.
5. Measure the voltage from EEM2 PIN70 (+12 Vdc) to PIN69 (ground) of connector X70. If voltage is more than
1 V below the battery voltage, check the wiring from EEM2 PIN70 of connector X70 to screw connection X1/10
of the engine print A14 to fuse F92.
6. Measure the voltage from EEM2 PIN48 (+12 Vdc) to PIN46 (ground) of connector X70. If voltage is more than
1 V below the battery voltage, check the wiring from EEM2 PIN48 of connector X70 to screw connection X1/14
of the engine print A14 to fuse F94.
7. Measure the ground line from EEM2 PIN69 of connector X70 to weld point X0/4/1and up to grounding point 11.
8. Measure the ground line from EEM2 PIN46 of connector X70 to weld point X0/4/1and up to grounding point 11.
9. Measure the ground line from housing of the EEM2 controller to weld point X0/4/1 and up to grounding point 11.
10. Measure the terminating resistor of EEM2 controller on connector X70 PIN44 and PIN20
(resistance 120 Ohms ± 10%). Disconnect the connector X9/7 of the Injection pump first.
11. If the CAN bus between the injection pump and EEM2 controller and also power supply are OK. Possible causes
are defective EEM2 controller or defective PCU(pump control unit).
Test PCU functionality with another EEM2 controller.
NOTE: If EEM2 controller from another tractor is used, FC 175 will be activated, because of pump serial number
mismatch. If FC 51disappears, EEM2 controller was damaged. Replace the controller and couple current injection
pump(serial number) to the new EEM2 controller with CNH service tool.
If FC 51 does not disappear with another EEM2 controller, PCU A2/2 is damaged. Contact the Bosch service agency.

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EEM2 - 52 Emergency shutdown signal (MAB) test dedects a defect

Description:
Normally the engine shutdown is managed by CAN bus. If the normal shutdown can not be managed by CAN bus,
the EEM2 controller activates MAB emergency shutdown signal which will shutdown the engine and always after
some seconds EEM2 hardware cuts power supply to the PCU(if MAB signal has been activated). To be sure that the
MAB signal is working in emergency situations, the EEM2 tests the MAB line continuously. If the test fails The FC 52
is stored.
Reaction in EEM:
FC is stored and warning lamp is activated.
Solution:
1. Check MAB line between EEM2 controller of connector X70 PIN43 to the injection pump A2/1, connector X9/7
PIN5.
Test PCU functionality with another EEM2 controller.
NOTE: If EEM2 controller from another tractor is used, FC 175 will be activated, because of pump serial number
mismatch.
If FC 52 disappears, EEM2 controller was damaged. Replace the controller and couple current injection pump(serial
number) to the new EEM2 controller with CNH service tool.
If FC 52 does not disappear with another EEM2 controller, PCU A2/2 is damaged. Contact to the Bosch service
agency.

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EEM2 - 53 PSG1 signal is missing

Description:
EEM controller can not communicate correctly with PCU, by CAN bus. This message contains important information
to run the engine.
Reaction in EEM:
FC is stored and warning lamp is activated. Emergency shutdown will be activated by the EEM2 controller.
Solution:
The probably cause of the problem is a defective PCU.
1. Check CAN bus wiring from the injection pump A2/1 (connector X9/7 PIN1 for CANL) to X70 PIN44 of the EEM2
controller. For short circuit.
2. Check CAN bus wiring from the injection pump (connector X9/7 PIN2 for CANH) to X70 PIN20 of the EEM2 con-
troller. For short circuit.
3. Check contacts through wiring from the battery to the injection pump for bad contact at some connector. So, check
the wiring from EEM2 PIN1 of connector X70 to PIN7 of the Injection pump connector X9/7.
4. Check the ground wiring from EEM2 PIN23 of connector X70 to PIN6 of the Injection pump connector X9/7.
5. Measure the voltage from EEM2 PIN70 (+12 Vdc) to PIN69 (ground) of connector X70. If voltage is more than
1 V below the battery voltage, check the wiring from EEM2 PIN70 of connector X70 to screw connection X1/10
of the engine print A14 to fuse F92.
6. Measure the voltage from EEM2 PIN48 (+12 Vdc) to PIN46 (ground) of connector X70. If voltage is more than
1 V below the battery voltage, check the wiring from EEM2 PIN48 of connector X70 to screw connection X1/14
of the engine print A14 to fuse F94.
7. Measure the ground line from EEM2 PIN69 of connector X70 to weld point X0/4/1 and up to grounding point 11.
8. Measure the ground line from EEM2 PIN46 of connector X70 to weld point X0/4/1 and up to grounding point 11.
9. Measure the ground line from the housing of the EEM2 controller to weld point X0/4/1 and up to
grounding point 11.
10. Measure the terminating resistor of EEM2 controller of connector X70 PIN44 and PIN20
(resistance 120 Ohms ± 10%).
11. Check the bridge of EEM2 connector X70 between PIN66 and 67.
12. Make sure the CAN bus lines between the injection pump and EEM2 controller and also power supply
(see FC 17) are OK. Possible causes are defective EEM2 controller or defective PCU A2/2 (pump control unit).
13. Test PCU functionality with another EEM2 controller.
NOTE: If EEM2 controller from another tractor is used, FC 175 will be activated, because of pump serial number
mismatch.
If FC 53 disappears, EEM2 controller was damaged. Replace the controller and couple current injection pump(se-
rial number) to the new EEM2 controller with CNH service tool. If FC 53 does not disappear with another EEM2
controller, the PCU is damaged. Contact the Bosch service agency.
Switch the ignition off (5 sec.) and back to on, if the fault is still active, problem is defective PCU(Pump Central Unit).
Take a contact to the BOSCH service agency.

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EEM2 - 54 Injection control pulse width defect

Description:
EEM2 controller can not manage normal shutdown by zero fuel quantity. Because of defective Can bus or power sup-
ply or EEM2 controller or PCU.
Reaction in EEM:
FC is stored and warning lamp is activated. Emergency shutdown will be activated by the EEM controller.
Solution:
The probably cause of the problem is defective PCU.
1. Check CAN bus wiring from the injection pump A2/1 (connector X9/7 PIN1 for CANL) to X70 PIN44 of the EEM2
controller for short circuit.
2. Check CAN bus wiring from the injection pump (connector X9/7 PIN2 for CANH) to X70 PIN20 of the EEM2 con-
troller for short circuit.
3. Check contacts through wiring from the battery to the injection pump for bad contact at some connector. So, check
the wiring from EEM2 PIN1 of connector X70 to PIN7 of the Injection pump connector X9/7.
4. Check the ground wiring from EEM2 PIN23 of connector X70 to PIN6 of the Injection pump connector X9/7.
5. Measure the voltage from EEM2 PIN70 (+12 Vdc) to PIN69 (ground) of connector X70. If voltage is more than
1 V below the battery voltage, check the wiring from EEM2 PIN70 of connector X70 to screw connection X1/10
of the engine print A14 to fuse F92.
6. Measure the voltage from EEM2 PIN48 (+12 Vdc) to PIN46 (ground) of connector X70. If voltage is more than
1 V below the battery voltage, check the wiring from EEM2 PIN48 of connector X70 to screw connection X1/14
of the engine print A14 to fuse F94.
7. Measure the ground line from EEM2 PIN69 of connector X70 to weld point X0/4/1 and up to grounding point 11
8. Measure the ground line from EEM2 PIN46 of connector X70 to weld point X0/4/1 and up to grounding point 11.
9. Measure the ground line from the housing of the EEM2 controller to weld point X0/4/1 and up to
grounding point 11.
10. Measure the terminating resistor of EEM2 controller of connector X70 PIN44 and PIN20
(resistance 120 Ohms ± 10%).
11. Check the bridge of EEM2 connector X70 between PIN66 and 67.
Check if the CAN bus between the injection pump and EEM2 controller and also power supply (see FC 17) are
OK. Possible causes are defective EEM2 controller or defective PCU A2/2 (pump control unit).
12. Test PCU functionality with another EEM2 controller.
NOTE: If EEM2 controller from another tractor is used, FC 175 will be activated, because of pump serial number
mismatch.
If FC 54 disappears, EEM2 controller was damaged. Replace the controller and couple current injection pump
(serial number) to the new EEM2 controller with CNH service tool. If FC 54 does not disappear with another EEM2
controller, PCU is damaged. Contact the Bosch service agency.
Switch the ignition off (5 sec.) and back to on, if the fault is still active, the problem is a defective PCU(Pump Control
Unit). Contact to the BOSCH service agency.

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EEM2 - 55 Pump speed deviation

Description:
The EEM2 controller has inconsistent speed information between crank speed (detected by a speed sensor from the
flywheel ring gear) and pump speed (detected inside the Injection pump). Possible cause for the problem is PCU,
because if there is a failure with the speed sensor (B20), there would be another failure code.
Reaction in EEM:
FC is stored and warning lamp is activated. Emergency shutdown will be activated by the EEM2 controller.
Solution:
The probably cause of the problem is a defective PCU A2/2.
Switch the ignition off for 5 sec, then start the engine. If the fault is still active, the problem is a defective PCU (Pump
Central Unit). Contact the BOSCH service agency.

EEM2 - 56 Pump supply voltage too low (< 6.8V)

Description:
Supply voltage is too low for defined time. Engine may not start.
Reaction in EEM:
FC is stored and warning lamp is activated.
Solution 1:
The probably cause of the problem is an excessive voltage drop during cranking.
1. Check condition of the battery for too low voltage (<11.5V).
2. Check working of the generator (13,8 to 14,5 V).
If the failure is active continuously after ignition on (see also FC 17):
1. Measure the voltage from EEM2 PIN70 (+12 Vdc) to PIN69 (ground) of connector X70. If voltage is more than
1 V below the battery voltage, check the wiring from EEM2 PIN70 of connector X70 to screw connection X1/10
of the engine print A14 to fuse F92.
2. Measure the voltage from EEM2 PIN48 (+12 Vdc) to PIN46 (ground) of connector X70. If voltage is more than
1 V below the battery voltage, check the wiring from EEM2 PIN48 of connector X70 to screw connection X1/14
of the engine print A14 to fuse F94.
3. Measure the ground line from EEM2 PIN69 of connector X70 to weld point X0/4/1 and up to grounding point 11.
4. Measure the ground line from EEM2 PIN46 of connector X70 to weld point X0/4/1 and up to grounding point 11.
5. Measure the ground line from the housing of the EEM2 controller to weld point X0/4/1 and up to
grounding point 11.
6. Check contacts through wiring from the battery to the injection pump for bad contact at some connector. So, check
the wiring from EEM2 PIN1 of connector X70 to PIN7 of the injection pump A2/1 connector X9/7.
7. Check the ground wiring from EEM2 PIN23 of connector X70 to PIN6 of the Injection pump connector X9/7.

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EEM2 - 57 Pump supply voltage too high (>17.0V)

Description:
Supply voltage is too high for defined time.
Reaction in EEM:
FC is stored and warning lamp is activated. EEM2 controller will switch off supply voltage to PCU and will stop the
engine if the failure is active for more than 20 seconds.
Solution:
1. Check if the generator is working and if the charging voltage is correct (<15 V).
2. Measure the voltage from EEM2 PIN70 (+12 Vdc) to PIN69 (ground) of connector X70. If voltage is more than
1 V below the battery voltage, check the wiring from EEM2 PIN70 of connector X70 to screw connection X1/10
of the engine print A14 to fuse F92.
3. Measure the voltage from EEM2 PIN48 (+12 Vdc) to PIN46 (ground) of connector X70. If voltage is more than
1 V below the battery voltage, check the wiring from EEM2 PIN48 of connector X70 to screw connection X1/14
of the engine print A14 to fuse F94.
4. Measure the ground line from EEM2 PIN69 of connector X70 to weld point X0/4/1 and up to grounding point 11.
5. Measure the ground line from EEM2 PIN46 of connector X70 to weld point X0/4/1 and up to grounding point 11.
6. Measure the ground line from the housing of the EEM2 controller to weld point X0/4/1 and up to
grounding point 11.
If power supply and wirings to the EEM2 are correct:
1. Test current EEM2 controller functionality with another EEM2 controller.
NOTE: If EEM2 controller from another tractor is used, FC 175 will be activated, because of pump serial number
mismatch.
If FC 57 disappears, EEM2 controller was damaged. Replace the controller and couple current injection pump
(serial number) to the new EEM2 controller with CNH service tool.

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EEM2 - 66 Signal of speed sensor B20 faulty

Description:
EEM2 controller can not recognize correct speed signal from the speed sensor B20.
Reaction in EEM:
FC is stored and warning lamp is activated. EEM2 will start to use redundant speed information from the injection
pump and engine speed is limited to 1800 rpm. Engine power will be reduced and injection timing delayed.
Solution:
1. Check contact surfaces of pins. (oxidation)
2. Check +12V supply voltage for the speed sensor. Use Adapter 380000070.
Check the voltages from the speed sensor (B20) on connector X3/20 between PIN3 (+12V) and PIN1 (GND).
3. Check the wiring from speed sensor (B20) on connector X3/20 PIN3 (+12V) to EEM2 controller connector X70
PIN45.
4. Check the wiring from speed sensor (B20) on connector X3/20 PIN1 (GND) to EEM2 controller connector X70
PIN62.
5. Check the wiring from speed sensor (B20) on connector X3/20 PIN2 (rpm signal) to EEM2 controller connector
X70 PIN39.
Check the sensor. Start the engine.
Use monitor function of CNH service tool "engine speed rpm" and "requested engine speed").
If the engine speed is more than 100 rpm lower on idle than requested speed or the engine speed is changing a wide
range, the speed sensor might be defective.
• Keep the engine running and measure the speed pulses between the tractor ground X3/20 PIN1 and the
sensor connector X3/20 PIN2. The pulses should be from 0 V to battery voltage (12 V).
• Battery voltage may drop down (<12V) during post heating.
If no pulses are detected replace faulty sensor.

EEM2 - 94 Engine overspeed (> 3000 rpm)

Description:
The fault is activated if the engine speed exceeds 3000 rpm during operation. Possible cause is engine braking at
downhill with wrong gear ratio or driving downhill too fast (vehicle speed).
Reaction in EEM:
FC is stored and warning lamp is activated. No fuel injection. Engine will recover after returning to normal condition
(<3000rpm).

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EEM2 - 99 Oil pressure too low, alarm

Description:
Oil pressure drops below the alarm level (<0.5 bar).
Reaction in EEM:
FC is stored and warning lamp is activated. The engine will stop automatically, after 30 seconds. Activation of the
stopping procedure can be detected with ICU(stop signal on the LCD and buzzer). Oil pressure lamp has been swit-
ched on.
Possible causes:
1. There are impurities in the oil pressure control valve.
2. The oil is of incorrect SAE grade.
3. The oil is too hot.
4. The bearings have excessive clearance.
5. The idling speed is too low.
6. The oil pressure switch S6 is defective or the wiring has a short circuit to ground.
7. The control unit is defective.
8. The oil filter is clogged.
9. The oil is diluted by fuel.
10. The engine has run short of oil.
11. Check mechanical condition of the engine.
Solution:
Find cause for the low oil pressure indication. Check and repair according to service instructions. To check the elec-
trical defects, check the oil pressure switch, the switch wiring and the controller input:
1. Remove the oil pressure switch (S6).
NOTE: Do not run the engine when the oil pressure switch is removed.
2. Apply a pressure of 0.5 - 10 bar to the pressure port of the switch.
3. Verify, that the switch is open by measuring the resistance between the switch terminal and the switch body.
4. If the pressure switch is defective, replace it.
5. If the oil pressure switch is working correctly, check the wiring from EEM2controller PIN34 of connector X70 to
the pressure switch (S6) terminal for short circuit to ground. Re-install the pressure switch and connect the wire.
If the wiring is correct, check the control unit input operation. Disconnect wiring from EEM2controller PIN34 of con-
nector X70. Switch on the ignition. If the failure is still active EEM2 controller has to be replaced. Replace the controller
and couple current injection pump (serial number) to the new EEM2 controller with CNH service tool.

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EEM2 - 100 Boost pressure signal out of range (too low)

Description:
The measured signal by the boost pressure sensor B29 lies below the normal operating range. Reason could be a
defective boost pressure sensor, or a problem in the wiring between boost pressure sensor and EEM2-controller, or
defective EEM2 controller.
Reaction in EEM:
FC is stored and warning lamp is activated. Functions by the boost pressure are not active.
Solution:
1. Check contact surfaces of connector X4/71 (all pins) and EEM2 controller PINs 59, 12, 11, 35 of connector X70.
(oxidation)
2. Check the wiring from the EEM2 controller to the boost pressure sensor B29.
3. Check the GND wiring from the boost pressure sensor connector X4/71 PIN1 to the EEM2 controller PIN59 of
connector X70.
4. Check the supply (+5 V) wiring from the boost pressure sensor connector X4/71 PIN3 to the EEM2 controller
PIN11 of connector X70, check also +5 V supply.
5. Check the boost pressure output signal wiring from the boost pressure sensor connector X4/71 PIN4 to the EEM2
controller PIN35 of connector X70.
6. Boost pressure can be monitored with CNH service tool via CAN bus monitoring function "boost pressure". Pre-
sent pressure can be compared to output voltage of boost pressure sensor connector X4/71 PIN4. (see signal
voltage of boost pressure)
7. If the engine is running >1200 rpm (so boost pressure should be present) and if no boost pressure is detected by
the boost pressure sensor, the boost pressure sensor has to be replaced.
If the boost pressure signal is present on EEM2 controller connector X70, PIN35, then test current EEM2 controller
functionality with another EEM2 controller.
NOTE: If EEM2 controller from another tractor is used, FC 175 will be activated, because of pump serial number
mismatch.
If FC 100 disappears, EEM2 controller was damaged. Replace the controller and couple current injection pump (serial
number) to the new EEM2 controller with CNH service tool.

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EEM2 - 101 Boost pressure signal out of range (too high)

Description:
The measured signal by the boost pressure sensor B29 lies above the normal operating range. Reason could be a
defective boost pressure sensor, or a problem in the wiring between boost pressure sensor and EEM2-controller, or
defective EEM2 controller.
Reaction in EEM:
FC is stored and warning lamp is activated. Functions by the boost pressure are not active.
Solution:
1. Check the wiring from the EEM2 controller to the boost pressure sensor B29.
2. Check the GND wiring from the boost pressure sensor connector X4/71 PIN1 to the EEM2 controller PIN59 of
connector X70.
3. Check the supply (+5 V) wiring from the boost pressure sensor connector X4/71 PIN3 to the EEM2 controller
PIN11 of connector X70. If the wire is OK, but +5 V supply between X4/71 PIN3 and PIN1 is higher than 5.2 V,
the EEM2 controller might be defective. Test current EEM2 controller functionality with another EEM2 controller.
NOTE: If EEM2 controller from another tractor is used, FC 175 will be activated, because of pump serial number
mismatch. If FC 101 disappears, EEM2 controller was damaged. Replace the controller and couple current injection
pump(serial number) to the new EEM2 controller with CNH service tool.
4. Check the boost pressure output signal wiring from the boost pressure sensor connector X4/71 PIN4 to the EEM2
controller PIN35 of connector X70. If the boost pressure output signal is > 4.8 V, boost pressure sensor has to be
replaced.
5. Boost pressure can be monitored with CNH service tool via CAN bus monitoring function(boost pressure). Pre-
sent pressure can be compared to output voltage of boost pressure sensor connector X4/71 PIN4. (see signal
voltage of boost pressure)
If the correct boost pressure signal is present on EEM2 controller connector X70, PIN35, then test current EEM2 con-
troller functionality with another EEM2 controller.
NOTE: If EEM2 controller from another tractor is used, FC 175 will be activated, because of pump serial number
mismatch. If FC 100 disappears, EEM2 controller was damaged. Replace the controller and couple current injection
pump(serial number) to the new EEM2 controller with CNH service tool.

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EEM2 - 102 Boost pressure too low

Description:
Boost pressure drops below the alarm level.
Reaction in EEM:
FC is stored and warning lamp is activated.
Solution:
Find a cause for the low boost pressure indication.
Possible causes:
1. Check the boost pressure pipelines tightness of the engine.
2. Check the turbo charger condition of the engine.
3. Check mechanical condition of the engine.
4. Check the boost pressure sensor B29.
5. Check contact surfaces of connector X4/71 (all pins) and EEM2 controller PINs 59, 12, 11, 35 of connector X70.
(oxidation)
Check the wiring from the EEM2 controller to the boost pressure sensor B29.
1. Check the GND wiring from the boost pressure sensor connector X4/71 PIN1 to the EEM2 controller PIN59 of
connector X70.
2. Check the supply (+5 V) wiring from the boost pressure sensor connector X4/71 PIN3 to the EEM2 controller
PIN11 of connector X70, check also +5 V supply.
3. Check the boost pressure output signal wiring from the boost pressure sensor connector X4/71 PIN4 to the EEM2
controller PIN35 of connector X70.
4. Check the temperature signal wiring from the boost pressure sensor connector X4/71 PIN2 to the EEM2 controller
PIN12 of connector X70.
5. Boost pressure can be monitored with CNH service tool via CAN bus monitoring function(boost pressure). Pre-
sent pressure can be compared to output voltage of boost pressure sensor connector X4/71 PIN4. (see compa-
rison boost pressure / signal voltage)
Test current EEM2 controller functionality with another EEM2 controller.
NOTE: If EEM2 controller from another tractor is used, FC 175 will be activated, because of pump serial number
mismatch. If FC 102 disappears, EEM2 controller was damaged. Replace the controller and couple current injection
pump(serial number) to the new EEM2 controller with CNH service tool.

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EEM2 - 110 Coolant temperature signal out of range (too low)

Description:
The measured signal of the coolant temperature sensor lies below the normal operating range. The cause of the pro-
blem might be the sensor itself, wirings or EEM2 controller.
Reaction in EEM:
FC is stored and warning lamp is activated. Engine power will be reduced. Engine protection and others functions by
the coolant temperature are not active. For instance overheating protection is not active.
NOTE: May cause engine damage, if the engine will overheat.
Solution:
1. Check contact surfaces of temperature sensor B22 pins of connector X2/22 and the pins of the EEM2 controller
connector X70 (PINs 9 and 33) (oxidation).
2. Check the sensor wiring. From temperature sensor B22 connector X2/22 PIN1 to EEM2 controller connector X70
PIN33.
3. Check the sensor wiring. From temperature sensor B22 connector X2/22 PIN2 to EEM2 controller connector X70
PIN9.
4. Engine temperature can be monitored with CNH service tool via CAN bus monitoring function(engine coolant
temperature). Present temperature can be compared to resistance of temperature sensor (B22) connector X2/22
between PIN1 and 2. (see resistance of coolant temperature sensor)
Test current EEM2 controller functionality with another EEM2 controller.
NOTE: If EEM2 controller from another tractor is used, FC 175 will be activated, because of pump serial number
mismatch. If FC 110 disappears, EEM2 controller was damaged. Replace the controller and couple current injection
pump(serial number) to the new EEM2 controller with CNH service tool.

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EEM2 - 111 Coolant temperature signal out of range (too high)

Description:
The measured signal by the coolant temperature sensor lie above the normal operating range. The cause of the pro-
blem might be sensor itself, wirings or EEM2 controller.
Reaction in EEM:
FC is stored and warning lamp is activated. Fuel quantity reduction. Engine protection and others functions by the
coolant temperature are not active. For instance overheating protection is not active.
NOTE: May cause engine damage, if the engine will overheat.
Solution:
1. Check contact surfaces of temperature sensor (B22) pins of connector X2/22 and the pins of the EEM2 controller
connector X70 (pins 9 and 33). (oxidation)
2. Check the sensor wiring. From temperature sensor B22 connector X2/22 PIN1 to EEM2 controller connector X70
PIN33.
3. Check the sensor wiring. From temperature sensor B22 connector X2/22 PIN2 to EEM2 controller connector X70
PIN9.
4. Engine temperature can be monitored with CNH service tool via CAN bus monitoring function(engine coolant
temperature). Present temperature can be compared to resistance of temperature sensor (B22) connector X2/22
between PIN1 and 2. (see resistance of coolant temperature sensor values)
Test current EEM2 controller functionality with another EEM2 controller.
NOTE: If EEM2 controller from another tractor is used, FC 175 will be activated, because of pump serial number
mismatch. If FC 111 disappears, EEM2 controller was damaged. Replace the controller and couple current injection
pump(serial number) to the new EEM2 controller with CNH service tool.

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EEM2 - 112 Coolant temperature too high, warning

Description:
Coolant temperature exceed the overheating limit value (106°C). Warning can be detected with the ADIC after 110°C.
Reaction in EEM:
FC is stored and warning lamp is activated. The Engine power will be reduced above this limit to prevent overheating
of the engine.
Solution:
Find cause for the overheating.
Possible causes:
1. Check the coolant level.
2. Check condition of the radiator.
3. Check mechanical condition of the engine.
4. Check contact surfaces of temperature sensor (B22) pins (oxidation).
5. Check the sensor wiring. From temperature sensor B22 connector X2/22 PIN1 to EEM2 controller connector X70
PIN33.
From temperature sensor B22 connector X2/22 PIN2 to EEM2 controller connector X70 PIN9.
6. Check the temperature sensor. (see resistance of coolant temperature sensor values)
7. Engine temperature can be monitored with CNH service tool via CAN bus monitoring function(engine coolant
temperature). Present temperature can be compared to resistance of temperature sensor (B22) connector X2/22
between PIN1 and 2.
Test current EEM2 controller functionality with another EEM2 controller.
NOTE: If EEM2 controller from another tractor is used, FC 175 will be activated, because of pump serial number
mismatch. If FC 112 disappears, EEM2 controller was damaged. Replace the controller and couple current injection
pump(serial number) to the new EEM2 controller with CNH service tool.

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EEM2 - 113 Coolant temperature too high, alarm

Description:
Coolant temperature rise above the alarm level (113°C). Warning can be detected with the ADIC after 110°C.
Reaction in EEM:
FC is stored and warning lamp is activated. The ICU is giving a warning on LCD and activates the buzzer. After then
the engine will stop automatically, after 30 seconds.
Solution:
Find cause for the overheating.
Possible causes:
1. Check the coolant level.
2. Check condition of the radiator.
3. Check mechanical condition of the engine.
4. Check contact surfaces of temperature sensor (B22) pins (oxidation).
5. Check the sensor wiring. From temperature sensor B22 connector X2/22 PIN1 to EEM2 controller connector X70
PIN33.
From temperature sensor B22 connector X2/22 PIN2 to EEM2 controller connector X70 PIN9.
6. Check the temperature sensor. (see resistance of coolant temperature sensor values)
7. Engine temperature can be monitored with CNH service tool via CAN bus monitoring function(engine coolant
temperature). Present temperature can be compared to resistance of temperature sensor (B22) connector X2/22
between PIN1 and 2.
Test current EEM2 controller functionality with another EEM2 controller.
NOTE: If EEM2 controller from another tractor is used, FC 175 will be activated, because of pump serial number
mismatch. If FC 113 disappears, EEM2 controller was damaged. Replace the controller and couple current injection
pump(serial number) to the new EEM2 controller with CNH service tool.

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EEM2 - 114 Intake air temperature signal out of range (too low)
Description:
The measured signal by the temperature sensor (integrated in the boost pressure sensor) lies below the normal ope-
rating range. Reason could be a defective boost pressure sensor, or a problem in the wiring between boost pressure
sensor B29 and EEM2-controller, or defective EEM2 controller.
Reaction in EEM:
FC is stored and warning lamp is activated. Functions by the intake manifold temperature are not active.
Solution:
1. Check contact surfaces of connector X4/71 (all pins) and EEM2 controller pins 59, 12, 11, 35 of connector X70.
(oxidation)
2. Check the GND wiring from the boost pressure sensor connector X4/71 PIN1 to the EEM2 controller PIN59 of
connector X70.
3. Check the supply (+5 V) wiring from the boost pressure sensor connector X4/71 PIN3 to the EEM2 controller
PIN11 of connector X70, check also +5 V supply.
4. Check the temperature signal wiring from the boost pressure sensor connector X4/71 PIN2 to the EEM2 controller
PIN12 of connector X70.
5. Intake manifold temperature can be monitored with CNH service tool via CAN bus monitoring function (Intake ma-
nifold temperature). Present temperature can be compared to resistance of boost pressure sensor connector
X4/71 between PIN2 (temperature output) and PIN1 (GND). (see resistance of boost pressure sensor values)
If the intake manifold temperature signal is present on EEM2 controller connector X70, PIN12, then test current EEM2
controller functionality with another EEM2 controller.
NOTE: If EEM2 controller from another tractor is used, FC 175 will be activated, because of pump serial number
mismatch. If FC 114 disappears, EEM2 controller was damaged. Replace the controller and couple current injection
pump(serial number) to the new EEM2 controller with CNH service tool.

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EEM2 - 115 Intake air temperature signal out of range (too high)
Description:
The measured signal by the temperature sensor (integrated in the boost pressure sensor) lies above the normal ope-
rating range. Reason could be a defective boost pressure sensor B29, or a problem in the wiring between boost pres-
sure sensor and EEM2-controller, or defective EEM2 controller.
Reaction in EEM:
FC is stored and warning lamp is activated. Functions by the intake manifold temperature are not active.
Solution:
1. Check the wiring from the EEM2 controller to the boost pressure sensor B29.
2. Check the GND wiring from the boost pressure sensor connector X4/71 PIN1 to the EEM2 controller PIN59 of
connector X70.
3. Check the supply (+5 V) wiring from the boost pressure sensor connector X4/71 PIN3 to the EEM2 controller
PIN11 of connector X70, check also +5 V supply.
4. Check the temperature signal wiring from the boost pressure sensor connector X4/71 PIN2 to the EEM2 controller
PIN12 of connector X70.
5. Intake manifold temperature can be monitored with CNH service tool via CAN bus monitoring function
(Intake manifold temperature). Present temperature can be compared to resistance of boost pressure sensor con-
nector X4/71 between PIN2(temperature output) and PIN1 (GND)
(see resistance of boost pressure sensor values).
If the intake manifold temperature signal is present on EEM2 controller connector X70, PIN12, then test current EEM2
controller functionality with another EEM2 controller.
NOTE: If EEM2 controller from another tractor is used, FC 175 will be activated, because of pump serial number
mismatch. If FC 114 disappears, EEM2 controller was damaged. Replace the controller and couple current injection
pump(serial number) to the new EEM2 controller with CNH service tool.

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EEM2 - 116 Intake air temperature too high

Description:
Intake manifold temperature rise above the warning limit value (90°C). The air temperature sensor is integrated in the
boost pressure sensor B29.
Reaction in EEM:
FC is stored and warning lamp is activated. Engine power will be reduced.
Solution:
Find cause for the too high intake manifold temperature.
Possible causes:
1. Check condition of the air cooling system. (cleanliness, pressure tightness, etc.)
2. Check contact surfaces of boost pressure connector X4/71 sensor pins. (oxidation)
3. Check the GND wiring from the boost pressure sensor connector X4/71 PIN1 to the EEM2 controller PIN59 of
connector X70.
4. Check the supply (+5 V) wiring from the boost pressure sensor connector X4/71 PIN3 to the EEM2 controller
PIN11 of connector X70, check also +5 V supply.
5. Check the temperature signal wiring from the boost pressure sensor connector X4/71 PIN2 to the EEM2 controller
PIN12 of connector X70.
6. Intake manifold temperature can be monitored with CNH service tool via CAN bus monitoring function
(Intake manifold temperature). Present temperature can be compared to resistance of boost pressure sensor con-
nector X4/71 between PIN2 (temperature output) and PIN1(GND), according to the table 4.
Test current EEM2 controller functionality with another EEM2 controller.
NOTE: If EEM2 controller from another tractor is used, FC 175 will be activated, because of pump serial number
mismatch. If FC 116 disappears, EEM2 controller was damaged. Replace the controller and couple current injection
pump(serial number) to the new EEM2 controller with CNH service tool.

EEM2 - 121 Water in fuel (dedecting optional)

Description:
Water level in the water separator rises to warning level. For xample: condensation water.
Reaction in EEM:
FC is stored and warning lamp is activated.
Solution:
Check water separator bottom of the prefilter. Drain water from the fuelling system.
If there is no water in the fuelling system:
1. Check the supply voltage at water detector B23 connector X3/13 between PINA (+12V) and PINC (GND).
2. If power supply is not correct. Check the wiring from EEM2 connector X70 PIN25 to water sensor connector
X3/12 PIN1 and connector X3/13 PINA.
3. If power supply is not correct. Check the wiring from EEM2 connector X70 PIN22 to water sensor connector
X3/12 PIN3 and connector X3/13 PINC.
4. Check the resistance between connector X3/13 PINB and PINC, when the sensor is dry. If there is a short cut ->
replace water detector sensor.
If there is not short cut. Check the wiring from EEM2 connector X70 PIN31, connector X3/12 PIN2 and water de-
tector sensor X3/13 PINB, if there is a short cut to ground.
If there is no short cut to the ground and no sensor fault, but monitor function of the CNH service tool (water in fuel
system) is still telling yes. Test current EEM2 controller functionality with another EEM2 controller.
NOTE: If EEM2 controller from another tractor is used, FC 175 will be activated, because of pump serial number
mismatch. If FC 121 disappears, EEM2 controller was damaged. Replace the controller and couple current injection
pump(serial number) to the new EEM2 controller with CNH service tool.

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EEM2 - 122 Fuel delivery pressure too low

Description:
The fuel delivery pressure on the pressure filter is too low (> 20 seconds).
Response in EEM:
FC is saved and the warning lamp is activated.
Solution:
Check whether the electric delivery pump above the pre-filter is running. It should run for one minute after the ignition
is switched on. Use the corresponding function of the CNH service tool to monitor the fuel delivery pump.
If the pump runs, check the following:
• Use the corresponding monitoring function of the CNH service tool to establish whether the fuel filter is
blocked or not.
If a fault is displayed, check the following:
1. Check the fuel supply in the tank. (under certain circumstances, ADIC indicates an incorrect level.)
2. Filter blocked (dirty, frozen etc.)
3. Leaks/air in the fuel system
4. Check whether the fuel delivery pressure switch indicates a ground contact when there is pressure. If there is a
ground contact, the switch is damaged and must be replaced.
5. Refer to the workshop manual for how to check delivery pressure
6. If there is no ground contact here, check the wiring between the delivery pressure sensor, plug X1/3, PIN1 and
theEEM2 controller, plug X70, PIN55 to establish whether there is a ground contact there. If there is no ground
contact here, check the function of the current EEM2 controller using another EEM2 controller. NOTE: If an EEM2
controller from another tractor is used, FC 175 is activated because the pump serial numbers do not match. If FC
122 disappears, the EEM2 controller has been damaged. Replace the controller and connect the current fuel in-
jection pump (serial number) with the CNH service tool on the new EEM2 controller.
If the delivery pump does NOT run, check the following:
1. Check the delivery pump's voltage supply at plug M13 between PIN3 (12 V) and PIN1 (ground). If there is no
voltage at this plug, check the wiring to plug M13 between the delivery pump and plug X20/1 (Würth), X24/12
(Berifors), PIN 16 from Motorprint A14.
If there is voltage, the delivery pump is damaged and must be replaced.
2. Check the 12 V supply (ignition) from Motorprint A14 at relay K5/3, PIN 87. If there is no voltage at PIN87, check
the voltages at relay K5/3, PIN30. If there is no voltage, check the voltages at screw connection X1/12 and fuse
F200.
3. Check whether there is voltage at relay K5/3, PIN86 and ground at PIN85. If there is no voltage supply between
PIN30 and PIN87, relay K5/3 must be replaced. If there is no voltage at PIN86, check the wiring between plug
X20/1, PIN19 from Motorprint A14, plug X23/1 PINR and plug X18/1, PIN8 via the W1/4 bridge to fuse F30
(15/2) 5A.
Check the voltage supply at EEM2 controller, plug X70, PIN50 and the wiring between X70, PIN50 and Motorprint
A14, plug X20/1, PIN5. The function of the CNH service tool for monitoring the fuel delivery pump must be ACTIVA-
TED. If there is no voltage at plug X70, PIN50, under certain circumstances, this means that the EEM2 controller is
damaged. Check the function of the current EEM2 controller using another EEM2 controller.
NOTE: If a EEM2 controller from another tractor is used, FC 175 is activated because the pump serial numbers do
not match. If FC 122 disappears, the EEM2 controller has been damaged. Replace the controller and connect the
current fuel injection pump (serial number) with the CNH service tool on the new EEM2 controller.

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EEM2 - 123 Air in fuel system

Description:
EEM2 controller has recognized continuous timing device piston oscillation of the injection pump. Air in the fuel may
cause the problem. EEM2 controller will activate fault mode to avoid internal injection pump damage.
Reaction in EEM:
FC is stored and warning lamp is activated. Engine speed is limited to 1500 rpm and engine power will be reduced.
Solution:
1. The cause of the problem is air leak into the fuel system at the suction side, at the low-pressure side or air already
in the fuel system.
2. Check the tightness and condition of all the fuel lines according vehicle service manual. Check the filters for tight-
ness and sealing condition.
3. Check the fuel supply pressure (after cleaning the area) at the injection pump fuel inlet to see if fuel filters or fuel
lines are clogged. Run the engine at idle speed for some seconds. The feed pressure should be between
1,0 - 1,2 bar. If possible, run the engine at maximum load, the feed pressure should not drop below 1,0 bar.
4. Replace the original metal fuel feed pipe between the injection pump and the main filter with a transparent flexible
tube (plastic). Run the engine to see that there is no air in the fuel anymore. If there is still air in the fuel, check
all fuel lines and filters tightness once again.
NOTE: If there is no air in the system and FC 42 is also continuously active, problem could be also a defective IAT
sensor of the Bosch VP injection pump.
In this case, you will have to replace the injection-pump.
NOTE: If the injection pump was changed, but the job concerning the serial number (see paragraph 5) was not
done, FC 175 will be activated, because of pump serial number mismatch.
5. If the injection pump is to be changed, couple the new injection pump (serial number) to the EEM2 controller with
CNH service tool.

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EEM2 - 141 CAN off (vehicle bus)

Description:
The control unit detects that data transfer between the EEM2 controller and the vehicle bus is interrupted.
Possible causes:
1. Temporary malfunction of CAN communications between the EEM2 controller and the vehicle bus.
2. Short circuit on the CAN bus.
3. Bus termination incorrect or missing.
4. Contacts of the CAN bus plugs bent, broken or corroded.
5. Control unit defective.
Reaction in the EEM:
The fault code is stored and displayed on the instrument panel. Control commands, which are usually sent via the
CAN bus, are not functional.
Remedy:
A temporary malfunction can be caused by a temporary bus overload. Ensure that the power supply to the EEM2
controller is correct and it is ONLINE on the bus.
Use the "Control module status" function of the Service Tool to check this.
If the EEM2 controller is OFFLINE, go to step 2. If the EEM2 controller is ONLINE, this is a temporary fault. Store the
fault using the Service Tool and then cancel it. Make a test drive to check the function. If the fault code does not occur
again, no further action is required.
Check supply to EEM.
+12V permanent plus EEM2 (fuse F92 (+30) 10A):
Measure the voltage of the EEM2 controller (plug X70) at PIN70 (+12V) against PIN69 (ground). If the voltage is more
than 1 V lower than the battery voltage, check the wiring of the EEM2 controller. Test the wiring between PIN70 of the
EEM2 controller plug X70 and screw connection X1/10. Also check the voltage at engine print A14 between screw
connection X1/10 and the fuse F92.
+12V ignition (fuse F97 (+15) 10A):
Measure the voltage of the EEM2 controller (plug X70), PIN21 (+12V) against PIN69. If the voltage is more than 1 V
lower than the battery voltage, check the wiring of the EEM2 controller. Test the wiring between Pin 21 of the EEM2
controller plug X70 and plug X20/1 (Würth), X24/12 (Berifors) on the engine print A14 PIN7. Also check the voltage
at engine print A14 between plug X20/1 (Würth), X24/12 (Berifors) PIN7 until the fuse F97.
1. Check the ground supplies:
Check the ground line from the EEM2 controller plug X70 PIN69 to weld point X0/4/1 and further to
grounding point 11.
Check the ground line from the EEM2 controller plug X70 PIN46 to weld point X0/4/1 and further to
grounding point 11.
2. Check the ground line from the housing of the EEM2 controller to weld point X0/4/1 and further to
grounding point 11.
If one of the fuses should be defective, replace the fuse by a new one with the correct amperage.
Should the fuse trigger again immediately, you have probably overlooked a fault when you checked the supply
lines. In this case, start again with step 1).
If you do not detect a fault, but if the fuse still triggers, replace the EEM2 controller.
Replace the EEM2 controller and store the serial number of the injection pump in the EEM2 controller using the
CNH service tool. (CONFIGURATION MENU)
If the power supply to the EEM2 controller is correct, check the entire CAN bus for short-circuits. On the CAN bus,
disconnect one control module after the other and reconnect it again, checking the status of the control units
("Control module status" function of the Service Tool). If the control unit status is ONLINE, the disconnected unit
is causing the problem.
If the power supply to the EEM2 controller is correct, check the entire CAN bus for interruptions or defective ter-
minating resistors. If the CAN bus is interrupted, only those control modules are OFFLINE which are connected
to the CAN bus after the interruption.

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Check vehicle bus:
Diagnostics interface S31 (CAN H PIN8, CAN L PIN7),
Armrest X18/4 (CAN H PIN17, CAN L PIN18),
AUX1 X4/90 (CAN H PIN3, CAN L PIN2),
AUX2 X4/91 (CAN H PIN3, CAN L PIN2),
AUX3 X4/92 (CAN H PIN3, CAN L PIN2),
AUX4 X4/93 (CAN H PIN3, optionally CAN L PIN2),
AUX5 X4/94 (CAN H PIN3, CAN L PIN2),
ECCU2 CN1a (CAN H PIN15, CAN L PIN16),
EDC X55 (CAN H PIN50, CAN L PIN52),
EEM X70 (CAN H PIN18, CAN L PIN42).
Also check whether the jumper on X70 of the EEM between PIN 66 and PIN 67 is present.
ICU P8/1 (CAN H PIN3, CAN L PIN4) via P8/2 (CAN H PIN3, CAN L PIN4) after ADIC CN3 (CAN H PIN26, CAN
L PIN25),
KEYPAD X4/63 (CAN H PIN3, CAN L PIN2),
Terminating resistor X3/10 (CAN H PINA, CAN L PINB).

Check transmission bus:

Diagnostics interface S31 (CAN H PIN2, CAN L PIN1),
FMGR A4/3 (CAN H PIN3, CAN L PIN2),
SGR X16/21 (CAN H PIN1, CAN L PIN2)

Disconnect the EEM2 control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 ohms +/- 10%)
by measuring between PIN 42 and PIN18 of EEM plug X70. Also check the terminating resistance in EEM box
A2 between PIN42 and PIN18 with the EEM box disconnected (setpoint 120 ohms +/- 10%).

If the connection is ok, check the EEM2 controller plug X70 for bent, broken or corroded contacts and repair them
if required.

Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.

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EEM2 - 142 CAN off between EEM and PCU

Description:
EEM controller is not able to communicate with the injection pump.
Reaction in EEM:
FC is stored and warning lamp is activated. EEM2 controller is not able to govern speed of the engine. "Limp home"
function will be activated in the injection pump A2/1. The engine will run at constant speed 1400 rpm with reduced
power. If power supply is missing the engine will not start.
Solution:
1. Check CAN bus wiring from the injection pump (connector X9/7 PIN1 for Can low) to X70 PIN44 of the EEM2
controller. For short circuit.
2. Check CAN bus wiring from the injection pump (connector X9/7 PIN2 for Can high) to X70 PIN20 of the EEM2
controller. For short circuit.
3. Check contacts through wiring from the battery to the injection pump for bad contact at some connector. So, check
the wiring from EEM2 PIN1 of connector X70 to PIN7 of the Injection pump connector X9/7.
4. Check the ground wiring from EEM2 PIN23 of connector X70 to PIN6 of the Injection pump connector X9/7.
5. Measure the voltage from EEM2 PIN70 (+12 Vdc) to PIN69 (ground) of connector X70. If voltage is more than
1 V below the battery voltage, check the wiring from EEM2 PIN70 of connector X70 to screw connection X1/10
of the engine print A14 to fuse F92.
6. Measure the voltage from EEM2 PIN48 (+12 Vdc) to PIN46 (ground) of connector X70. If voltage is more than
1 V below the battery voltage, check the wiring from EEM2 PIN48 of connector X70 to screw connection X1/14
of the engine print A14 to fuse F94.
7. Measure the ground line from EEM2 PIN69 of connector X70 to the weld point X0/4/1and up to the
grounding point 11.
8. Measure the ground line from EEM2 PIN46 of connector X70 to the weld point X0/4/1and up to the
grounding point 11.
9. Measure the ground line from the housing of the EEM2 controller to the weld point X0/4/1and up to the
grounding point 11.
10. Measure the terminating resistor of EEM2 controller of connector X70 PIN44 and PIN20
(resistance 120 Ohms ± 10%). Disconnect the connector X9/7 of the Injection pump first.
11. If the CAN bus between the injection pump and EEM2 controller and also power supply are OK. Possible causes
are defective EEM2 controller or defective PCU(pump control unit).
12. Test PCU functionality with another EEM2 controller.
NOTE: If EEM2 controller from another tractor is used, FC 175 will be activated, because of pump serial number
mismatch.
If FC 142 disappears, EEM2 controller was damaged. Replace the controller and couple current injection
pump(serial number) to the new EEM2 controller with CNH service tool. If FC 142 does not disappear with
another EEM2 controller, PCU A2/2 is damaged. Take a contact to the Bosch service agency.
Delete the fault code. Switch the ignition off (5 sec.) and back to on and start the engine. If the fault is still active, the
problem is a defective PCU (Pump Central Unit). Contact the BOSCH service agency.

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EEM2 - 146 Requested speed (CAN) out of range

(too low < 500 rpm)
Description:
Requested speed by the FMGR controller is below 500 rpm.
Reaction in EEM:
FC is stored and warning lamp is activated. The EEM2 controller will start to use hardwired throttles for speed control.
In case there are no hardwired throttles the engine runs at low-idle speed.
Solution:
Check all other failure codes of the EEM2 controller and the FMGR controller. If there are other failure codes (e.g.
CAN-bus failures), solve this problems first.
If there are no other failures any more, check the requested engine speed by using the monitorfunction of the CNH
service tool "requested engine speed".
If the value is higher than 500rpm, but failure 146 is still active, then the EEM2 controller has a problem.
Try to download the EEM2 controller software. Then deleted the fault an do the test again. If the failure is still active,
you will have to replace the EEM2 controller.
Couple current injection pump A2/1 (serial number) to the new EEM2 controller with CNH service tool.
If the monitored requested speed of the FMGR controller is lower than 500rpm, try to download the FMGR software
(same version as in SGR controller), and deleted the failure.
Then do the test again. If the requested speed is still lower than 500rpm, the FMGR A4 controller is damaged and
has to be replaced!

EEM2 - 147 Requested speed (CAN) out of range

(too high >3000 rpm)
Description:
Requested speed by the FMGR controller is above 3000 rpm.
Reaction in EEM:
FC is stored and warning lamp is activated. The EEM2 controller will start to use hardwired throttles for speed control.
In case there are no hardwired throttles the engine runs at low-idle speed.
Solution:
Check all other failure codes of the EEM2 controller and the FMGR controller. If there are other failure codes (e.g.
CAN-bus failures), solve this problems first.
If there are no other failures any more, check the requested engine speed by using the monitorfunction of the CNH
service tool (requested engine speed). If the value is lower than 3000rpm, but failure 147 is still active, then the EEM2
controller has a problem.
Try to download the EEM2 controller software. Then deleted the fault an do the test again. If the failure is still active,
you will have to replace the EEM2 controller.
Couple current injection pump A2/1 (serial number) to the new EEM2 controller with CNH service tool.
If the monitored requested speed of the FMGR controller is higher than 3000rpm, try to download the FMGR software
(same version as in SGR controller), and deleted the failure.
Then do the test again. If the requested speed is still higher than 3000rpm, the FMGR A4 controller is damaged and
has to be replaced!

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EEM2 - 172 Upgrade protection fault

Description:
Maximum vehicle speed configuration or FMGR controller are not correct for the engine. Correct gearbox speed ran-
ge has been stored in the EEM2 controller after production line. Fault code has been activated, because gearbox
speed range has been changed.
Reaction in EEM:
FC is stored and warning lamp is activated. Engine will not start.
Solution:
Change gearbox speed range to correct value for this vehicle.

EEM2 - 173 Power parameters too high

Description:
Power parameters do not match with the current EEM2 controller. Fault code will be activated example if wrong ap-
plication software has been downloaded to the EEM2 controller. If for example 180HP software has been downloaded
into an EEM2 controller, which had 160 HP software inside originally, this failure is shown too.
In that case, also Fault code FMGR 64 will be activated!
Reaction in EEM:
FC is stored and warning lamp is activated. Engine will start, but fuel quantity has been reduced.
If FC FMGR 64 is active too, the tractor cannot be driven (driveline cannot be engaged).
Solution:
1. Switch the ignition off (5 sec.) and back to on to see if the fault is still active. If it is:
2. Download correct software (for correct horse-power setting) to the EEM2 controller with CNH service tool.
3. If this does not help, change EEM2 controller for the engine.
In case of new (spare part) EEM2 controller, couple current injection pump (serial number) to the new EEM2 controller
with CNH service tool.

EEM2 - 174 Absolute maximum power not set

Description:
Absolute maximum power value has not been activated. Example wrong software in the EEM2 controller.
Reaction in EEM:
FC is stored and warning lamp is activated. Fuel quantity reduction.
Solution:
This problem can not be solved on the field. Replace the EEM2 controller and couple current injection pump A2/1
(serial number) to the new EEM2 controller with CNH service tool.

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EEM2 - 175 Injection pump serial number mismatch

Description:
Injection pump serial number does not match with the current EEM2 controller.
Reaction in EEM:
FC is stored and warning lamp is activated. Engine will start, but fuel quantity has been reduced.
Solution:
1. Try to couple current injection pump(serial number) to the new EEM2 controller with CNH service tool.
2. If this does not help, change EEM2 controller for the engine.
In case of new (spare part) EEM2 controller, couple current injection pump A2/1 (serial number) to the new EEM2
controller with CNH service tool.

COMPONENTS SUMMARY
(11) Ground point engine device carrier................................................................................................... Fig. 1
A2 EEM2 control unit ............................................................................................................................. Fig. 2
A2/2 PCU electronic pumps - control unit ................................................................................................. Fig. 3
A4 FMGR .............................................................................................................................................. Fig. 4
B20 Engine speed sensor ....................................................................................................................... Fig. 5
B21 Test switch, fuel delivery pressure ................................................................................................... Fig. 5
B22 Engine temperature sensor ............................................................................................................. Fig. 6
B23 ’Water in fuel’ sensor ........................................................................................................................ Fig. 6
B29 Charge-air pressure / temperature sensor........................................................................................ Fig. 7
F200 Main fuse .......................................................................................................................................... Fig. 7
M13 Fuel delivery pump ........................................................................................................................... Fig. 8
S6 Engine oil pressure switch ............................................................................................................... Fig. 9
X1/3 Plug connection, fuel filter pressure sensor .................................................................................... Fig. 8
X1/12 Plug connection, engine print, potential 30.................................................................................... Fig. 10
X2/22 Plug connection, temperature sensor EEM2 [22] ..........................................................................Fig. 11
X3/10 Plug connection, terminal resistance ............................................................................................. Fig. 12
X3/12 Plug connection, “Water in fuel” sensor .......................................................................................... Fig. 13
X3/13 Plug connection, sensor B23 ......................................................................................................... Fig. 14
X3/20 Plug connection, engine speed sensor .......................................................................................... Fig. 15
X4/71 Plug connection, charger pressure / charged air temperature sensor ........................................... Fig. 16
X9/7 Plug connection, fuel injection pump [7] .......................................................................................... Fig. 3
X18/1 Plug connection, instruments wiring harness - central print [1] ...................................................... Fig. 17
X20/1 Plug connection, engine wiring harness (Würth) ............................................................................ Fig. 18
X23/1 Plug connection, instruments wiring harness - engine wiring harness .......................................... Fig. 19
X24/12 Plug connection, engine wiring harness (Berifors) ......................................................................... Fig. 18
X70 Plug connection, engine control unit EEM2 .................................................................................... Fig. 20

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Fig. 1 Fig. 5

Fig. 2 Fig. 6

Fig. 3 Fig. 7

Fig. 4

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Fig. 8 Fig. 11

Fig. 12

Fig. 9

Fig. 13

Fig. 10

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Fig. 14 Fig. 18

Fig. 15 Fig. 19

Fig. 16

Fig. 17

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Fig. 20

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*) see Note page 8 FUNCTIONAL SCHEMATIC DIAGRAM FOR EEM2

A12 F19 5A

F20 5A
X20/1 F97 10A
+15/1 7 +15/2
ARMREST F16 5A
F94 25A
+15/2 X1/14
(16) 31
*A28 PLUG MODULE X1/10 F92 10A
+30
X1 X18/4
*A30 PRINT ARU X24/2 17 18 2 X5/1
8 10
X3 7 13
B28 5V X70 21 48 70 46 69
1 9 9 (11)
CAN H A14
CAN + 18 A2 EEM2 A2 _GND
X7 15 CAN L
0.4V to 4.7V CAN - 42
X 2 2 16 Supply
CAN H
3 17
GND 4 CAN L
4 18
X1/21
P8/1 4 3 1 2 Pre-glowing and
+15

P8 ICU P8/2 fuel delivery pump X70 X20/1 A50/1 E10/1

*YA1 39 40 25 8 6 33 4 2 3 1 5 7
3 3 12V 4 (11)
K8/2
4 50 12V 5 SSR1
X1/12 30 87
*YB1 39 40 25 8 6 33 4 2 3 1 5 7 +30

1 2
X20/1 (11)
12V
CN3 17
* A27 CAN MODULE A1 ADIC 12V
26 16
M13 (11)
25 Emergency signal
X70
3 M 1
36 0.8 to 4.4 V
A2/2 PCU 2
X70 X9/7 (11)
12V
R8 X23/2 1 7
GND M13 _GND
4 U 23 6
CAN H
PCU activation 20 2 2.5 V
CAN L
44 1 2.5 V
S6
43 5 Emergency shut-down
130 Hz at 900 rpm
B21 X1/3 p 19 8 DZG
335 Hz at 2300 rpm
1 X70
p 34 GND A1 ADIC X1 14-pin plug connection
A2 EEM2 X1/3 1-pin plug connection
X3/20 55 GND A2/2 PCU X1/10 Plug connection
GND
n 1 62 A12 Central print X1/12 Plug connection
B20 2 39 510 Hz at 900 rpm
1300 Hz at 2300 rpm
A14 Engine print X1/14 Plug connection
f 12V A27 CAN module ---> DBD..... X1/21 Plug connection
3 45 A28 Plug module ---> DBD..... X2/22 2-pin plug connection
Switches and A30 Print ARU DBD..... ---> X3 4-pin plug connection
sensors A50/1 Power module X3/12 3-pin plug connection
t X2/22 B20 Engine speed sensor X3/13 3-pin plug connection
GND
B22 1 33 B21 Test switch, fuel delivery pressure X3/20 3-pin plug connection
R 2 PTC 1kΩ to 4.6 kΩ B22 Engine temperature sensor X4/71 4-pin plug connection
9
B23 „Water in fuel“ sensor X5/1 Plug connection
X3/13 X3/12 B28 Manual throttle X7 4-pin plug connection
12V B29 Sensor for charger pressure, X9/7 9-pin plug connection
R A 1 25
0.7 V at water in fuel charged air temperature X18/4 18-pin plug connection
B23 B 2 31 9 V no water in fuel CN3 26-pin plug connection X20/1 20-pin plug connection
U C 3
GND
22 E10/1 Heating flange X23/2 23-pin plug connection
K8/2 Relay, heating flange X24/2 24-pin plug connection
X4/71 M13 Fuel delivery pump X70 70-pin plug connection
GND
p,t 1 59 P8 ICU YA1 44-pin plug connection ---> DBD.....
NTC 32 kΩ to 102 Ω P8/1 4-pin plug connection
B29 2 12 YB1 44-pin plug connection ---> DBD.....
P8/2 4-pin plug connection (11) Ground point, engine device carrier
U,R 3 5V
11 R8 Potentiometer, accelerator pedal (16) Ground point, starter
4 35 1 V to approx. 2 V S6 Switch, engine oil pressure

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FAULTCODES EEM3 FROM DBD100001

EEM3 - 10 EEPROM error ................................................................................................................................ 355
EEM3 - 17 Battery voltage is much too low ...................................................................................................... 355
EEM3 - 18 Battery voltage is much too high ..................................................................................................... 356
EEM3 - 19 Battery voltage, no signal ................................................................................................................ 356
EEM3 - 20 Temperature in engine controller too high ...................................................................................... 356
EEM3 - 21 Temperature sensor in the engine controller, signal voltage too low .............................................. 357
EEM3 - 22 Temperature sensor in the engine controller, signal voltage too high ............................................. 357
EEM3 - 23 Temperature sensor in the engine controller, no signal .................................................................. 358
EEM3 - 80 Accelerator pedal potentiometer, signal voltage too low ................................................................. 358
EEM3 - 81 Accelerator pedal potentiometer, signal voltage too high ............................................................... 359
EEM3 - 92 Oil pressure too high ....................................................................................................................... 360
EEM3 - 93 Oil pressure sensor, no signal ......................................................................................................... 361
EEM3 - 94 Overspeed ....................................................................................................................................... 361
EEM3 - 95 Oil pressure sensor is faulty ............................................................................................................ 362
EEM3 - 96 Oil pressure sensor, signal voltage too low ..................................................................................... 363
EEM3 - 97 Oil pressure sensor, signal voltage too high ................................................................................... 364
EEM3 - 98 Oil pressure too low ........................................................................................................................ 365
EEM3 - 99 Oil pressure too low, alarm ............................................................................................................. 366
EEM3 - 100 Boost pressure sensor, signal voltage too low .............................................................................. 367
EEM3 - 101 Boost pressure sensor signal voltage too high ............................................................................. 368
EEM3 - 102 Charge presure too low ................................................................................................................. 369
EEM3 - 103 Boost pressure too high ................................................................................................................ 370
EEM3 - 104 Boost pressure, no signal .............................................................................................................. 371
EEM3 - 109 Coolant temperature sensor, no signal ......................................................................................... 371
EEM3 - 110 Coolant temperature sensor, signal voltage too low ..................................................................... 372
EEM3 - 111 Coolant temperature sensor, signal voltage too high .................................................................... 373
EEM3 - 112 Coolant temperature too high ........................................................................................................ 374
EEM3 - 113 Coolant temperature alarm ........................................................................................................... 375
EEM3 - 114 Charge air temperature sensor, signal voltage too low ................................................................. 376
EEM3 - 115 Charge air temperature sensor, signal voltage too high ............................................................... 377
EEM3 - 116 Charge air temperature, value too high ......................................................................................... 378
EEM3 - 117 Charge air temperature sensor, no signal ..................................................................................... 378
EEM3 - 121 Water in fuel .................................................................................................................................. 379
EEM3 - 141 CAN Bus OFF (vehicle bus) .......................................................................................................... 380
EEM3 - 143 CAN bus OFF (ID modules - EEM3) ............................................................................................. 381
EEM3 - 146 Speed setting through FMGR too low ........................................................................................... 382
EEM3 - 147 Speed setting through FMGR too high .......................................................................................... 382
EEM3 - 172 Upgrade protective error ............................................................................................................... 383
EEM3 - 211 Supply voltage 1 too low ............................................................................................................... 384
EEM3 - 212 Supply voltage 1 too high .............................................................................................................. 385
EEM3 - 215 Supply voltage 3 too low ............................................................................................................... 386
EEM3 - 216 Supply voltage 3 too high .............................................................................................................. 387
EEM3 - 221 Engine electronics self-test, internal error 1 .................................................................................. 388
EEM3 - 222 Engine electronics self-test, internal error 2 .................................................................................. 388
EEM3 - 223 Engine electronics self-test, internal error 3 .................................................................................. 388
EEM3 - 231 Engine controller does not switch off ............................................................................................ 389
EEM3 - 233 Engine controller switch-off did not function the last time ............................................................. 389
EEM3 - 235 Final stage 1, short-circuit to ground ............................................................................................. 390
EEM3 - 237 Final stage 3, short-circuit to ground ............................................................................................. 391
EEM3 - 241 Final stage 1, short-circuit to battery + .......................................................................................... 391

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EEM3 - 245 Engine controller switches off briefly while operating and then functions again ............................ 392
EEM3 - 246 Engine controller switches off briefly 3 times while operating and then functions again ............... 392
EEM3 - 248 Water in fuel sensor - supply voltage too low ................................................................................ 393
EEM3 - 249 Water in fuel sensor - supply voltage too high .............................................................................. 393
EEM3 - 251 Fuel temperature sensor signal voltage too low ............................................................................ 394
EEM3 - 252 Fuel temperature sensor signal voltage too high .......................................................................... 395
EEM3 - 253 Fuel temperature too high ............................................................................................................. 396
EEM3 - 261 Fuel temperature sensor, no signal ............................................................................................... 397
EEM3 - 263 Rail pressure sensor - signal voltage too low ................................................................................ 398
EEM3 - 264 Rail pressure sensor - signal voltage too high .............................................................................. 399
EEM3 - 265 Rail pressure too high ................................................................................................................... 400
EEM3 - 266 Rail pressure, no signal ................................................................................................................. 400
EEM3 - 269 Engine speed, signals faulty .......................................................................................................... 401
EEM3 - 271 Engine speed sensor signal faulty ................................................................................................. 402
EEM3 - 272 Faulty engine speed sensor signal ................................................................................................ 403
EEM3 - 273 Engine speed sensor connections reversed ................................................................................. 404
EEM3 - 276 Pressure drop in intake system too high during engine start-up ................................................... 405
EEM3 - 281 Faulty camshaft position sensor signal ......................................................................................... 406
EEM3 - 282 Faulty camshaft position sensor signal ......................................................................................... 407
EEM3 - 283 Camshaft position sensor connections reversed ........................................................................... 408
EEM3 - 284 Camshaft position sensor signal not plausible .............................................................................. 409
EEM3 - 291 Fuel delivery pressure sensor, signal voltage too low ................................................................... 410
EEM3 - 292 Fuel delivery pressure sensor, signal voltage too high ................................................................. 411
EEM3 - 293 Fuel delivery pressure sensor, no signal ....................................................................................... 412
EEM3 - 311 Injector 1 - solenoid valve short circuit to ground .......................................................................... 412
EEM3 - 312 Injector 1 - solenoid valve short-circuit on +supply ....................................................................... 413
EEM3 - 313 Injector 1 - solenoid valve open circuit .......................................................................................... 414
EEM3 - 314 Injector 1 - solenoid valve is open too long ................................................................................... 414
EEM3 - 315 Injector 1 - solenoid valve error ..................................................................................................... 415
EEM3 - 321 Injector 2 - solenoid valve short circuit to ground .......................................................................... 415
EEM3 - 322 Injector 2 - solenoid valve short circuit on +supply ........................................................................ 416
EEM3 - 323 Injector 2 - solenoid valve open circuit .......................................................................................... 417
EEM3 - 324 Injector 2 - solenoid valve is open too long ................................................................................... 417
EEM3 - 325 Injector 2 - solenoid valve error ..................................................................................................... 418
EEM3 - 331 Injector 3 - solenoid valve short circuit to ground .......................................................................... 418
EEM3 - 332 Injector 3 - solenoid valve short-circuit on +supply ....................................................................... 419
EEM3 - 333 Injector 3 - solenoid valve open circuit .......................................................................................... 420
EEM3 - 334 Injector 3 - solenoid valve is open too long ................................................................................... 420
EEM3 - 335 Injector 3 - solenoid valve error ..................................................................................................... 421
EEM3 - 341 Injector 4 - solenoid valve short-circuit to ground .......................................................................... 421
EEM3 - 342 Injector 4 - solenoid valve short-circuit on +supply ....................................................................... 422
EEM3 - 343 Injector 4 - solenoid valve open circuit .......................................................................................... 423
EEM3 - 344 Injector 4 - solenoid valve is open too long ................................................................................... 423
EEM3 - 345 Injector 4 - solenoid valve error ..................................................................................................... 424
EEM3 - 351 Injector 5 - solenoid valve short-circuit to ground .......................................................................... 424
EEM3 - 352 Injector 5 - solenoid valve short-circuit at +supply ........................................................................ 425
EEM3 - 353 Injector 5 - solenoid valve open circuit .......................................................................................... 426
EEM3 - 354 Injector 5 - solenoid valve is open too long ................................................................................... 426
EEM3 - 355 Injector 5 - solenoid valve error ..................................................................................................... 427
EEM3 - 361 Injector 6 - solenoid valve short-circuit to ground .......................................................................... 427
EEM3 - 362 Injector 6 - solenoid valve short-circuit on +supply ....................................................................... 428
EEM3 - 363 Injector 6 - solenoid valve open circuit .......................................................................................... 429

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EEM3 - 364 Injector 6 - solenoid valve is open too long ................................................................................... 429
EEM3 - 365 Injector 6 - solenoid valve error ..................................................................................................... 430
EEM3 - 371 Battery voltage is too low .............................................................................................................. 430
EEM3 - 372 Battery voltage is too high ............................................................................................................. 431
EEM3 - 381 Rail pressure too low ..................................................................................................................... 432
EEM3 - 382 Rail pressure too high ................................................................................................................... 433
EEM3 - 383 Rail pressure is lower than expected ............................................................................................ 434
EEM3 - 384 Rail pressure is higher than expected ........................................................................................... 435
EEM3 - 385 Rail pressure, leakage at no-load speed ....................................................................................... 436
EEM3 - 386 Rail pressure, leakage .................................................................................................................. 437
EEM3 - 387 Rail pressure signal, leaks during overspeed ............................................................................... 438
EEM3 - 391 Pressure relief valve open ............................................................................................................. 439
EEM3 - 392 Pressure relief valve is stuck ......................................................................................................... 440
EEM3 - 421 High-pressure pump solenoid valve, short-circuit to ground ......................................................... 441
EEM3 - 422 High-pressure pump solenoid valve, short-circuit to +supply ........................................................ 442
EEM3 - 423 High-pressure pump solenoid valve open circuit .......................................................................... 443
EEM3 - 424 High-pressure pump solenoid valve, driving circuit overtemperature ........................................... 443
EEM3 - 441 Fuel delivery pressure, value fluctuates ........................................................................................ 444
EEM3 - 442 Fuel delivery pressure sensor, drop-out ........................................................................................ 445
EEM3 - 445 Fuel delivery pressure, too high .................................................................................................... 446
EEM3 - 446 Fuel delivery pressure, too low ..................................................................................................... 447
EEM3 - 451 Incorrect engine specification ........................................................................................................ 448
EEM3 - 452 Incorrect serial number ................................................................................................................. 448
EEM3 - 453 ID module, no communication ....................................................................................................... 449
EEM3 - 454 ID module, not compatible ............................................................................................................ 450
EEM3 - 455 ID module, memory 1 faulty .......................................................................................................... 450
EEM3 - 456 ID module, supply voltage too high ............................................................................................... 450
EEM3 - 457 ID module, supply voltage too low ................................................................................................ 451
EEM3 - 458 ID module, temperature too high ................................................................................................... 451
EEM3 - 459 ID module, memory 2 faulty .......................................................................................................... 452
EEM3 - 461 ID module, internal error 1 ............................................................................................................ 452
EEM3 - 462 ID module, start error .................................................................................................................... 452
EEM3 - 463 Missing engine specification ......................................................................................................... 453
EEM3 - 464 Missing serial number ................................................................................................................... 453
EEM3 - 465 Missing ID module, by pass function activated ............................................................................. 453
EEM3 - 466 Missing ID module, by pass function deactivated ......................................................................... 454
EEM3 - 467 Missing ID module, by pass function time expired ........................................................................ 454
EEM3 - 471 Air pressure sensor in engine controller, signal voltage too low ................................................... 454
EEM3 - 472 Air pressure sensor in the engine controller, signal voltage too high ............................................ 455
EEM3 - 473 Air pressure too high ..................................................................................................................... 455
EEM3 - 474 Air pressure sensor in the engine controller, no signal ................................................................. 456
COMPONENTS SUMMARY ............................................................................................................................. 457
FUNCTIONAL SCHEMATIC DIAGRAM FOR EEM3 ........................................................................................ 465

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EEM3 - 10 EEPROM error

Description:
If the starter switch is turned to the "ON" position, the engine controller carries out an internal system test. If a problem
arises during the test, the error code becomes active.
Possible cause:
1. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the maximum engine speed
is 1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Turn the starter switch to the "OFF" position (5 sec.) and then to "ON" again. If the error code remains active, the
cause of the problem lies in a faulty engine controller. Replace the engine controller. (see chapter 2002A)

EEM3 - 17 Battery voltage is much too low

Description:
The supply voltage is less than 6.5 V.
Possible causes:
1. Voltage drop during starting procedure
2. Cabling faulty between battery and engine controller
3. Faulty alternator
Reaction:
EC is stored and warning lamp is activated.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the battery charge.
a) If the battery charge is not OK, check the alternator charging voltage. If necessary, replace the alternator or
the battery.
b) If the battery charge is OK, go to step 2.
2. Check the supply voltage to the engine controller.
a) Disconnect the connector X89/1 from the controller and measure the voltage between:
X89/1 PIN40, 9, 8, 3, 2 and ground.
If the battery voltage to a pin is not reached, you must repair or replace the cabling.

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EEM3 - 18 Battery voltage is much too high

Description:
The supply voltage is greater than 36 V.
Possible cause:
1. Faulty alternator
Reaction:
EC is stored and warning lamp is activated.
Solution:
NOTE: As soon as the cause of the error code has been removed, delete the error code and check the system for
correct functioning.
1. Check the alternator charging voltage. If necessary replace the alternator.

EEM3 - 19 Battery voltage, no signal

Description:
The engine controller does not detect the battery voltage because of a hardware error.
Possible cause:
1. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated.
Solution:
NOTE: When the cause of the error code has been cleared, delete the error code and check the system for proper
functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If error code is not displayed, no further measures are necessary
b) If the error code is displayed, continue to step 2.
2. Load the current engine software version. If the error re-occurs, replace the controller. (see chapter 2002A)

EEM3 - 20 Temperature in engine controller too high

Description:
The temperature inside the engine controller is higher than 115 °C. One reason for this can be that the engine has
been turned off because of overheating and the cooling system is no longer working. Because of the radiant heat the
temperature inside the engine controller can rise, since there is no more cooling due to the missing air flow.
Possible cause:
1. Engine overheating
Reaction:
EC is stored and warning lamp is activated. Engine switches off delayed.
Solution:
NOTE: As soon as the cause of the error code has been removed, delete the error code and check the system for
proper functioning.
1. Check the engine controller housing temperature. If the controller is not hot but the error code continues to be
active, the controller must be replaced.
2. If the error code is no longer active, check if error codes EEM3 112 and 113 have also occurred. If so, the errror
was probably triggered by the engine overheating. In this case you can ignore the error code.

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EEM3 - 21 Temperature sensor in the engine controller, signal

voltage too low
Description:
The engine controller detects an invalid voltage value for the internal temperature sensor. The cause is probably an
engine controller hardware error.
Possible cause:
1. Faulty engine controller
Reaction:
EC is stored and warning lamp is activated. Starting is not possible.
Solution:
NOTE: As soon as the cause of the error code has been removed, delete the error code and check the system for
proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not displayed, no further measures are necessary
b) If the error code is displayed, continue to step 2.
2. Load the current engine software version. If the fault re-occurs, replace the controller. (see chapter 2002A)

EEM3 - 22 Temperature sensor in the engine controller, signal

voltage too high
Description:
The engine controller detects an invalid voltage for the internal temperature sensor. The cause is probably an engine
controller hardware error.
Possible cause:
1. Faulty engine controller
Reaction:
EC is stored and warning lamp is activated. Starting is not possible.
Solution:
NOTE: As soon as the cause of the error code has been removed, delete the error code and check the system for
proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not displayed, no further measures are necessary
b) If the error code is displayed, continue to step 2.
2. Load the current engine software version. If the fault re-occurs, replace the controller. (see chapter 2002A)

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EEM3 - 23 Temperature sensor in the engine controller, no signal

Description:
The engine controller does not detect the signal of the internal temperature sensor. The cause is probably an engine
controller hardware error.
Possible cause:
1. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. Starting is not possible.
Solution:
NOTE: As soon as the cause of the error code has been removed, delete the error code and check the system for
proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not displayed, then no more measures are necessary
b) If the error code is displayed, continue to step 2.
2. Load the current engine software version. If the fault re-occurs, replace the controller. (see chapter 2002A)

EEM3 - 80 Accelerator pedal potentiometer, signal voltage too low

Description:
The accelerator pedal potentiometer R8 signal voltage is below the permitted range.
Possible causes:
1. Connector or wiring faulty
2. Faulty potentiometer
3. Faulty engine controller
Reaction:
EC is stored and warning lamp is activated.
Solution:
NOTE: As soon as the cause of the error code has been removed, delete the error code and check the system for
proper functioning.
NOTE: If error code FMGR 87 is also active, remove this error first of all.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Check the connector X4/70 of the potentiometer R8 and the connector X89/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. If necessary undertake repair or replacement.
b) If the connectors are okay, continue to step 3.
3. Check the wiring between the potentiometer and the engine controller against ground and for breaks. Use the
test adapter 380000062.
a) Connect the adapter to the connector X4/70. (Potentiometer unplugged) Disconnect the connector X89/1 from
the engine controller. Check between connector:
X4/70 PIN4 and ground
X4/70 PIN4 and X89/1 PIN79
If a short-circuit to ground or a break is displayed, repair or replace the cable.
b) If the cable is OK, load the current engine software version. If the fault re-occurs, replace the controller.
(see chapter 2002A)

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EEM3 - 81 Accelerator pedal potentiometer, signal voltage too high

Description:
The signal voltage of the accelerator pedal potentiometer R8 is over the permitted range.
Possible causes:
1. Faulty connector or wiring
2. Faulty potentiometer
3. Faulty engine controller
Reaction:
EC is stored and warning lamp is activated.
Solution:
NOTE: As soon as the cause of the error code has been removed, delete the error code and check the system for
proper functioning.
NOTE: If error code FMGR 84 is also active, then remove this error first of all.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Check the connector X4/70 of the potentiometer R8 and the connector X89/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. If necessary, repair or replace.
b) If the connectors are okay, continue to step 3.
3. Check the wiring between potentiometer and engine controller for short-circuit against + supply. Use test adapter
380000062.
a) Connect the adapter to the connector X4/70. (Potentiometer unplugged) Switch the starter switch to the "ON"
position and measure the coltage between connector:
X4/70 PIN4 and PIN1
If a short-circuit at + supply is displayed, the cable must be repaired or replaced.
b) If no short-circuit is displayed at + supply, ypu can load the current engine software version. If the fault re-oc-
curs, replace the controller. (see chapter 2002A)

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EEM3 - 92 Oil pressure too high

Description:
The error code is displayed when the oil pressure is over 9.5 bar. The error code only becomes active when the coo-
lant temperature is above 30 °C.
Possible causes:
1. Faulty oil pressure control valve
2. Faulty connector or wiring
3. Faulty oil pressure sensor
4. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75% and the engine speed to
1,800 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, delete the error code and check the system for
proper functioning.
1. Check if the oil pressure control valve is functioning properly. Run the tractor under normal conditions in order to
check the oil pressure (see chapter 2002A).
a) If the engine oil pressure is not okay, repair as necessary.
b) If a fault with the engine oil pressure is not indicated, continue to step 2.
2. Check the connector X3/37 of the sensor B37 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as necessary.
b) If the connectors are okay, continue to step 3.
3. Check the sensor supply using test adapter 380002717.
a) Connect the test adapter to the connector X3/37. (Sensor unplugged) Tuen the starter switch to the "ON" po-
sition and measure the supply voltage between connector:
X3/37 PIN3 and PIN1.
The displayed voltage must be 5 volts. If the voltage is higher than 5 volts, there is a short-circuit against +12 volts.
Repair or replace the cable.
b) If the supply voltage is correct, go to step 4.
4. Check the signal cable for short-circuit against +supply.
a) Check between connector:
X3/37 PIN2 and PIN1
If a short circuit at +supply is displayed, the cable must be repaired or replaced.
b) If a short-circuit is displayed, go to step 5.
5. Check the sensor.
a) Connect the sensor to the test adapter. Turn the starter switch to the "ON" position and check the signal voltage
between connector:
X3/37 PIN2 and PIN1
The displayed signal voltage must be 0.5 volts. If a higher voltage is displayed, the sensor must be replaced.
If the signal voltage is OK, replace the engine controller. (see chapter 2002A)

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EEM3 - 93 Oil pressure sensor, no signal

Description:
The engine controller does not detect the signal from the oil pressure sensor B37.
Possible cause:
1. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75%. Protective features relating to
oil pressure are no longer active.
Solution:
NOTE: As soon as the cause of the error code has been removed, delete the error code and check the system for
proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not displayed, no further measures are necessary.
b) If the error code is displayed, continue to step 2.
2. Load the current engine software version. If the error re-occurs, replace the controller. (see chapter 2002A)

EEM3 - 94 Overspeed
Description:
The error code becomes active if the engine speed exceeds 3,000 rpm in operation.
NOTE: Exceeding the highest permitted engine speed leads to damage to the engine and the gearbox.
Reaction:
EC is stored and the warning lamp is activated. The injection is set to zero.
Solution:
Return the engine to the normal operating condition. Select an appropriate gear ratio.

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4011-362

EEM3 - 95 Oil pressure sensor is faulty

Description:
The oil pressure sensor B37 supplies too large a figure 1.3 V(= 2 bar) with the starter switch in the "ON" position (en-
gine does not run). >
Possible causes:
1. Faulty connector or wiring
2. Faulty oil pressure sensor
3. Supply voltage for oil pressure sensor is faulty.
4. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75%.
Solution:
NOTE: As soon as the cause of the error code has been removed you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Check the connector X3/37 of the sensor B37 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as necessary.
b) If the connectors are okay, continue to step 3.
3. Check the sensor supply using test adapter 380002717.
a) Connect the test adapter to the connector X3/37. (Sensor unplugged) Turn the starter switch to the "ON" po-
sition and measure the supply voltage between connector:
X3/37 PIN3 and PIN1.
The displayed voltage must be 5 volts. If the voltage is greater than 5 volts there is a short-circuit against
+12 volts. Repair or replace the cable as required.
b) If the supply voltage is correct, go to step 4.
4. Check the signal cable for short-circuit against +supply.
a) Check between connector:
X3/37 PIN2 and PIN1
If a short-circuit at +supply is displayed, repair or replace the cable.
b) If no short-circuit is displayed, go to step 5.
5. Check the sensor.
a) Connect the sensor to the test adapter. Turn the starter switch to the "ON" position and check the signal voltage
between connector:
X3/37 PIN2 and PIN1
The displayed signal voltage must be 0.5 volts. If a higher voltage is displayed, replace the sensor.
If the signal voltage is OK, you must replace the engine controller. (see chapter 2002A)

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EEM3 - 96 Oil pressure sensor, signal voltage too low

Description:
The signal voltage of oil pressure sensor B37 is under the permitted range (< 0.2 V).
Possible causes:
1. Faulty connector or wiring
2. Faulty oil pressure sensor
3. Supply voltage to oil pressure sensor is faulty
4. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75%. Protective functions relating to
oil pressure are switched off.
Solution:
NOTE: As soon as the cause of the error code has been removed you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Check the connector X3/37 of the sensor B37 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as necessary.
b) If the connectors are okay, continue to step 3.
3. Check the supply of the sensors using test adapter 380002717.
a) Connect the test adapter to the connector X3/37. (Sensor unplugged) Turn the starter switch to the "ON" po-
sition and measure the supply voltage between connector:
X3/37 PIN3 and PIN1.
The displayed voltage must be 5 volts. If the voltage is not reached, go to step 4.
b) If the supply voltage is correct, go to step 5.
4. Check the wiring to the sensor for short-circuit against ground and for breaks.
a) Disconnect the connector X36/1 from the engine controller. Check between connector:
X3/37 PIN2 and ground
X3/37 PIN3 and ground
X3/37 PIN1 and X36/1 PIN24
X3/37 PIN2 and X36/1 PIN27
X3/37 PIN3 and X36/1 PIN32
If a short-circuit to ground or a break is displayed, repair or replace the cable.
5. Check the sensor.
a) Connect the connector X36/1 on the engine controller and the sensor on the test adapter. Turn the starter
switch to the "ON" position and check the signal voltage between connector:
X3/37 PIN2 and PIN1
The displayed signal voltage must be 0.5 volts. If the voltage is not reached, replace the sensor.
If the signal voltage is OK, replace the engine controller. (see chapter 2002A)

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EEM3 - 97 Oil pressure sensor, signal voltage too high

Description:
The signal voltage of the oil pressure sensor B37 is over the permitted range (> 4.7 V).
Possible causes:
1. Faulty connector or wiring
2. Faulty oil pressure sensor
3. Supply voltage to oil pressure sensor is faulty
4. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75%. Protective punctions relating
to oil pressure are switched off.
Solution:
NOTE: As soon as the cause of the error code has been removed you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Check the connector X3/37 of the sensor B37 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the sensor supply using test adapter 380002717.
a) Connect the test adapter to the connector X3/37. (Sensor unplugged) Turn rge starter switch to the "ON" po-
sition and measure the supply voltage between connector:
X3/37 PIN3 and PIN1.
The displayed voltage must be 5 volts. If the voltage is higher than 5 volts, there is a short-circuit against +12 volts.
Repair or replace the cable.
b) If the supply voltage is correct, go to step 4.
4. Check the signal cable for short-circuit against +supply.
a) Check between connector:
X3/37 PIN2 and PIN1
If a short-circuit to +supply is displayed, repair or replace the cable.
b) If no short-circuit is displayed, go to step 5.
5. Check the sensor
a) Connect the sensor to the test adapter. Turn the starter switch to the "ON" position and check the signal voltage
between connector:
X3/37 PIN2 and PIN1
The displayed signal voltage must be 0.5 volts. If a higher voltage is displayed, replace the sensor.
If the signal voltage is OK, replace the engine controller. (see chapter 2002A)

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 4011-365

EEM3 - 98 Oil pressure too low

Description:
The error code is displayed if the oil prewssure is too low. The limit value is speed-dependent (0.5 bar at 900 rpm, 1
bar at 2,300 rpm). If the engine speed is between 900 rpm and 2,300 rpm, an interpolated value is taken for the oil
pressure.
Possible causes:
1. Engine oil level too low, oil filter dirty, oil too hot, poor oil quality, fuel in the oil
2. Faulty oil pressure control valve
3. Lube oil pump worn
4. Faulty connector or wiring
5. Faulty oil pressure sensor
6. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated.
Solution:
NOTE: As soon as the cause of the error code has been removed you must delete the error code and check the
system for proper functioning.
1. Check that the engine oil level, the oil filter and the oil quality are OK.
2. Check whether the oil pressure control valve and the lube oil pump operate properly. Run the tractor under normal
conditions to test the oil pressure. (see chapter 2002A)
a) If the cause of the too low oil pressure lies with a mechanical component, remedy this fault.
b) If the lube system mechanical components are OK, then the fault lies inn the electrical system. Go to step 3.
3. Check the connector X3/37 of the sensor B37 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as necessary.
b) If the connectors are okay, continue to step 4.
4. Check the sensor supply using test adapter 380002717.
a) Connect the test adapter to the connector X3/37. (Sensor unplugged) Turn the starter switch to the "ON" po-
sition and measure the supply voltage between connector:
X3/37 PIN3 and PIN1.
The displayed voltage must be 5 volts. If the voltage is not reached, go to step 5.
b) If the supply voltage is correct, go to step 6.
5. Check the wiring to the sensor for short-circuit against ground and for breaks.
a) Disconnect the connector X36/1 from the engine controller. Check between connector:
X3/37 PIN2 and ground
X3/37 PIN3 and ground
X3/37 PIN1 and X36/1 PIN24
X3/37 PIN2 and X36/1 PIN27
X3/37 PIN3 and X36/1 PIN32
If a short-circuit to ground or a break is displayed, repair or replace the cable.
6. Check the sensor.
a) Connect the connector X36/1 on the engine controller and the sensor on the test adapter. Turn the starter
switch to the "ON" position and check the signal voltage between connector:
X3/37 PIN2 and PIN1
The displayed signal voltage must be 0.5 volts. If the voltage is not reached, replace the sensor.
If the signal voltage is OK, replace the engine controller. (see chapter 2002A)

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EEM3 - 99 Oil pressure too low, alarm

Description:
The error code is displayed when the oil pressure is much too low. The limit value is speed-dependent (0.5 bar at 900
rpm, 1 bar at 2,300 rpm). If the engine speed is between 900 rpm and 2,300 rpm, then an interpolated value is taken
for the oil pressure.
Possible causes:
1. Engine oil level too low, oil filter dirty, oil too hot, poor oil quality, fuel in the oil.
2. Faulty oil pressure control valve.
3. Lube oil pump worn
4. Faulty connector or wiring
5. Faulty oil pressure sensor
6. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. After 30 seconds the engine is switched off.
Solution:
NOTE: As soon as the cause of the error code has been removed you must delete the error code and check the
system for proper functioning.
1. Check that the engine oil level, the oil filter and the oil quality are OK.
2. Check whether the oil pressure control valve and the lube oil pump operate properly. Run the tractor under normal
conditions to test the oil pressure. (see chapter 2002A)
a) If the cause for the too low oil pressure lies with a mechanical component, remedy this fault.
b) If the lube system mechanical components are OK, the fault lies in the electrical system. Go to step 3.
3. Check the connector X3/37 of the sensor B37 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 4.
4. Check the sensor supply using test adapter 380002717.
a) Connect the test adapter to the connector X3/37. (Sensor unplugged) Turn the starter switch to the "ON" po-
sition and measure the supply voltage between connector:
X3/37 PIN3 and PIN1.
The displayed voltage must be 5 volts. If the voltage is not reached, go to step 5.
b) If the supply voltage is correct, go to step 6.
5. Check the wiring to the sensor for short-circuit against ground and for breaks.
a) Disconnect the connector X36/1 from the engine controller. Check between connector:
X3/37 PIN2 and ground
X3/37 PIN3 and ground
X3/37 PIN1 and X36/1 PIN24
X3/37 PIN2 and X36/1 PIN27
X3/37 PIN3 and X36/1 PIN32
If a short-circuit to ground or a break is displayed, repair or replace the cable.
6. Check the sensor.
a) Plug in the connector X36/1 at the engine controller and the sensor at the test adapter. Turn the starter switch
to the "ON" position and check the signal voltage between connector:
X3/37 PIN2 and PIN1
The signal voltage displayed must be 0.5 volts. If the voltage is not reached replace the sensor.
If the signal voltage is OK, replace the engine controller. (see chapter 2002A)

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 4011-367

EEM3 - 100 Boost pressure sensor, signal voltage too low

Description:
The signal voltage of the boost pressure sensor B29 is below the permitted range (< 0.2V).
Possible causes:
1. Faulty connector or wiring
2. Faulty boost pressure sensor
3. Supply voltage for boost pressure sensor is faulty
4. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75%.
Solution:
NOTE: As soon as the error code has been removed you must delete the error code and check the system for pro-
per functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Check the connector X4/29 of the sensor B29 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 2.
3. Check the sensor supply using test adapter 380001588.
a) Connect the test adapter to the connector X4/29. (Sensor unplugged) Turn the starter switch to the "ON" po-
sition and measure the supply voltage between:
X4/29 PIN3 and PIN1.
The displayed voltage must be 5 volts. If the voltage is not reached, go to step 4.
b) If the supply voltage is correct, go to step 5.
4. Check the wiring to the sensor for short-circuit against ground and for breaks.
a) Disconnect the connector X36/1 from the engine controller. Check between connector:
X4/29 PIN3 and ground
X4/29 PIN4 and ground
X4/29 PIN3 and X36/1 PIN33
X4/29 PIN4 and X36/1 PIN34
X4/29 PIN1 and X36/1 PIN25
If a short-circuit to ground or a break is displayed, repair or replace the cable.
5. Check the sensor.
a) Connect the connector X36/1 on the engine controller and the sensor on the test adapter. Turn the starter
switch to the "ON" position and check the signal voltage between connector:
X4/29 PIN4 and PIN1
The displayed signal voltage must be 1.07 volts (at 1 bar atmospheric pressure). If the voltage is not reached,
replace the sensor.
If the signal voltage is OK, replace the engine controller. (see chapter 2002A)

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EEM3 - 101 Boost pressure sensor signal voltage too high

Description:
The boost pressure sensor B29 signal voltage is above the permitted range (> 4.7 V).
Possible causes:
1. Faulty connector or wiring
2. Faulty boost pressure sensor
3. Supply voltage for boost pressure sensor is faulty
4. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75%.
Solution:
NOTE: As soon as the cause of the error code has been removed you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Check the connector X4/29 of the sensor B29 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Nehmen Sie gegebenenfalls eine Reparatur oder einen Austausch vor.
b) If the connectors are okay, continue to step 2.
3. Check the sensor supply using test adapter 380001588.
a) Connect the test adapter to the connector X4/29. (Sensor unplugged) Turn the starter switch to the "ON" po-
sition and measure the supply voltage between connector:
X4/29 PIN3 and PIN1.
The displayed voltage must be 5 volts. If the voltage is greater than 5 volts, there is a short-circuit against
+12 volts. Repair or replace the cable.
b) If the supply voltage is correct, go to step 4.
4. Check the signal cable for short-circuit against +supply.
a) Check between connector:
X4/29 PIN4 and PIN1
If a short-circuit to +supply is displayed, repair or replace the cable.
b) If no short-circuit is displayed, go to step 5.
5. Check the sensor.
a) Connect the connector X36/1 on the engine controller and the sensor on the test adapter. Turn the starter
switch to the "ON" position and check the signal voltage between connector:
X4/29 PIN4 and PIN1
The displayed voltage must be 1.07 volts (at 1 bar atmospheric pressure). If the voltage is not reached replace
the sensor.
If the signal voltage is OK, replace the engine controller. (see chapter 2002A)

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EEM3 - 102 Charge presure too low

Description:
The error code becomes active if the charge pressure exceeds a specific value during operation.
Possible causes:
1. Leakage in the charging air system
2. Fault in turbocharger
3. Faulty connector or wiring
4. Faulty boost pressure sensor
5. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75% and the engine speed to
1,800 rpm.
Solution:
NOTE: As soon as the cause of the errorcode has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the mechanical components of the charge system for tightness and functioning. (charge cooler, hoses,
turbocharger)
a) If the cause of the boost pressure being too low is a mechanical component, remedy this fault.
(see chapter 2002A)
b) If the mechanical components of the charge system are OK, the error is in the electrical system. Go to step 2
2. Check the connector X4/29 of the sensor B29 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the sensor supply using test adapter 380001588.
a) Connect the test adapter to the connector X4/29. (Sensor unplugged) Turn the starter switch to the "ON" po-
sition and measure the supply voltage between connector:
X4/29 PIN3 and PIN1.
The displayed voltage must be 5 volts. If the voltage is not reached, go to step 4.
b) If the supply voltage is correct, go to step 5.
4. Check the wiring to the sensor for short-circuit against ground and for breaks.
a) Disconnect the connector X36/1 from the engine controller. Check between connector:
X4/29 PIN3 and ground
X4/29 PIN4 and ground
X4/29 PIN3 and X36/1 PIN33
X4/29 PIN4 and X36/1 PIN34
X4/29 PIN1 and X36/1 PIN25
If a short-circuit to ground or a break is displayed, repair or replace the cable.
5. Check the sensor.
a) Connect the connector X36/1 on the engine controller and the sensor on the test adapter. Turn the starter
switch to the "ON" position and check the signal voltage between connector:
X4/29 PIN4 and PIN1
The displayed signal voltage must be 1.07 volts (at 1 bar atmospheric pressure). If the voltage is not achieved,
replace the sensor.
If the signal voltage is OK, replace the engine controller. (see chapter 2002A)

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EEM3 - 103 Boost pressure too high

Description:
The error code is displayed when the boost pressure exceeds 2.5 bar during operation.
Possible causes:
1. Injection quantity too large
2. Incorrect turbocharger is obstructing
3. Incorrect injector is obstructing
4. Faulty connector or wiring
5. Faulty boost pressure sensor
6. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75% and the engine speed to
1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed you must delete the error code and check the
system for proper functioning.
1. Check the mechanical components of the injection system to see if they comply with the original condition and
also that no additional parts (tuning chip) are used.
a) If the cause of the boost pressure being too high is a mechanical component or a hardware change, remedy
this fault. (see chapter 2002A)
b) If the mechanical components of the injection system are OK, the fault is in the electrical system. Go to step 3.
2. Check the connector X4/29 of the sensor B29 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 2.
3. Check the sensor supply using test adapter 380001588.
a) Connect the test adapter to the connector X4/29. (Sensor unplugged) Turn the starter switch to the "ON" po-
sition and measure the supply voltage between connector:
X4/29 PIN3 and PIN1.
The displayed voltage must be 5 volts. If the voltage is higher that 5 volts, there is a short-circuit against +12 volts.
Repair or replace the cable.
b) If the supply voltage is correct, go to step 4.
4. Check the signal cable for short-circuit aginst +supply.
a) Check between connector:
X4/29 PIN4 and PIN1
If a short-circuit at +supply is displayed, repair or replace the cable.
b) If no short-circuit is displayed, go to step 5.
5. Check the sensor.
a) Connect the sensor on the test adapter. Turn the starter switch to the "ON" position and check the signal volta-
ge between connector:
X4/29 PIN4 and PIN1
The displayed signal voltage must be 1.07 volts (at 1 bar atmospheric pressure). If the voltage is not reached,
replace the sensor,
If the signal voltage is OK, replace the engine controller. (see chapter 2002A)

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EEM3 - 104 Boost pressure, no signal

Description:
The engine controller does not detect the boost pressure sensor signal.
Possible cause:
1. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75%. The engine functions dependent
on boost pressure are not actve.
Solution:
NOTE: As soon as the cause of the error code has been removed you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not displayed then no further measures are necessary.
b) If the error code is displayed, continue to step 2.
2. Load the current engine software version. If the error re-occurs, replace the engine controller.
(see chapter 2002A)

EEM3 - 109 Coolant temperature sensor, no signal

Description:
The engine controller does not detect the signal from the coolant temperature sensor B22.
Possible cause:
1. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75%. The protection against over-
heating is no longer active.
Solution:
NOTE: As soon as the cause of the error code has been removed you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not displayed no further measures are necessary.
b) If the error code is displayed, continue to step 2.
2. Load the current engine software version. If the error re-occurs, replace the engine controller.
(see chapter 2002A)

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4011-372

EEM3 - 110 Coolant temperature sensor, signal voltage too low

Description:
The signal voltage of the coolant temperature sensor B22 is under the permitted range.
Possible causes:
1. Faulty connector or wiring
2. Faulty coolant temperature sensor
3. Supply voltage to coolant temperature sensor is faulty
4. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75%. The protection against over-
heating does not function.
Solution:
NOTE: As soon as the cause of the error code has been removed you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Check the connector X2/22 of sensor B22 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure Repair or replace as necessary.
b) If the connectors are okay, continue to step 3.
3. Check the sensor supply using test adapter 380002716.
a) Connect the test adapter to the connector X2/22. (Sensor unplugged) Turn the starter switch to the "ON" po-
sition and measure the supply voltage between connector:
X2/22 PIN1 and PIN2.
The displayed voltage must be 5 volts. If the voltage is not reached, go to step 4.
b) If the supply voltage is correct, go to step 5.
4. Check the wiring to the sensor for short-circuit against ground and for breaks.
a) Disconnect the connector X36/1 from the engine controller. Check between connector:
X2/22 PIN1 and ground
X2/22 PIN2 and ground
X2/22 PIN1 and X36/1 PIN15
X2/22 PIN2 and X36/1 PIN26
If a short-circuit to ground or a break is displayed, repair or replace the cable.
5. Check the sensor
a) Connect the test adapter to the sensor. Measure the resistance at the sensor between:
PIN2 and PIN1
The resistance must be 2.5 kOhm at 20 °C. If the resistance is not reached, replace the sensor.
b) If the resistance is OK, replace the engine controller. (see chapter 2002A)

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EEM3 - 111 Coolant temperature sensor, signal voltage too high

Description:
The signal voltage of the coolant temperature sensor B22 is over the permitted range.
Possible causes:
1. Faulty connector or wiring.
2. Faulty coolant temperature sensor
3. Supply voltage to coolant temperature sensor is faulty
4. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75%. The protection against over-
heating does not function.
Solution:
NOTE: As soon as the cause of the error code has been removed you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Check the connector X2/22 of the sensor B22 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as necessary.
b) If the connectors are okay, continue to step 3.
3. Check the signal cable for short-circuit against +supply. Use the test adapter 380002716.
a) Connect the test adapter to the connector X2/22. (Sensor unplugged) Turn the starter switch to the "ON" po-
sition and measure the voltage between connector:
X2/22 PIN1 and PIN2.
The displayed voltage must be 5 volts. If the voltage is greater than 5 volts, there is a short-circuit against +
12 volts. Repair or replace the cable.
b) If the voltage is correct, go to step 4.
4. Check the sensor.
a) Connect the test adapter to the sensor. Measure the resistance at the sensor between:
PIN2 and PIN1
The resistance must be 2.5 kOhm at 20 °C. If the resistance is not reached, replace the sensor.
b) If the resistance is OK, replace the engine controller. (see chapter 2002A)

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EEM3 - 112 Coolant temperature too high

Description:
The error code is displayed if the coolant temperature sensor B22 gives a value higher than 106 °C. Between 106 °C
and 113 °C there is a continuous reduction of engine power to 75% of the rated power. If the coolant temperature rises
above 113 °C the engine switches off and error code EEM3 113 is displayed.
NOTE: Overheating of the engine can cause damage to it.
Possible causes:
1. Engine is overloaded
2. Coolant level too low or cooler contaminated
3. Coolant pump drive belt slipping
4. Viscofan does not engage
5. Coolant pump is faulty
6. Cooling system is clogged
7. Thermostat is faulty or or wrongly installed
8. Faulty connector or wiring
9. Faulty coolant temperature sensor
10. Faulty engine controller
Reaction:
EC is stored and the warning fan is activated. The engine power is reduced to 75%.
Solution:
NOTE: As soon as the cause of the error code has been removed, delete the error code and check the system for
proper functioning.
1. Check that the coolant level is OK.
2. Check the mechanical components of the cooling system for proper functioning. (cooler, drive belts, coolant
pump, thermostat, viscofan)
a) If the cause of the overheating lies in a mechanical component, remedy the fault. (see chapter 2002A)
b) If the mechanical components of the cooling system are OK, the fault lies in the electrical system. Go to step 3.
3. Check the connedctor X2/22 of the sensor B22 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as necessary.
b) If the connectors are okay, continue to step 4.
4. Check the signal cable for a short-circuit against +supply. Use the test adapter 380002716.
a) Connect the test adapter to the connector X2/22. (Sensor unplugged) Turn the starter switch to the "ON" po-
sition and measure the voltage between connector:
X2/22 PIN1 and PIN2.
The displayed voltage must be 5 volts. If the voltage is higher than 5 volts, there is a short-circuit against +
12 volts. Repair or replace the cable.
b) If the voltage is correct. go to step 5.
5. Check the sensor.
a) Connect the test adapter to the sensor. Measure the resistance at the sensor between:
PIN2 and PIN1
The resistance must be 2.5 kOhm at 20 °C. If the resistance is not reached, replace the sensor.
b) If the resistance is OK, replace the engine controller. (see chapter 2002A)

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EEM3 - 113 Coolant temperature alarm

Description:
The error code is displayed if the coolant temperature sensor B22 gives a value higher than 113 °C. After about 30
seconds the motor switches off.
NOTE: Overheating of the engine can damage it.
Possible causes:
1. Engine is overloaded
2. Coolant level is too low or cooler is contaminated.
3. Coolant pump drive belt slipping
4. Viscofan does not engage
5. Coolant pump is faulty
6. Cooling system is clogged
7. Thermostat is faulty or incorrectly installed
8. Faulty connector or wiring
9. Faulty coolant temperature sensor
10. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated The engine switches off after 30 seconds.
Solution:
NOTE: As soon as the cause of the error code has been removed you must delete the error code and check the
system for proper functioning.
1. Check that the coolant level is OK.
2. Check the coolant system mechanical components for proper functioning. (cooler, drive belt, coolant pump, ther-
mostat, viscofan)
a) If the cause of the overheating is a mechanical component, remedy the fault. (see chapter 2002A)
b) If the mechanical components of the cooling system are OK, the fault lies in the electrical system. Go to step 3.
3. Check the connector X2/22 of the sensor B22 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 4.
4. Check the signal cable for short-circuit against +supply. Use test adapter 380002716.
a) Connect the test adapter to the connector X2/22. (Sensor unplugged) Turn the starter switch to the "ON" po-
sition and measure the voltage between connector:
X2/22 PIN1 and PIN2.
The displayed voltage must be 5 volts. If the voltage is higher than 5 volts, there is a short-circuit against +
12 volts. Repair or replace the cable.
b) If the voltage is correct, go to step 5.
5. Check the sensor.
a) Connect the test adapter to the sensor. Measure the resistance at the sensor between:
PIN2 and PIN1
The resistance must be 2.5 kOhm at 20 °C. If the resistance is not reached, replace the sensor.
b) If the resistance is OK, replace the engine controller. (see chapter 2002A)

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EEM3 - 114 Charge air temperature sensor, signal voltage too low
Description:
The signal voltage of the charge air temperature sensor B29 is under the permitted range.
Possible causes:
1. Faulty connector or wiring
2. Faulty charge air temperature sensor
3. Supply voltage to charge air temperature sensor is faulty
4. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75%.
Solution:
NOTE: As soon as the cause of the error code has been removed you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Check the connector X4/29 of the sensor B29 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the sensor supply using test adapter 380001588.
a) Connect the test adapter to the connector X4/29. (Sensor unplugged) Tyrn the starter switch to the "ON" posi-
tion and measure the supply voltage between connector:
X4/29 PIN1 and PIN2.
The displayed voltage must be 5 volts. If the voltage is not reached, go to step 4.
b) If the supply voltage is correct, go to step 5.
4. Check the wiring to the sensor for short-circuit against ground and for breaks.
a) Disconnect the connector X36/1 from the engine controller. Check between connector:
X4/29 PIN1 and ground
X4/29 PIN2 and ground
X4/29 PIN1 and X36/1 PIN25
X4/29 PIN2 and X36/1 PIN29
If a short-circuit to ground or a break is displayed, repair or replace the cable.
5. Check the sensor.
a) Connect the test adapter to the sensor. Measure the resistance at the sensor between:
PIN2 and PIN1
The resistance must be 2.5 kOhm at 20 °C. If the resistance is not reached, replace the sensor.
b) If the resistance is OK, replace the engine controller. (see chapter 2002A)

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EEM3 - 115 Charge air temperature sensor, signal voltage too high
Description:
The signal voltage of the charge air temperature sensor B29 is above the permitted range.
Possible causes:
1. Faulty connector or wiring
2. Faulty charge air temperature sensor
3. Supply voltage to charge air temperature sensor is faulty
4. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75%.
Solution:
NOTE: As soon as the cause of the error code has been removed you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Check the connector X4/29 of the sensor B29 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the signal cable for short-circuit against +supply. Use test adapter 380001588.
a) Connect the test adapter to the connector X4/29. (Sensor unplugged) Turn the starter switch to the "ON" po-
sition and measure the voltage between connector:
X4/29 PIN1 and PIN2.
The displayed voltage must be 5 volts. If the voltage is higher than 5 volts, there is a short-circuit against +
12 volts. Repair or replace the cable.
b) If the voltage is correct, go to step 4.
4. Check the sensor.
a) Connect the test adapter to the sensor. Measure the resistance at the sensor between:
PIN2 and PIN1
The resistance must be 2.5 kOhm at 20 °C. If the resistance is not reached, replace the sensor.
b) If the resistance is OK, replace the engine controller. (see chapter 2002A)

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EEM3 - 116 Charge air temperature, value too high

Description:
The error code is displayed if the charge air temperature sensor B29 gives a value higher than 90 °C.
Possible causes:
1. Charge air cooler contaminated
2. Faulty connector or wiring
3. Faulty charge air temperature sensor
4. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75%.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check whether the charge air cooler is contaminated.
2. Check the mechanical components of the intake system for proper operation. (intake system charge air cooler,
hoses and pipework)
a) If the cause of the overheating is in a mechanical component, remedy the fault. (see chapter 2002A)
b) If the cooling system mechanical components are OK, the fault is in the electrical system. Go to step 3.
3. Check the signal cable for short-circuit against +supply. Use test adapter 380001588.
a) Connect the test adapter to the connector X4/29.. (Sensor unplugged) Turn the starter switch to the "ON" po-
sition and measure the voltage between connector:
X4/29 PIN1 and PIN2.
The displayed voltage must be 5 volts. If the voltage is higher than 5 volts, there is a short-circuit against +12 volts.
Repair or replace the cable.
b) If the voltage is correct, go to step 4.
4. Check the sensor.
a) Connect the test adapter to the sensor. Measure the resistance at the sensor between:
PIN2 and PIN1
The resistance must be 2.5 kOhm at 20 °C. If the resistance is not reached, replace the sensor.
b) If the resistance is OK, replace the engine controller. (see chapter 2002A)

EEM3 - 117 Charge air temperature sensor, no signal

Description:
The engine controller does not detect the charge air temperature sensor B29 signal.
Possibile cause:
1. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75%.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not displayed, no further measures are necessary.
b) If the error code is displayed, continue to step 2.
2. Load the current engine software version. If the fault re-occurs, replace the engine controller. (see chapter 2002A)

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EEM3 - 121 Water in fuel

Description:
The water level in the water separator reaches the warning threshold value.
Possible causes:
1. Water in fuel
2. Faulty connector or wiring
3. Faulty "Water in fuel" sensor
4. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75% and the maximum engine speed
is 1,800 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check whether water has collected in the preliminary filter (water separator). If necessary drain all the water from
the preliminary filter.
a) If the error is no longer active, check whether the system is working properly.
b) If the error code is still avtive, continue to step 2
2. Check the connector X3/12 of the "Water in fuel" sensor B23 and the connector X89/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the supply voltage and signal voltage to the sensor using test adapter 380000061.
a) Connect the test adapter to the connector X3/12. (Sensor unplugged) Turn the starter switch to the "ON" po-
sition and measure the supply voltage and signal voltage between connector:
X3/12 PINA and PINC
X3/12 PINB and PINC
The supply voltage and the signal voltage must be 12 volts. If the voltages are not reached, go to step 4.
b) If the voltages are correct, go to step 5.
4. Check the wiring to the sensor for short circuits against ground and for breaks.
a) Disconnect the connector X89/1 from the engine controller. Check between connector:
X3/12 PINA and ground
X3/12 PINB and ground
X3/12 PINA and X89/1 PIN50
X3/12 PINB und X89/1 PIN47
If a short-circuit to ground or a break is displayed, repair or replace the cable.
5. Check the sensor. Ensure that there is no more water in the preliminary filter.
Connect the connector X89/1 on the engine controller and the sensor (X3/12) on the test adapter. Turn the starter
switch to the "ON" position and check the signal voltage (after 3 seconds) between connector:
X3/12 PINB and PINC
The measured signal voltage must be 12 volts.
a) If the measured signal voltage is 0 volt, replace the sensor.
b) If the measured signal voltage is OK (12 volts) and the error continues to be active, the engine controller must
be replaced. (see chapter 2002A).

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EEM3 - 141 CAN Bus OFF (vehicle bus)

Description:
The engine controller cannot communicate with the other vehicle bus users.
Possible causes:
1. Intermittent CAN communication malfunction between the engine controller and the vehicle bus.
2. CAN bus short-circuit
3. Incorrect or missing termination resistance
4. Contacts of the CAN bus plugs bent, broken or corroded
5. Faulty engine controller
6. Other controllers faulty
Reaction:
EC is stored and the warning lamp is activated. Speed control via the CAN bus no longer possible. The accelerator
pedal signal is used directly.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for correct functioning.
1. Ensure that the EEM3 controller is supplied with current and is ONLINE at the bus. Verify this with the service tool
function "Control module status". If the EEM3 controller is OFFLINE, go to step 2. If the EEM3 controller is
ONLINE, it is a matter of a short-term error. In this case a test drive is to be carried out. If the error code does not
occur again no further measures are necessary.
2. Check EEM3 supply.
Potential 30 Fuse F203 (30A):
Measure the voltage at connector X89/1 PIN2, 3, 8, 9 (+12V) against PIN5, 6, 10, 11 (ground). If the voltage is
more than 1 volt lower than the battery voltage, check the wiring of connector X89/1 PIN2, 3, 8, 9 up to the screw
connection X1/30/EEM at the engine print A14 and fuse F203.
Potential 15 fuse F207 (5A):
Measure the voltage at connection X89/1 PIN40 (+12V), against PIN5, 6, 10, 11 (ground). If the voltage is more
than 1 volt lower than the battery voltage, check the wiring of connector X89/1 PIN40 up to the connector X12/1
PIN2 at the engine print A14 and fuse F207.
Ground:
Check the ground wire at the connector X89/1 PIN5, 6, 10, 11 up to grounding point 11.
Check the ground wire from grounding point 2 up to grounding point 11.
3. Should one of the fuses be faulty, replace it with a new one.
a) If the fuse becomes faulty again, a fault was probably overlooked during the check of the supply cables. In this
case start again at step 2.
b) If no error is identifiable, but the fuse is still faulty, replace the EEM3 controller.
4. Check the terminating resistance in the EEM3 box between PIN35 and PIN34 (desired value 120 Ohm +/- 10%).
5. Check the complete CAN bus for short-circuits. To do this use the CAN bus schematic. Disconnect all the con-
trollers located on the CAN bus (except ICU). Measure the resistance (desired value 120 Ohm +/- 10%) between
CANH and CANL. Disconnect the terminal resistance X3/10 and measure again between CANH and CANL; the
resistance must now be infinite. Measure also CANH against ground and CANL against ground; the resistance
must also be infinite here. If a short-circuit occurs, repair or replace as required.
6. Connect one controller after another and check with the "Controller module status" service tool function if they go
ONLINE. Start with the EEM3 engine controller. If a controller stays OFFLINE, check this controller's cable for
breaks and repair or replace as necessary. If the controller continues to remain OFFLINE, replace it.

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EEM3 - 143 CAN bus OFF (ID modules - EEM3)

Description:
The engine controller cannot communicate with the ID module via the CAN bus.
Possible causes:
1. Intermittent CAN communication malfunction between the engine controller and the ID module.
2. CAN bus short-circuit between engine controller and ID module
3. Faulty terminating resistance
4. Contacts of the CAN bus plugs bent, broken or corroded
5. Faulty engine controller
6. Faulty ID module
Reaction:
EC is stored and the warning lamp is activated. Error codes 453 and 466 may also appear.
Solution:
NOTE: As soon as the cause of the error code has been removed, delete the error code and check the system for
proper functioning.
1. Check the connector X4/4 and the connector X89/1.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are OK, go to step 2.
2. Check the wiring of the local CAN bus for short-circuits. Insert the test adapter 380000062 in the screw connection
X4/4. (ID module unplugged) Disconnect the connector X89/1 from the engine controller and measure between:
X4/4 PIN3 and ground
X4/4 PIN2 and ground
X4/4 PIN3 and PIN4
X4/4 PIN2 and PIN4
X4/4 PIN3 and PIN2
If a short-circuit is displayed, repair or replace. If no short-circuit is displayed, go to step 3.
3. Check the wiring of the local CAN bus for breaks. Measure between:
X89/1 PIN53 and X4/4 PIN3
X89/1 PIN52 and X4/4 PIN2
If a break is displayed, repair or replace. If no break is displayed, go to step 4.
4. Check the Check the terminating resistances. Measure at the components between:
X89/1 PIN53 and PIN52
X4/4 PIN3 and PIN2
If the resistance value deviates from the desired value (120 Ohm +/- 10%), the appropriate component (engine
controller / ID module) must be replaced. If the resistances are OK, continue to step 5.
5. If the error code continues to be active, replace the engine controller. (see chapter 2002A)
6. If the error code occurs again, replace the ID module as well.

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EEM3 - 146 Speed setting through FMGR too low

Description:
The engine speed requested from FMGR is less than 500 rpm.
Possible causes:
1. Faulty FMGR
2. CAN bus faulty
3. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The EEM3 uses the accelerator signal.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check if error codes relating to CAN Bus or FMGR are active. Remedy these first.
2. If no other error codes are active, check the requested engine speed with the service tool monitoring function. If
the value is above 500 rpm but error code 146 continues active, the cause lies in the engine controller.
3. Load the current engine software, then clear the error code and carry out another check. If the error code conti-
nues active, replace the engine controller. (see chapter 2002A)

EEM3 - 147 Speed setting through FMGR too high

Description:
The engine speed requested from FMGR is greater than 3,000 rpm.
Possible causes:
1. Faulty FMGR
2. CAN bus faulty
3. Faulty engine controller
Reaction:
EC is stored and warning lamp is activated. The engine uses the accelerator signal.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check whether the error codes relating to CAN bus or FMGR are active. Remedy these first.
2. If no other error codes are active, check the requested engine speed with the service tool monitoring function. If
the value is under 3,000 rpm but error code 147 continues active, the cause lies in the engine controller.
3. Load the current engine software, then clear the error code and carry out another check. If the error code conti-
nues active, replace the engine controller. (see chapter 2002A)

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EEM3 - 172 Upgrade protective error

Description:
The transmission specification (FMGR) and the engine specification (ID module) do not match.
Possible causes:
1. Installation of an FMGR with incorrect maximum vehicle speed.
2. Installation of an ID module with incorrect specification
Reaction:
EC is stored and the warning lamp is activated. Engine fails to start.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
This error can only be remedied by personnel authorized to do so. Contact the Customer Service Department.

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EEM3 - 211 Supply voltage 1 too low

Description:
The supply voltage (5 VDC) for the sensors (boost pressure / charge air temperature B29, oil pressure B37, fuel de-
livery pressure B39) is too low (< 4.6 V).
Possible causes:
1. Faulty connector
2. Faulty cable
3. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75%.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. The error can occur during engine start-up or even with the starter switch in the "ON" position. Before proceeding
clear the error code and turn the starter switch to the "OFF" position.
a) Turn the starter switch back to the "ON" position. If the error code is displayed, continue to step 2.
b) If the error code is not active, start the engine. If the error is active, the cause lies in too great a battery voltage
drop during the starting operation. Check battery charge level. (see also error code EEM3 - 371)
2. Check the connectors X4/29, X3/37, X3/39 and the connector X36/1 of the engine controller.
a) All connectors must be connected and show no signs of damage. The pins must be in the correct position and
the connectors must fit securely. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the supply of sensor B29 for a short-circuit to ground. Use test adapter 380001588.
a) Disconnect the connector X4/29 and the connector X36/1. Connect the test adapter to connector X4/29 and
check for short-circuit between connector:
X4/29 PIN3 and PIN1
X4/29 PIN3 and ground
If no short-circuit is displayed, repair or replace the cable.
b) If a short to ground is not indicated, continue to step 4.
4. Check the supply of sensor B37 for a short-circuit to ground. Use test adapter 380002717.
a) Disconnect the connector X3/37 and the connector X36/1. Connect the test adapter to connector X3/37 and
check for short-circuit between connector:
X3/37 PIN3 and PIN1
X3/37 PIN3 and ground
If a short-circuit is displayed, repair or replace the cable.
b) If a short to ground is not indicated, continue to step 5.
5. Check the supply of sensor B39 for a short-circuit to ground. Use test adapter 380002717.
a) Disconnect the connector X3/39 and the connector X36/1. Connect the test adapter to connector X3/39 and
check for short-circuit between connector:
X3/39 PIN3 and PIN1
X3/39 PIN3 and ground
If a short-circuit is displayed, repair or replace the cable.
b) If a short to ground is not indicated, continue to step 6.
6. If the cable is OK, you can load the current engine software version. If the error re-occurs, replace the engine
controller. (see chapter 2002A)

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EEM3 - 212 Supply voltage 1 too high

Description:
The supply voltage (5 VDC) for the sensors (boost pressure / charge air temperature B29, oil pressure B37, fuel de-
livery pressure B39) is too high (> 5.2 V).
Possible causes:
1. Faulty connector
2. Faulty cable
3. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75%.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Check the connectors X4/29, X3/37, X3/39 and the connector X36/1 of the engine controller.
a) All connectors must be connected and show no signs of damage. The pins must be in the correct position and
the connectors must fit securely. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the supply of sensor B29 for a short-circuit to +12 V. Use test adapter 380001588.
a) Insert the test adapter in the plug-in connection X4/29. Turn the starter switch to the "ON" position and measure
the voltage between connectors:
X4/29 PIN3 and PIN1
X4/29 PIN3 and ground
If the displayed voltage is over 5.2 V, repair or replace the cable.
b) If the displayed voltage is about 5 V, you can continue with step 4.
4. Check the supply of sensor B37 for a short-circuit to +12 V. Use test adapter 380002717.
a) Insert the test adapter in the plug-in connection X3/37. Turn the starter switch to the "ON" position and measure
the voltage between connectors:
X3/37 PIN3 and PIN1
X3/37 PIN3 and ground
If the displayed voltage is over 5.2 V, repair or replace the cable.
b) If the displayed voltage is about 5 V, you can continue with step 5.
5. Check the supply of sensor B39 for a short-circuit to +12 V. Use test adapter 380002717.
a) Insert the test adapter in the plug-in connection X3/39. Turn the starter switch to the "ON" position and measure
the voltage between connectors:
X3/39 PIN3 and PIN1
X3/39 PIN3 and ground
If the displayed voltage is over 5.2 V, repair or replace the cable.
b) If the displayed voltage is about 5 V, you can continue with step 6.
6. If the cables are OK, you can load the current engine software version. If the error re-occurs, replace the engine
controller. (see chapter 2002A)

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EEM3 - 215 Supply voltage 3 too low

Description:
The supply voltage (5 VDC) for the rail pressure sensor B38 is too low (< 4.6 V).
Possible causes:
1. Faulty connector
2. Faulty cable
3. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75%.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. The error can occur during engine start-up or even with the starter switch in the "ON" position. Before proceeding
clear the error code and turn the starter switch to the "OFF" position.
a) Turn the starter switch back to the "ON" position. If the error code is displayed, continue to step 2.
b) If the error code is not active, start the engine. If the error is active, the cause is too great a battery voltage drop
during start-up. Check battery charge level. (see also error code EEM3 - 371)
2. Check the connector X3/38 and the connector X36/1 of the engine controller.
a) The connectors must be connected and show no signs of damage. The pins must be in the correct position
and the connectors must fit securely. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the supply of sensor B38 for a short-circuit to ground. Use test adapter 380002718.
a) Disconnect the connector X3/38 and the connector X36/1. Connect the test adapter to connector X3/38 and
check for short-circuit between connectors:
X3/38 PIN3 and PIN1
X3/38 PIN3 and ground
If a short-circuit is displayed, repair or replace the cable.
b) If a short to ground is not indicated, continue to step 4.
4. If the cables are OK, you can load the current engine software version. If the error re-occurs, replace the engine
controller. (see chapter 2002A)

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EEM3 - 216 Supply voltage 3 too high

Description:
The supply voltage (5 VDC) for the rail pressure sensor B38 is too high (> 5.2 V).
Possible causes:
1. Faulty connector
2. Faulty cable
3. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75%.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Check the connector X3/38 and the connector X36/1 of the engine controller.
a) The connectors must be connected and show no signs of damage. The pins must be in the correct position
and the connectors must fit securely. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the supply of sensor B38 for a short-circuit to +12 V. Use test adapter 380002718.
a) Insert the test adapter in the plug-in connection X3/38. Turn the starter switch to the "ON" position and measure
the voltage between connectors:
X3/38 PIN3 and PIN1
X3/38 PIN3 and ground
If the displayed voltage is over 5.2 V, repair or replace the cable.
b) If the displayed voltage is about 5 V, you can continue with step 4.
4. If the cables are OK, you can load the current engine software version. If the error re-occurs, replace the engine
controller. (see chapter 2002A)

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EEM3 - 221 Engine electronics self-test, internal error 1

Description:
After the starter switch is turned to the "ON" position, the engine controller runs an automatic self-test. In this the ope-
ration of the internal electronics are checked and any error detected.
Possibile cause:
1. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine cannot be started.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Turn the starter switch to the "OFF" position (5 sec.) and then "ON" again. If the error code continues active, the
cause of the problem lies in a faulty engine controller. Replace the engine controller. (see chapter 2002A)

EEM3 - 222 Engine electronics self-test, internal error 2

Description:
After the starter switch is turned to the "ON" position, the engine controller runs an automatic self-test. In this the
function of the internal electronics are checked and any error detected.
Possibile cause:
1. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine cannot be started.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Turn the starter switch to the "OFF" position (5 sec.) and then "ON" again. If the error code continues active, the
cause of the problem lies in a faulty engine controller. Replace the engine controller. (see chapter 2002A)

EEM3 - 223 Engine electronics self-test, internal error 3

Description:
After the starter switch is turned to the "ON" position, the engine controller runs an automatic self-test. In this the
function of the internal electronics is checked and any error detected.
Possibile cause:
1. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine cannot be started.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Turn the starter switch to the "OFF" position (5 sec.) and then to "ON" again. If the error code continues active,
the cause of the problem lies in a faulty engine controller. Replace the engine controller. (see chapter 2002A)

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EEM3 - 231 Engine controller does not switch off

Description:
After the starter switch is turned to the "OFF" position, the engine switches off in a controlled manner. If the switching
off is not functioning, the error is active and the engine controller continues to operate.
Possibile cause:
1. Faulty engine controller
Reaction:
EC is stored.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Turn the starter switch to the "OFF" position (5 sec.) and then to "ON" again. If the error code continues active,
the cause of the problem lies in a faulty engine controller. Replace the engine controller. (see chapter 2002A)

EEM3 - 233 Engine controller switch-off did not function the last
time
Description:
After the starter switch is turned to the "OFF" position, the engine controller is switched off in a controlled manner. If
the switch-off did not function the last time, the error becomes active when the starter switch is turned to the "ON"
position again.
Possibile cause:
1. Faulty engine controller
Reaction:
EC is stored.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Turn the starter switch to the "OFF" position (5 sec.) and then to "ON" again. If the error code continues active,
the cause of the problem lies in a faulty engine controller. Replace the engine controller. (see chapter 2002A)

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EEM3 - 235 Final stage 1, short-circuit to ground

Description:
The +supply of the high pressure pump Y20 solenoid valve has a short-circuit to ground.
Possible causes:
1. Faulty cable
2. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Turn the starter switch to the "OFF" position. Wait 5 seconds and turn the
starter switch to the "ON" position. If the error re-occurs, continue with step 2.
2. Check the electrical connections of the high pressure pump solenoid valve Y20 and the connector X16/1 of the
engine controller.
a) Ensure the connector is connected, not damaged, the pins are in the correct position and that the fit is tight.
Repair or replace as required.
b) If the electrical connections are OK, continue with step 2.
3. Check the supply for a short-circuit to ground. Use test adapter 380002716.
a) Connect the test adapter to the connector X2/21. (Solenoid valve unplugged) Turn the starter switch to "ON".
Measure the voltage between connector X2/21 PIN1 and ground. If the voltage indicated is approximately
+12 volts, continue to step 4.
b) If a short-circuit to ground is displayed, repair or replace the cable.
4. If no short-circuit exists, load the current engine software version. If the error re-occurs, replace the engine con-
troller.(see chapter 2002A)

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EEM3 - 237 Final stage 3, short-circuit to ground

Description:
The +supply of the ID module has a short-circuit to ground.
Possible causes:
1. Faulty cable
2. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Turn the starter switch to the "OFF" position. Wait 5 seconds and turn the
starter switch to the "ON" position. If the error re-occurs, continue with step 2.
2. Check the supply for a short-circuit to ground. Use test adapter 380000062
a) Connect the test adapter to the connector X4/4. (ID module A7 unplugged) Turn the starter switch to the "ON"
position. Measure the voltage between connector X4/4 PIN4 and ground. If the voltage indicated is approxima-
tely +12 volts, continue to step 3.
b) If a short-circuit to ground is displayed, repair or replafce the cable.
3. If no short-circuit exists, you can load the current engine software version. If the error re-occurs, replace the en-
gine controller. (see chapter 2002A)

EEM3 - 241 Final stage 1, short-circuit to battery +

Description:
The ground supply of the high pressure pump solenoid valve Y20 has a short-circuit on battery +.
Possible causes:
1. Faulty cable
2. Faulty engine controller
Reaction:
EC is stored and warning lamp is activated.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Turn the starter switch to the "OFF" position. Wait 5 seconds and turn the
starter switch to the "ON" position. If the fault re-occurs, continue with step 2.
2. Check the electrical connections of the high pressure pump solenoid valve Y20 and the connector X16/1 of the
engine controller.
a) Ensure the connector is connected, not damaged, the pins are in the correct position and that the fit is tight.
Repair or replace as required.
b) If the electrical connections are OK, continue with step 2.
3. Check the ground supply for a short-circuit on battery +. Use test adapter 380002716.
a) Connect the test adapter to the connector X2/21. (Solenoid valve unplugged) Turn the starter switch to "ON".
Measure the voltage between connector X2/21 PIN1 and ground. If the voltage indicated is approximately +4
volts, continue to step 0.
b) If a short-circuit is displayed on battery +, rerpair or replace the cable.
4. If no short-circuit exists you can load the current engine software version. If the error re-occurs, replace the engine
controller. (see chapter 2002A)

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EEM3 - 245 Engine controller switches off briefly while operating

and then functions again
Description:
After the starter switch is turned to the "OFF" position, the engine controller is switched off in a controlled manner. If
the engine controller is switched off and on once uncontrolled while operating, this error code is produced.
Possibile cause:
1. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated.
Solution:
NOTE: As soon as the casue of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Turn the starter switch to the "OFF" position (5 sec.) and then back to "ON". If the error code continues active,
the cause of the problem lies in a faulty engine controller. Replace the engine controller. (see chapter 2002A)

EEM3 - 246 Engine controller switches off briefly 3 times while

operating and then functions again
Description:
After the starter switch is turned to the "OFF" position, the engine controller is switched off in a controlled manner. If
the engine controller is switched off and on 3 times briefly uncontrolled while operating, this error code is produced.
Possibile cause:
1. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Turn the starter switch to the "OFF" position (5 sec.) and then back to "ON". If the error code continues active,
the cause of the problem lies in a faulty engine controller. Replace the engine controller. (see chapter 2002A)

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 4011-393

EEM3 - 248 Water in fuel sensor - supply voltage too low

Description:
The supply voltage of sensor B23 is under the permitted range. (< 6.5 V)
The error can also be initiated by a too high battery voltage drop during start-up.
Possible causes:
1. Poor battery charge level
2. Faulty connector
3. Faulty cable
4. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75%.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. The error can occur during engine start-up or even with the starter switch in the "ON" position. Before proceeding
clear the error code and turn the starter switch to the "OFF" position.
a) Turn the starter switch back to the "ON" position. If the error code is displayed, continue to step 2.
b) If the error code is not active, start the engine. If the error is active, the cause lies in a too high battery voltage
drop during start-up. Check battery charge level. (see also error code EEM3 - 371)
2. Check the connector X3/12 of the sensor and the connector X89/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the supply of sensor (+12 V) for a short-circuit to ground.
a) Disconnect connector X3/12. Turn the starter switch to the "ON" position. Check between connector:
X3/12 PINA and PINC
If a short-circuit to ground is displayed, repair or replace as necessary.
b) If the supply is OK, you can load the current engine software version. If the error re-occurs, replace the engine
controller. (see chapter 2002A)

EEM3 - 249 Water in fuel sensor - supply voltage too high

Description:
The supply voltage of the psensor B23 is over the permitted range. (>32 V)
Possibile cause:
1. Faulty alternator
Reaction:
EC is stored and the warning lamp is activated.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the alternator charging voltage. (see error code EEM3 - 18)

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EEM3 - 251 Fuel temperature sensor signal voltage too low

Description:
The fuel remperature sensor B36 signal voltage is below the permitted range.
Possible causes:
1. Faulty connector or wiring
2. Faulty fuel temperature sensor
3. Fuel temperature sensor supply voltage faulty
4. Faulty engine controller
Reaction:
EC is stored and warning lamp is activated. The engine power is reduced to 75%.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Check the connector X2/36 of the sensor B36 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the sensor supply using test adapter 380002716.
a) Connect the test adapter to the connector X2/36. (Sensor unplugged) Turn the starter switch to the "ON" po-
sition and measure the supply voltage between connector:
X2/36 PIN1 and PIN2.
The displayed voltage must be 5 volts. If the voltage is not reached, go to step 4.
b) If the supply voltage is correct, go to step 5.
4. Check the wiring to the sensor for short-circuit against ground and for breaks.
a) Disconnect the connector X36/1 from the engine controller. Check between connector:
X2/36 PIN1 and ground
X2/36 PIN2 and ground
X2/36 PIN1 and X36/1 PIN35
X2/36 PIN2 and X36/1 PIN8
If a short-circuit to ground or a break is displayed, repair or replace the cable.
5. Check the sensor.
a) Connect the test adapter to the sensor. Measure the resistance at the sensor between:
PIN2 and PIN1
The resistance must be 2.5 kOhm at 20 °C. If the resistance is not reached, replace the sensor.
b) If the resistance is OK, replace the engine controller. (see chapter 2002A)

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 4011-395

EEM3 - 252 Fuel temperature sensor signal voltage too high

The signal voltage of the fuel temperature sensor B36 is above the permitted range.
Possible causes:
1. Faulty connector or wiring
2. Faulty fuel temperature sensor
3. Faulty supply voltage to fuel temperature sensor
4. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75%.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and chack the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Check the connector X2/36 of the sensor B36 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the signal cable for short-circuit against +supply. Use test adapter 380002716.
a) Connect the test adapter to the connector X2/36. (Sensor unplugged) Turn the starter switch to the "ON" po-
sition and measure the voltage between connector:
X2/36 PIN1 and PIN2.
The displayed voltage must be 5 volts. If the voltage is higher than 5 volts, there is a short-circuit against +
12 volts. Repair or replace the cable.
b) If the voltage is correct, go to step 4.
4. Check the sensor.
a) Connect the test adapter to the sensor. Measure the resistance at the sensor between:
PIN2 and PIN1
The resistance must be 2.5 kOhm at 20 °C. If the resistance is not reached, replace the sensor.
b) If the resistance is OK, replace the engine controller. (see chapter 2002A)

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EEM3 - 253 Fuel temperature too high

Description:
The error code is displayed when the fuel temperature sensor B36 gives a value higher then 90 °C.
Possible causes:
1. Fuel temperatue too high due to overheated engine
2. Faulty connector or wiring
3. Faulty fuel temperature sensor
4. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75%.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check if the engine is overheated. If other error codes are active, clear these first (e.g. 112, 113).
2. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
3. Check the connector X2/36 of the sensor B36 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 4.
4. Check the signal cable for short-circuit against +supply. Use test adapter 380002716.
a) Connect the test adapter to the connector X2/36. (Sensor unplugged) Turn the starter switch to the "ON" po-
sition and measure the voltage between connector:
X2/36 PIN1 and PIN2.
The displayed voltage must be 5 volts. If the voltage is higher than 5 volts, there is a short circuit against +
12 volts. Repair or replace the cable.
b) If the voltage is correct, go to step 5.
5. Check the sensor.
a) Connect the test adapter to the sensor. Measure the resistance at the sensor between:
PIN2 and PIN1
The resistance must be 2.5 kOhm at 20 °C. If the resistance is not reached, replace the sensor.
b) If the resistance is OK, replace the engine controller. (see chapter 2002A)

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EEM3 - 261 Fuel temperature sensor, no signal

Description:
The engine controller does not detect the B36 fuel temperature sensor signal.
Possibile cause:
1. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75%.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not displayed, no further measures are necessary.
b) If the error code is displayed, continue to step 2.
2. Load the current engine software version. If the error re-occurs, replace the engine controller.
(see chapter 2002A)

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4011-398

EEM3 - 263 Rail pressure sensor - signal voltage too low

Description:
The sensor signal voltage is below the permitted range (< 0.4 V).
Possible causes:
1. Faulty connector or wiring
2. Faulty rail pressure sensor
3. Faulty supply voltage to rail pressure sensor
4. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm. EC 391 can appear at the same time.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Check the connector X3/38 of the sensor B38 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the sensor supply using test adapter 380002718.
a) Connect the test adapter to the connector X3/38. (Sensor unplugged) Turn the starter switch to the "ON" po-
sition and measure the supply voltage between connector:
X3/38 PIN3 and PIN1.
The displayed voltage must be 5 volts. If the voltage is not reached, go to step 4.
b) If the supply voltage is correct, go to step 5.
4. Check the wiring to the sensor for short-circuit against ground and for breaks.
a) Disconnect the connector X36/1 from the engine controller. Check between connector:
X3/38 PIN2 and ground
X3/38 PIN3 and ground
X3/38 PIN1 and X36/1 PIN12
X3/38 PIN2 and X36/1 PIN13
X3/38 PIN3 and X36/1 PIN14
If a short-circuit to ground or a break is displayed, repair or replace the cable.
5. Check the sensor.
a) Connect the connector X36/1 to the engine controller and the sensor to the test adapter. Turn the starter switch
to the "ON" position and check the signal voltage between controller:
X3/38 PIN2 and PIN1
The displayed signal voltage must be 0.5 volt. If the voltage is not reached, replace the sensor.
If the signal voltage is OK, replace the engine controller. (see chapter 2002A)

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EEM3 - 264 Rail pressure sensor - signal voltage too high

Description:
The rail pressure sensor signal voltage is above the permitted range (> 4.8 V).
Possible causes:
1. Faulty connector or wiring
2. Faulty rail pressure sensor
3. Supply voltage to rail pressure sensor is faulty
4. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm. EC 391 can appear at the same time.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Check the connector X3/38 of the sensor B38 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the sensor supply using test adapter 380002718.
a) Connect the test adapter to the connector X3/38. (Sensor unplugged) Turn the starter switch to the "ON" po-
sition and measure the supply voltage between connector:
X3/38 PIN3 and PIN1.
The displayed voltage must be 5 volts. If the voltage is higher than 5 volts, there is a short-circuit against +12 volts.
Repair or replace the cable.
b) If the supply voltage is correct, go to step 4.
4. Check the signal cable for short-circuit against +supply.
a) Check between connector:
X3/38 PIN2 and PIN1
If a short-circuit to +supply is displayed, repair or replace the cable.
b) If no short-circuit is displayed, go to step 5.
5. Check the sensor.
a) Connect the sensor to the test adapter. Turn the starter switch to the "ON" position and check the signal voltage
between connector:
X3/38 PIN2 and PIN1
The displayed signal voltage must be 0.5 volt. If a higher voltage is displayed, replace the sensor.
If the signal voltage is OK, replace the engine controller. (see chapter 2002A)

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EEM3 - 265 Rail pressure too high

Description:
The error code is displayed if the rail pressue is higher than 1,300 bar.
Possible causes:
1. High pressure pump is not working correctly.
2. Faulty connector or wiring.
3. Faulty rail pressure sensor
4. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code is removed, you must delete the error code and check the system for
proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Check the high pressure pump with the "Test Function" in the service tool.
a) If the high pressure pump does not operate properly, it must be repaired by an authorized specialist service
centre. (Disassembly, installation - see chapter 3001A)
b) If the high pressure pump is operating properly, go to step 3.
3. Check the connector X3/38 of the sensor B38 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 4.
4. Check the sensor using test adapter 380002718.
a) Terminate the test adapter across the plug-in connection X3/38. Start the engine and check the signal voltage
between connector :
X3/38 PIN2 and PIN1
The displayed signal voltage at the no-load speed must be about 1.5 volts. If a higher voltage is displayed, replace
the sensor.
b) If the signal voltage is OK, replace the engine controller. (see chapter 2002A)

EEM3 - 266 Rail pressure, no signal

Description:
The engine controller does not detect the rail pressure sensor signal.
Possibile cause:
1. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm. The engine functions dependent on the rail pressure are not active.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must deleteb the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not displayed, no further measure is necessary.
b) If the error code is displayed, continue to step 2.
2. Load the current engine software version. If the fault re-occurs, replace the engine controller. (see chapter 2002A)

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 4011-401

EEM3 - 269 Engine speed, signals faulty

Description:
The engine speed sensor B20 and the camshaft position sensor B40 are used to calculate the speed. The two sen-
sors give contradictory signals.
Possible causes:
1. Very rapid changes of engine speed due to problems in the injection system.
2. Invalid or no engine speed sensor signal (faulty wiring, faulty sensor, sensor - sensor wheel distance too great or
damaged sensor wheel.
3. Invalid or no camshaft position sensor signal (faulty wiring, faulty sensor, sensor - sensor wheel distance too great
or damaged sensor wheel.
4. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75% and the maximum engine speed
is 1,800 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. If the engine runs irregularly, check the injection system and the mechanical system of the engine.
(see chapters 2002A and 3001A)
If the error occurs sporadically, this was probably caused by too rapid a change of engine speed (maloperation).
2. Check the connector X2/28 of the sensor B20 and the connector X36/1 of the engine controller.
Check the connector X3/40 of the sensor B40 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the wiring of both sensors for short-circuit to ground and for breaks. Use test adapters 380000060 and
380002718.
a) Disconnect the connector X36/1 from the engine controller and connect the appropriate adapter to connector
X2/28 or X3/40. (Sensor unplugged) Test between connector:
X2/28 PIN1 and ground
X2/28 PIN2 and ground
X2/28 PIN1 and X36/1 PIN19
X2/28 PIN2 and X36/1 PIN23

X3/40 PIN1 and ground

X3/40 PIN2 and ground
X3/40 PIN1 and X36/1 PIN9
X3/40 PIN2 and X36/1 PIN10
If a short-circuit to ground or a break is displayed, repair or replace the cable. If the wiring is OK, go to step 4.
4. Check the sensors.
a) Connect the test adapter to the sensors. (Cabling unplugged) Measure the resistances of the sensors between
PIN1 and PIN2.
Engine speed sensor: 1120 - 1530 Ohm at 20 °C
Camshaft position sensor: 774 - 946 Ohm at 20 °C
If the resistance values are not reached, replace the appropriate sensor.
b) If the resistances are OK, measure the sensor frequencies. Connect the cabling to the test adapter. Start the
engine and measure the frequency of the two sensors between PIN1 and PIN2.
Engine speed sensor: approx. 855 Hz (at 900 rpm.)
Camshaft position sensor: approx. 52 Hz (at 900 rpm.)
If the frequency values are not reached, go to step 5.
If the frequencies are reached go to step 6.
5. Check correct sensor fitting. The distance between sensor and sensor wheel must be 0.2 - 1.0 mm. In addition
check the sensor wheel of both sensors for damage and for firm fit.
6. Load the current engine software version. If the fault re-occurs, replace the engine controller. (see chapter 2002A)

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EEM3 - 271 Engine speed sensor signal faulty

Description:
The B20 engine speed sensor supplies pulses with a time lapse determined by the sensor wheel. In fault condition
the time lapse is incorrect.
Possible causes:
1. Very rapid changes in engine speed due to problems in the injection system.
2. Invalid engine speed sensor signal (faulty wiring, faulty sensor, sensor - sensor wheel distance too great or da-
maged sensor wheel)
3. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75% and the engine speed limited to
1,800 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. If the engine runs irregularly, check the injection system and the mechanical system of the engine.
(see chapters 2002A and 3001A)
If the error occurs sporadically, this was probably caused by too rapid changes in the engine speed
(maloperation).
2. Check the connector X2/28 of the sensor B20 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the wiring for short-circuit to ground and for breaks. Use test adapter 380000060.
a) Disconnect the connector X36/1 from the engine controller and connect the adapter to connector X2/28. (Sen-
sor unplugged) Check between connector:
X2/28 PIN1 und ground
X2/28 PIN2 and ground
X2/28 PIN1 and X36/1 PIN19
X2/28 PIN2 and X36/1 PIN23
If a short-circuit to ground or a break is displayed, repair or replace the cable. If the wiring is OK, go to step 4.
4. Check the sensor.
a) Connect the test adapter to the sensor. (Wiring unplugged) Measure the resistance between PIN1 and PIN2.
The value must be 1120 - 1530 Ohm at 20 °C.
If the resistance is not reached, replace the sensor.
b) If the resistance is OK, measure the frequency. Connect the wiring to the test adapter. Start the engine and
measure the frequency between PIN1 and PIN2.
The value must be about 855 Hz (at 900 rpm.).
If the frequency is not reached, go to step 5.
If the frequency is reached, go to step 6.
5. Check correct sensor fitting. The distance between sensor and sensor wheel must be 0.2 - 1.0 mm. In addition
test the sensor wheel for damage and firm fit.
6. Load the current engine software version. If the fault re-occurs, replace the engine controller. (see chapter 2002A)

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EEM3 - 272 Faulty engine speed sensor signal

Description:
The B20 engine speed sensor delivers pulses with a time lapse determined by the sensor wheel. In fault condition
the time lapse is incorrect.
Possible causes:
1. Electromagnetic signal interference.
2. Invalid engine speed sensor signal (faulty wiring, faulty sensor, distance sensor - sensor wheel too great or sensor
wheel is damaged)
3. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75% and the engine speed limited to
1,800 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check if electromagnetic fields surrounding the tractor can be the cause of the interference with the signals.
2. Check the connector X2/28 of the sensor B20 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the wiring for short-circuit to ground and for breaks. Use test adapter 380000060.
a) Disconnect the connector X36/1 from the engine controller and connect the adapter to connector X2/28. (Sen-
sor unplugged) Check between connector:
X2/28 PIN1 and ground
X2/28 PIN2 and ground
X2/28 PIN1 and X36/1 PIN19
X2/28 PIN2 and X36/1 PIN23
If a short-circuit to ground or a break is displayed, repair or replace the cable. If the wiring is OK, go to step 4.
4. Check the sensor.
a) Connect the test adapter to the sensor. (Wiring unplugged) Measure the resistance between PIN1 and PIN2.
The value must be 1120 - 1530 Ohm at 20 °C.
If the resistance is not reached, replace the sensor.
b) If the resistance is OK, measure the frequency. Connect the wiring to the test adapter. Start the engine and
measure the frequency between PIN1 and PIN2.
The value must be about 855 Hz (at 900 rpm.).
If the frequency is not reached, go to step 5.
If the frequency is reached, go to step 6.
5. Check correct sensor fitting. The distance between sensor and sensor wheel must be 0.2 - 1.0 mm. In addition
check the sensor wheel for damage and firm fit.
6. Load the current engine software version. If the fault re-occurs, replace the engine controller. (see chapter 2002A)

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EEM3 - 273 Engine speed sensor connections reversed

Description:
The direction of rotation can be established from the sensor signal time lapse. If the direction of rotation is incorrect,
the connections are reversed.
Possible causes:
1. Invalid engine speed sensor signal (wiring wrongly connected, faulty sensor, distance sensor - sensor wheel too
great or sensor wheel is damaged)
2. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75% and the engine speed limited to
1,800 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the connector X2/28 of the sensor B20 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 2.
Check the wiring for short-circuit to ground and for breaks. Use test adapter 380000060.
a) Disconnect the connector X36/1 from the engine controller and connect the adapter to connector X2/28. (Sen-
sor unplugged) Check between connector:
X2/28 PIN1 und ground
X2/28 PIN2 and ground
X2/28 PIN1 and X36/1 PIN19
X2/28 PIN2 and X36/1 PIN23
If a short-circuit to ground or a break is displayed, repair or replace the cable. If the wiring is OK, go to step 3.
2. Check the sensor.
a) Connect the test adapter to the sensor. (Wiring unplugged) Measure the resistance between PIN1 and PIN2.
The value must be 1120 - 1530 Ohm at 20 °C.
If the resistance is not reached, replace the sensor.
b) If the resistance is OK, measure the frequency. Connect the wiring to the test adapter. Start the engine and
measure the frequency between PIN1 and PIN2.
The value must be about 855 Hz (at 900 rpm.).
If the frequency is not reached, go to step 4.
If the frequency is reached, go to step 5.
3. Check correct sensor fitting. The distance between sensor and sensor wheel must be 0.2 - 1.0 mm. In addition
check the sensor wheel for damage and firm fit.
4. Load the current engine software version. If the fault re-occurs, replace the engine controller. (see chapter 2002A)

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EEM3 - 276 Pressure drop in intake system too high during engine
start-up
Description:
The pressure in the intake system (boost pressure sensor signal voltage) falls below ther warning limit during engine
start-up.
Possible causes:
1. Blockage in intake system
2. Faulty connector or wiring
3. Faulty boost pressure sensor
4. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine runs noisily or does not start.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the mechanical components of the intake system for proper functioning. (air filter, boost air cooler, hoses
and pipes of the complete intake and boost air system, turbocharger)
a) If the cause of the pressure drop lies in mechanical component, remedy the fault. (see chapter 2002A)
b) If the mechanical components are OK, the error is in the electrical system. Go to step 2
2. Check the connector X4/29 of the sensor B29 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the sensor supply using test adapter 380001588.
a) Connect the test adapter to the connector X4/29. (Sensor unplugged) Turn the starter switch to the "ON" po-
sition and measure the supply voltage between connector:
X4/29 PIN3 and PIN1.
The displayed voltage must be 5 volts. If the voltage is not reached, go to step 4.
b) If the supply voltage is correct, go to step 5.
4. Check the wiring to the sensor for short-circuit to ground and for breaks.
a) Disconnect the connector X36/1 from the engine controller. Check between connector:
X4/29 PIN3 and ground
X4/29 PIN4 and ground
X4/29 PIN3 and X36/1 PIN33
X4/29 PIN4 and X36/1 PIN34
X4/29 PIN1 and X36/1 PIN25
If a short-circuit to ground or a break is displayed, repair or replace the cable.
5. Check the sensor.
a) Connect the connector X36/1 to the engine controller and the sensor to the test adapter. Turn the starter switch
to the "ON" position and check the signal voltage between connector:
X4/29 PIN4 and PIN1
The displayed signal voltage must be 1.07 volt (at 1 bar atmospheric pressure). If the voltage is not reached, re-
place the sensor.
If the signal voltage is OK, replace the engine controller. (see chapter 2002A)

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EEM3 - 281 Faulty camshaft position sensor signal

Description:
The B40 camshaft position sensor delivers pulses with a time lapse determined by the sensor wheel. In fault condition
the time lapse is incorrect.
Possible causes:
1. Very rapid changes of motor speed due to problems in the injection system.
2. Invalid camshaft position sensor signal (faulty wiring, faulty sensor, distance sensor - sensor wheel too great or
sensor wheel is damaged)
3. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75% and the engine speed limited to
1,800 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. If the engine runs irregularly, check the injection system and the engine mechanical system. (see chapters 2002A
and 3001A)
If the error occurs sporadically, this was probably caused by too rapid engine speed changes (maloperation).
2. Check the connector X3/40 of the sensor B40 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the wiring for short-circuit to ground and for breaks. Use test adapter 380002718.
a) Disconnect the connector X36/1 from the engine controller and connect the adapter to the connector X3/40.
(Sensor unplugged) Check between connector:
X3/40 PIN1 and ground
X3/40 PIN2 and ground
X3/40 PIN1 and X36/1 PIN9
X3/40 PIN2 and X36/1 PIN10
If a short-circuit to ground or a break is displayed, repair or replace the cable. If the wiring is in order, go to step 4.
4. Check the sensor.
a) Connect the test adapter to the sensor. (Wiring unplugged) Measure the resistance between PIN1 and PIN2.
The value must be 774 - 946 Ohm at 20 °C.
If the resistance is not reached, replace the sensor.
b) If the resistance is OK, measure the frequency. Connect the wiring to the test adapter. Start the engine and
measure the frequency between PIN1 and PIN2.
The value must be about
52 Hz (at 900 rpm.).
If the frequency is not reached, go to step 5.
If the frequency is reached, go to step 6.
5. Check correct sensor fitting. The distance between sensor and sensor wheel must be 0.2 - 1.0 mm. In addition
check the sensor wheel for damage and firm fit.
6. Load the current engine software version. If the fault re-occurs, replace the controller. (see chapter 2002A)

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EEM3 - 282 Faulty camshaft position sensor signal

Description:
The B40 camshaft position sensor delivers pulses with a time lapse determined by the sensor wheel. In fault condition
the time lapse is incorrect.
Possible causes:
1. Very rapid changes in motor speed due to problems in the injection system.
2. Invalid camshaft position sensor signal (faulty wiring, faulty sensor, distance sensor - sensor wheel too great or
sensor wheel is damaged)
3. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75% and the engine speed limited to
1,800 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. If the engine runs noisily, check the injection system and the engine mechanical system. (see chapters 2002A
and 3001A)
If the error occurs sporadically, this was probably caused by too rapid engine speed changes (maloperation).
2. Check the connector X3/40 of the sensor B40 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the wiring for short-circuit to ground and for breaks. Use test adapter 380002718.
a) Disconnect the connector X36/1 from the engine controller and connect the adapter to the connector X3/40.
(Sensor unplugged) Check between connector:
X3/40 PIN1 and ground
X3/40 PIN2 and ground
X3/40 PIN1 and X36/1 PIN9
X3/40 PIN2 and X36/1 PIN10
If a short-circuit to ground or a break is displayed, repair or replace the cable. If the wiring is OK, go to step 4.
4. Check the sensor.
a) Connect the test adapter to the sensor. (Wiring unplugged) Measure the resistance between PIN1 and PIN2.
The value must be 774 - 946 Ohm at 20 °C.
If the resistance is not reached, replace the sensor.
b) If the resistance is OK, measure the frequency. Connect the wiring to the test adapter. Start the engine and
measure the frequency between PIN1 and PIN2.
The value must be about 52 Hz (at 900 rpm.).
If the frequency is not reached, go to step 5.
If the frequency is reached, go to step 6.
5. Check correct sensor fitting. The distance between sensor and sensor wheel must be 0.2 - 1.0 mm. In addition
check the sensor wheel for damage and firm fit.
6. Load the current engine software version. If the fault re-occurs, replace the engine controller. (see chapter 2002A)

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EEM3 - 283 Camshaft position sensor connections reversed

Description:
The direction of rotation can be established from the sensor signal time lapse. If the direction of rotation is incorrect,
the connections are reversed.
Possible causes:
1. Invalid camshaft position sensor signal (wiring wrongly connected, faulty sensor, distance sensor - sensor wheel
too great or sensor wheel is damaged)
2. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75% and the engine speed limited to
1,800 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the connector X3/40 of the sensor B40 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 2.
2. Check the wiring for short-circuit to ground and for breaks. Use test adapter 380002718.
a) Disconnect the connector X36/1 from the engine controller and connect the adapter to connector X3/40. (Sen-
sor unplugged) Check between connector:
X3/40 PIN1 and ground
X3/40 PIN2 and ground
X3/40 PIN1 and X36/1 PIN9
X3/40 PIN2 and X36/1 PIN10
If a short-circuit to ground or a break is displayed, repair or replace the cable. If the wiring is OK, go to step 3.
3. Check the sensor.
a) Connect the test adapter to the sensor. (Wiring unplugged) Measure the resistance between PIN1 and PIN2.
The value must be 774 - 946 Ohm at 20 °C.
If the resistance is not reached, replace the sensor.
b) If the resistance is OK, measure the frequency. Connect the wiring to the test adapter. Start the engine and
measure the frequency between PIN1 and PIN2.
The value must be about 52 Hz (at 900 rpm.).
If the frequency is not reached, go to step 4.
If the frequency is reached, go to step 5.
4. Check correct sensor fitting. The distance between sensor and sensor wheel must be 0.2 - 1.0 mm. In addition
check the sensor wheel for damage and firm fit.
5. Load the current engine software version. If the fault re-occurs, replace the engine controller. (see chapter 2002A)

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EEM3 - 284 Camshaft position sensor signal not plausible

Description:
The engine controller does not detect the B40 camshaft position sensor signal.
Possible causes:
1. Invalid camshaft position sensor signal (faulty wiring, faulty sensor, distance sensor - sensor wheel too great or
sensor wheel is damaged)
2. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75% and the engine speed limited to
1,800 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the connector X3/40 of the sensor B40 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 2.
2. Check the wiring for short-circuit to ground and for breaks. Use test adapter 380002718.
a) Disconnect the connector X36/1 from the engine controller and connect the adapter to connector X3/40. (Sen-
sor unplugged) Check between connector:
X3/40 PIN1 and ground
X3/40 PIN2 and ground
X3/40 PIN1 and X36/1 PIN9
X3/40 PIN2 and X36/1 PIN10
If a short-circuit to ground or a break is displayed, repair or replace the cable. If the wiring is OK, go to step 3.
3. Check the sensor.
a) Connect the test adapter to the sensor. (Wiring unplugged) Measure the resistance between PIN1 and PIN2.
The value must be 774 - 946 Ohm at 20 °C.
If the resistance is not reached, replace the sensor.
b) If the resistance is OK, measure the frequency. Connect the wiring to the test adapter. Start the engine and
measure the frequency between PIN1 and PIN2.
The value must be about 52 Hz (at 900 rpm.).
If the frequency is not reached, go to step 4.
If the frequency is reached, go to step 5.
4. Check correct sensor fitting. The distance between sensor and sensor wheel must be 0.2 - 1.0 mm. In addition
check the sensor wheel for damage and firm fit.
5. Load the current engine software version. If the fault re-occurs, replace the engine controller. (see chapter 2002A)

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EEM3 - 291 Fuel delivery pressure sensor, signal voltage too low
Description:
The signal voltage of the fuel delivery pressure sensor is under the permitted range (< 0.2 V).
Possible causes:
1. Faulty connector or wiring
2. Faulty fuel delivery pressure sensor
3. Supply voltage to the fuel delivery pressure sensor is faulty
4. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75%.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Check the connector X3/39 of the fuel delivery pressure sensor B39 and the connector X36/1 of the engine con-
troller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the sensor supply using test adapter 380002717.
a) Connect the test adapter to the sensor X3/39. (sensor unplugged) Turn the starter switch to the "ON" position
and measure the supply voltage between connector:
X3/39 PIN3 and PIN1.
The displayed voltage must be 5 volts. If the voltage is not reached, go to step 4.
b) If the supply voltage is correct, go to step 5.
4. Check the wiring to the sensor for short-circuit to ground and for breaks.
a) Disconnect the connector X36/1 from the engine controller. Check between connector:
X3/39 PIN2 and ground
X3/39 PIN3 and ground
X3/39 PIN1 and X36/1 PIN17
X3/39 PIN2 and X36/1 PIN21
X3/39 PIN3 and X36/1 PIN31
If a short-circuit to ground or a break is displayed, repair or replace the cable.
5. Check the sensor.
a) Connect the connector X36/1 to the engine controller and the sensor to the test adapter. Turn the starter switch
to the "ON" position and check the signal voltage between connector:
X3/39 PIN2 and PIN1
The displayed signal voltage must be 0.5 volt. If the voltage is not reached, replace the sensor.
If the signal voltage is OK, replace the engine controller. (see chapter 2002A)

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EEM3 - 292 Fuel delivery pressure sensor, signal voltage too high
Description:
The signal voltage of the fuel delivery pressure sensor is over the permitted range 4.7 V).
Possible causes:
1. Faulty connector or wiring
2. Faulty fuel delivery pressure sensor
3. Supply voltage to rail pressure sensor is faulty
4. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75%.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Check the connector X3/39 of the fuel delivery pressure sensor B39 and the connector X36/1 of the engine con-
troller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the sensor supply using test adapter 380002717.
a) Connect the test adapter to the connector X3/39. (Sensor unplugged) Turn the starter switch to the "ON" po-
sition and measure the supply voltage between connector:
X3/39 PIN3 and PIN1.
The displayed voltage must be 5 volts. If the voltage is higher than 5 volts, there is a short-circuit against +
12 volts. Repair or replace the cable.
b) If the supply voltage is correct, go to step 4.
4. Check the signal cable for short-circuit against +supply.
5. a) Check between connector:
X3/39 PIN2 and PIN1
If a short-circuit to +supply is displayed, repair or replace the cable.
b) If no short-circuit is displayed, go to step 5.
6. Check the sensor.
a) Connect the sensor to the test adapter. Turn the starter switch to the "ON" position and check the signal voltage
between connector:
X3/39 PIN2 and PIN1
The displayed signal voltage must be 0.5 volt. If a higher voltage is displayed, replace the sensor.
If the signal voltage is OK, replace the engine controller. (see chapter 2002A).

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EEM3 - 293 Fuel delivery pressure sensor, no signal

Description:
The engine controller does not detect the signal from the B39 fuel delivery pressure sensor.
Possibile cause:
1. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75%. The engine functions dependent
on the fuel delivery pressure are not active.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not displayed, no further measure is necessary.
b) If the error code is displayed, continue to step 2.
2. Load the current engine software version. If the error re-occurs, replace the engine controller.
(see chapter 2002A)

EEM3 - 311 Injector 1 - solenoid valve short circuit to ground

Description:
The engine controller detects a short-circuit to ground in the drive circuit to injector 1.
If the short-circuit is at cable C SL1 (low side), then injector 1 is disabled.
If the short-circuit is at cable C SH1 (high side), then injectors 1, 3 and 5 are disabled.
Possible causes:
1. Faulty connector or wiring.
2. Faulty solenoid
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm. Depending on the cause, several injectors can be disabled.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the electrical connections of injector Y21 and the connector X16/1 of the engine controller.
a) Ensure the connector is connected, not damaged, the pins are in the correct position and that the fit is tight.
Repair or replace as required. Check the nuts of the injector connecting lead for the correct tightening torque of
1.5 Nm.
b) If the electrical connections are OK, continue with step 2.
2. Check for a short to ground.
a) Disconnect the electrical connections at the injector and the connector X16/1. Check for continuity between:
Cable C SH1 and ground
Cable C SL1 and ground
If a short-circuit to ground is displayed, repair or replace the cable.
b) If a short to ground is not indicated, continue to step 3.
3. Check the injector solenoid valve for a short-circuit to ground. Check both terminal studs for continuity against
ground.
a) If a short-circuit to ground is displayed, replace the injector.
b) If a short to ground is not indicated, continue to step 4.
4. Check the resistance of the coil: 0.2 - 0.25 Ohm at 20 °C.
a) If the resistance is not reached, replace the injector.

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EEM3 - 312 Injector 1 - solenoid valve short-circuit on +supply

Description:
The engine controller detects a short-circuit between the cables in the drive circuit to injector 1.
The short-circuit is between cable C SL1 (low side) and C SH1 (high side = battery +) Injectors 1, 3 and 5 are disabled.
Possible causes:
1. Faulty connector or wiring.
2. Faulty solenoid
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the electrical connections of injector Y21 and the connector X16/1 of the engine controller.
a) Ensure the connector is connected, not damaged, the pins are in the correct position and that the fit is tight.
Repair or replace as required. Check the nuts of the injector connecting lead for the correct tightening torque of
1.5 Nm.
b) If the electrical connections are OK, continue with step 2.
2. Check the cable C SL1 (low side) for a short-circuit on +supply.
a) Disconnect the electrical connections at the injector. Turn the starter switch to the "ON" position. Check for
voltage between:
Cable C SL1 and ground
If a short-circuit to +supply is displayed, repair or replace the cable.
b) If a short-circuit to +supply is not indicated, continue with step 3.
3. Check the resistance of the coil: 0.2 - 0.25 Ohm at 20 °C.
a) If the resistance is not reached, replace the injector.

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EEM3 - 313 Injector 1 - solenoid valve open circuit

Description:
The engine controller detects an open circuit in the drive circuit to injector 1.
Possible causes:
1. Faulty connector or wiring
2. Faulty solenoid
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the electrical connections of injector Y21 and the connector X16/1 of the engine controller.
a) Ensure the connector is connected, not damaged, the pins are in the correct position and that the fit is tight.
Repair or replace as required. Check the nuts of the injector connecting lead for the correct tightening torque of
1.5 Nm.
b) If the electrical connections are OK, continue with step 2.
2. Check the wiring between the injector and the engine controller for an open circuit.
a) Disconnect the electrical connections at the injector and the connector X16/1. Check for continuity between:
Cable C SH1 and X16/1 PIN4
Cable C SL1 and X16/1 PIN13
If an open circuit is displayed, repair or replace the cable.
b) If an open circuit is not indicated, continue to step 3.
3. Check the resistance of the coil: 0.2 - 0.25 Ohm at 20 °C.
a) If the resistance is not reached, replace the injector.

EEM3 - 314 Injector 1 - solenoid valve is open too long

Description:
The electronics monitor whether the solenoid valve shuts quickly enough after each injection. The error becomes ac-
tive if the solenoid valve stays open longer than scheduled during an injection. Injectors 1, 3 and 5 are disabled.
Possibile cause:
1. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Turn the starter switch to the "OFF" position and then back to "ON". Start the engine. If the error code continues
active, the cause of the problem lies in a faulty engine controller. Replace the engine controller.
(see chapter 2002A)

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EEM3 - 315 Injector 1 - solenoid valve error

Description:
The engine controller detects an error in the current flow to the solenoid valve of injector 1. The cause is probably in
a transitory current spike in the solenoid valve. Injectors 1, 3 and 5 are disabled.
Possibile cause:
1. Faulty injector
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. The cause of the error can be a transitory current spike in the solenoid v alve of the injector, caused by a short-
term malfunction of the solenoid valve. Clear the error code. Turn the starter switch to the "OFF" position and
back to "ON". Start the engine.
a) If the error is no longer active, no further measures are necessary.
b) If the error is active, repeat the process several times. If the error is active after each engine start, replace the
injector. (see chapter 3001A)

EEM3 - 321 Injector 2 - solenoid valve short circuit to ground

Description:
The engine controller detects a short-circuit to ground in the drive circuit to injector 2.
If the short-circuit is at cable C SL2 (low side), then injector 2 is disabled.
If the short-circuit is at cable C SH2 (high side), then injectors 2, 4 and 6 are disabled.
Possible causes:
1. Faulty connector or wiring
2. Faulty solenoid
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm. Depending on the cause, several injectors can be disabled.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the electrical connections of injector Y22 and the connector X16/1 of the engine controller.
a) Ensure the connector is connected, not damaged, the pins are in the correct position and that the fit is tight.
Repair or replace as required. Check the nuts of the injector connecting lead for the correct tightening torque of
1.5 Nm.
b) If the electrical connections are OK, continue with step 2.
2. Check for a short-circuit to ground.
a) Disconnect the electrical connections at the injector and the connector X16/1. Check for continuity between:
Cable C SH2 and ground
Kabel C SL2 and ground
If a short-circuit to ground is displayed, repair or replace the cable.
b) If a short to ground is not indicated, continue to step 3.
3. Check the solenoid valve of the injector for a short-circuit to ground. Check both terminal studs for continuity
against ground.
a) If a short-circuit to ground is displayed, replace the injector.
b) If a short to ground is not indicated, continue to step 4.
4. Check the resistance of the coil: 0.2 - 0.25 Ohm at 20 °C.
a) If the resistance is not reached, replace the injector.

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EEM3 - 322 Injector 2 - solenoid valve short circuit on +supply

Description:
The engine controller detects a short-circuit between the cables in the drive circuit to injector 2.
The short-circuit is between cable C SL2 (low side) and C SH2 (high side = battery +) Injectors 2, 4 and 6 are disabled.
Possible causes:
1. Faulty conneector or wiring.
2. Faulty solenoid
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the electrical connections of the injector Y22 and the connector X16/1 of the engine controller.
a) Ensure the connector is connected, not damaged, the pins are in the correct position and that the fit is tight.
Repair or replace as required. Check the nuts of the injector connecting lead for the correct tightening torque of
1.5 Nm.
b) If the electrical connections are OK, continue with step 2.
2. Check the cable C SL2 (low side) for a short-circuit to +supply.
a) Disconnect the electrical connections at the injector' Turn the starter switch to the "ON" position. Check for
voltage between:
Cable C SL2 and ground
If a short-circuit to +supply is displayed, repair or replace the cable.
b) If a short-circuit to +supply is not indicated, continue with step 3.
3. Check the resistance of the coil: 0.2 - 0.25 Ohm at 20 °C.
a) If the resistance is not reached, replace the injector.

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EEM3 - 323 Injector 2 - solenoid valve open circuit

Description:
The engine controller detects an open circuit in the drive circuit to injector 2.
Possible causes:
1. Faulty connector or wiring
2. Faulty solenoid
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the electrical connections of the injector Y22 and the connector X16/1 of the engine controller.
a) Ensure the connector is connected, not damaged, the pins are in the correct position and that the fit is tight.
Repair or replace as required. Check the nuts of the injector connecting lead for the correct tightening torque of
1.5 Nm.
b) If the electrical connections are OK, continue with step 2.
2. Check the wiring between the injector und dem Motorsteuergerät auf einen offenen Stromkreis.
a) Disconnect the electrical connections at the injector and the connector X16/1. Check for continuity between:
Cable C SH2 and X16/1 PIN11
Cable C SL2 and X16/1 PIN6
If an open circuit is displayed, the cable must be repaired or replaced.
b) If an open circuit is not indicated, continue to step 3.
3. Check the resistance of the coil: 0.2 - 0.25 Ohm at 20 °C.
a) If the resistance is not reached, replace the injector.

EEM3 - 324 Injector 2 - solenoid valve is open too long

Description:
The electronics monitor whether the solenoid valve shuts quickly enough after each injection. The error becomes ac-
tive if the solenoid valve stays open longer than scheduled during an injection. Injectors 2, 4 and 6 are disabled.
Possibile cause:
1. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Turn the starter switch to the "OFF" position and then back to "ON". Start the engine. If the error code continues
active, the cause of the problem lies in a faulty engine controller. Replace the engine controller.
(see chapter 2002A)

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EEM3 - 325 Injector 2 - solenoid valve error

Description:
The engine controller detects an error in the current flow to the solenoid valve of injector 2. The cause probably lies
in a transitory current spike in the solenoid valve. Injectors 2, 4 and 6 are disabled.
Possibile cause:
1. Faulkty injector
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. The cause of the error can be a transitory current spike in the solenoid valve of the injector, caused by a short-
term malfunction of the solenoid valve. Clear the error code. Turn the starter switch to the "OFF" position and
back to "ON". Start the engine.
a) If the error is no longer actyive, no further measures are necessary.
b) If the error is active, repeat the process several times. If the error is active after each engine start-up, replace
the injector. (see chapter 3001A)

EEM3 - 331 Injector 3 - solenoid valve short circuit to ground

Description:
The engine controller detects a short-circuit to ground in the drive circuit to injector 3.
If the short-circuit is at cable C SL3 (low side), then injector 3 is disabled.
If the short-circuit is at cable C SH3 (high side), then injectors 1, 3 and 5 are disabled.
Possible causes:
1. Faulty connector or wiring
2. Faulty solenoid
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm. Depending on the cause, several injectors can be disabled.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the electrical connections of the injector Y23 and the connector X16/1 of the engine controller.
a) Ensure the connector is connected, not damaged, the pins are in the correct position and that the fit is tight.
Repair or replace as required. Check the nuts of the injector connecting lead for the correct tightening torque of
1.5 Nm.
b) If the electrical connections are OK, continue with step 2.
2. Check for a short-circuit to ground.
a) Disconnect the electrical connections at the injector and the connector X16/1. Check for continuity between:
Cable C SH3 and ground
Cable C SL3 and ground
If a short-circuit to ground is displayed, repair or replace the cable.
b) If a short-circuit to ground is not indicated, continue to step 3.
3. Check the injector solenoid valve for a short-circuit to ground. Check both terminal studs for continuity against
ground.
a) If a short-circuit to ground is displayed, replace the injector.
b) If a short to ground is not indicated, continue to step 4.
4. Check the resistance of the coil: 0.2 - 0.25 Ohm at 20 °C.
a) If the resistance is not reached, replace the injector.

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EEM3 - 332 Injector 3 - solenoid valve short-circuit on +supply

Description:
The engine controller detects a short-circuit between the cables in the drive circuit to injector 3.
The short-circuit is between cable C SL3 (low side) and C SH3 (high side = battery +) Injectors 1, 3 and 5 are disabled.
Possible causes:
1. Faulty connector or wiring.
2. Faulty solenoid
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the electrical connections of the injector Y23 and the connector X16/1 of the engine controller.
a) Ensure the connector is connected, not damaged, the pins are in the correct position and that the fit is tight.
Repair or replace as required. Check the nuts of the injector connecting lead for the correct tightening torque of
1.5 Nm.
b) If the electrical connections are OK, continue with step 2.
2. Check the C SL3 (low side) cable for a short-circuit to +supply.
a) Disconnect the electrical connections at the injector. Turn the starter switch to the "ON" position. Check for
voltage between:
Cable C SL3 and ground
If a short-circuit to +supply is displayed, repair or replace the cable.
b) If no sort-circuit to +supply is displayed, continue with step 3.
3. Check the resistance of the coil: 0.2 - 0.25 Ohm at 20 °C.
a) If the resistance is not reached, replace the injector.

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EEM3 - 333 Injector 3 - solenoid valve open circuit

Description:
The engine controller detects an open circuit in the drive circuit to injector 3.
Possible causes:
1. Faulty connector or wiring
2. Faulty solenoid
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the electrical connections of the injector Y23 and the connector X16/1 of the engine controller.
a) Ensure the connector is connected, not damaged, the pins are in the correct position and that the fit is tight.
Repair or replace as required. Check the nuts of the injector connecting lead for the correct tightening torque of
1.5 Nm.
b) If the electrical connections are OK, continue with step 2.
2. Check the wiring between the injector and the engine controller for an open circuit.
a) Disconnect the electrical connections at the injector and the connector X16/1. Check for continuity between:
Cable C SH3 and X16/1 PIN5
Cable C SL3 and X16/1 PIN12
If an open circuit is displayed, the cable must be repaired or replaced.
b) If an open circuit is not indicated, continue to step 3.
3. Check the resistance of the coil: 0.2 - 0.25 Ohm att 20 °C.
a) If the resistance is not reached, replace the injector.

EEM3 - 334 Injector 3 - solenoid valve is open too long

Description:
The electronics monitor whether the solenoid valve shuts quickly enough after each injection. The error becomes ac-
tive if the solenoid valve stays open longer than scheduled during an injection. Injectors 1, 3 and 5 are disabled.
Possibile cause:
1. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Turn the starter switch to the "OFF" position and then back to "ON". Start the engine. If the error code continues
active, the cause of the problem lies in a faulty engine controller. Replace the engine controller.
(see chapter 2002A)

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EEM3 - 335 Injector 3 - solenoid valve error

Description:
The engine controller detects an error in the current flow to the solenoid valve of injector 3. The cause probably lies
in a transitory current spike in the solenoid valve. Injectors 1, 3 and 5 are disabled.
Possibile cause:
1. Faulty injector.
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. The cause of the error can be a transitory current spike in the solenoid valve of the injector, caused by a short-
term malfunction of the solenoid valve. Clear the error code. Turn the starter switch to the "OFF" position and then
back to "ON". Start the engine.
a) If the error is no longer active, no further measures are required.
b) If the error is active, repeat the process several times. If the error is active after each engine start-up, replace
the injector. (see chapter 3001A)

EEM3 - 341 Injector 4 - solenoid valve short-circuit to ground

Description:
The engine controller detects a short-circuit to ground in the drive circuit to injector 4.
If the short-circuit is at cable C SL4 (low side), then injector 4 is disabled.
If the short-circuit is at cable C SH4 (high side), then injectors 2, 4 and 6 are disabled.
Possible causes:
1. Faulty connector or wiring.
2. Faulty solenoid
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm. Depending on the cause, several injectors can be disabled.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the electrical connections of injector Y24 and the connector X16/1 of the engine controller.
a) Ensure the connector is connected, not damaged, the pins are in the correct position and that the fit is tight.
Repair or replace as required. Check the nuts of the injector connecting lead for the correct tightening torque of
1.5 Nm.
b) If the electrical connections are OK, continue with step 2.
2. Check for a short to ground.
a) Disconnect the electrical connections at the injector and the connector X16/1. Check for continuity between:
Cable C SH4 and ground
Cable C SL4 and ground
If a short-circuit to ground is displayed, repair or replace the cable.
b) If a short to ground is not indicated, continue to step 3.
3. Check the injector solenoid valve for a short-circuit to ground. Check both terminal studs for continuity against
ground.
a) If a short-circuit to ground is displayed, replace the injector.
b) If a short to ground is not indicated, continue to step 4.
4. Check the resistance of the coil: 0.2 - 0.25 Ohm at 20 °C.
a) If the resistance is not reached, replace the injector.

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EEM3 - 342 Injector 4 - solenoid valve short-circuit on +supply

Description:
The engine controller detects a short-circuit between the cables in the drive circuit to injector 4.
The short circuit is between the cable C SL4 (low side) and C SH4 (high side = battery +) Injectors 2, 4 and 6 are
disabled.
Possible causes:
1. Faulty connector or wiring.
2. Faulty solenoid
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the electrical connections of injector Y24 and the connector X16/1 of the engine controller.
a) Ensure the connector is connected, not damaged, the pins are in the correct position and that the fit is tight.
Repair or replace as required. Check the nuts of the injector connecting lead for the correct tightening torque of
1.5 Nm.
b) If the electrical connections are OK, continue with step 2.
2. Check the cable C SL4 (low side) for a short-circuit to +supply.
a) Disconnect the electrical connections at the injector. Turn the starter switch to the "ON" position. Check for
voltage between:
Cable C SL4 and ground
If a short-circuit is displayed at +supply, repair or replace the cable.
b) If no short-circuit to +supply is displayed, continue with step 3.
3. Check the resistance of the coil: 0.2 - 0.25 Ohm at 20 °C.
a) If the resistance is not reached, replace the injector.

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EEM3 - 343 Injector 4 - solenoid valve open circuit

Description:
The engine controller detects an open circuit in the drive circuit to injector 4.
Possible causes:
1. Faulty connector or wiring
2. Faulty solenoid
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the electrical connections of injector Y24 and the connector X16/1 of the engine controller.
a) Ensure the connector is connected, not damaged, the pins are in the correct position and that the fit is tight.
Repair or replace as required. Check the nuts of the injector connecting lead for the correct tightening torque of
1.5 Nm.
b) If the electrical connections are OK, continue with step 2.
2. Check the wiring between the injector and the engine controller for an open circuit.
a) Disconnect the electrical connections at the injector and the connector X16/1. Check for continuity between:
Cable C SH4 and X16/1 PIN3
Cable C SL4 and X16/1 PIN14
If an open circuit is displayed, repair or replace the cable.
b) If an open circuit is not indicated, continue to step 3.
3. Check the resistance of the coil: 0.2 - 0.25 Ohm at 20 °C.
a) If the resistance is not reached, replace the injector.

EEM3 - 344 Injector 4 - solenoid valve is open too long

Description:
The electronics monitor whether the solenoid valve shuts quickly enough after each injection. The error becomes ac-
tive if the solenoid valve stays open longer than scheduled during an injection. Injectors 2, 4 and 6 are disabled.
Possibile cause:
1. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Turn the starter switch to the "OFF" position and then back to "ON". Start the engine. If the error code continues
active, the cause of the problem lies in a faulty engine controller. Replace the engine controller.
(see chapter 2002A)

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EEM3 - 345 Injector 4 - solenoid valve error

Description:
The engine controller dtects an error in the current flow to the solenoid valve of injector 4. The cause probably lies in
a transitory current spike in the solenoid valve. Injectors 2, 4 and 6 are disabled.
Possibile cause:
1. Faulty injector
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. The cause of the error can be a transitory current spike in the solenoid valve of the injector, caused by a short-
term malfunction of the solenoid valve. Clear the error code. Turn the starter switch to the "OFF" position and then
back to "ON". Start the engine.
a) If the error is no longer active, no further measures are required.
b) If the error is active, repeat the process several times. If the error is active after each engine start-up, replace
the injector. (see chapter 3001A)

EEM3 - 351 Injector 5 - solenoid valve short-circuit to ground

Description:
The engine controller detects a short-circuit to ground in the drive circuit to injector 5.
If the short-circuit is at cable C SL5 (low side), then injector 5 is disabled.
If the short-circuit is at cable C SH5 (high side), then injectors 1, 3 and 5 are disabled.
Possible causes:
1. Faulty connector or wiring
2. Faulty solenoid
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm. Depending on the cause, several injectors can be disabledd.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the electrical connections of injector Y25 and the connector X16/1 of the engine controller.
a) Ensure the connector is connected, not damaged, the pins are in the correct position and that the fit is tight.
Repair or replace as required. Check the nuts of the injector connecting lead for the correct tightening torque of
1.5 Nm.
b) If the electrical connections are OK, continue with step 2.
2. Check for a short to ground.
a) Disconnect the electrical connections at the injector and the connector X16/1. Check for continuity between:
Cable C SH5 and ground
Cable C SL5 and ground
If a short-circuit to ground is displayed, repair or replace the cable.
b) If a short to ground is not indicated, continue to step 3.
3. Check the solenoid valve of the injector for a short-circuit to ground . Check both terminal studs for continuity
against ground .
a) If a short-circuit to ground is displayed, replace the injector.
b) If a short to ground is not indicated, continue to step 4.
4. Check the resistance of the coil: 0.2 - 0.25 Ohm at 20 °C.
a) If the resistance is not reached, replace the injector.

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EEM3 - 352 Injector 5 - solenoid valve short-circuit at +supply

Description:
The engine controller detects a short-circuit between the cables in the drive circuit to injector 5.
The short circuit is between the cable C SL5 (low side) and C SH5 (high side = battery +) Injectors 1, 3 and 5 are
disabled.
Possible causes:
1. Faulty connector or wiring.
2. Faulty solenoid
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the electrical connections of injector Y25 and the connector X16/1 of the engine controller.
a) Ensure the connector is connected, not damaged, the pins are in the correct position and that the fit is tight.
Repair or replace as required. Check the nuts of the injector connecting lead for the correct tightening torque of
1.5 Nm.
b) If the electrical connections are OK, continue with step 2.
2. Check the cable C SL5 (low side) for a short-circuit to +supply.
a) Disconnect the electrical connections at the injector. Turn the starter switch to the "ON" position. Check for
voltage between:
Cable C SL5 and ground
If a short-circuit to +supply is displayed, repair or replace the cable.
b) If no short-circuit to +supply is displayed, contnue with step 3.
3. Check the resistance of the coil: 0.2 - 0.25 Ohm at 20 °C.
a) If the resistance is not reached, replace the injector.

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EEM3 - 353 Injector 5 - solenoid valve open circuit

Description:
The engine controller detects an open circuit in the drive circuit to injector 5.
Possible causes:
1. Faulty connector or wiring
2. Faulty solenoid
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the electrical connections of injector Y25 and the connector X16/1 of the engine controller.
a) Ensure the connector is connected, not damaged, the pins are in the correct position and that the fit is tight.
Repair or replace as required. Check the nuts of the injector connecting lead for the correct tightening torque of
1.5 Nm.
b) If the electrical connections are OK, continue with step 2.
2. Check the wiring between the injector and the engine controller for an open circuit.
a) Disconnect the electrical connections at the injector and the connector X16/1. Check for continuity between:
Cable C SH5 and X16/1 PIN1
Cable C SL5 and X16/1 PIN16
If an open circuit is displayed, repair or replace the cable.
b) If an open circuit is not indicated, continue to step 3.
3. Check the resistance of the coil: 0.2 - 0.25 Ohm at 20 °C.
a) If the resistance is not reached, replace the injector.

EEM3 - 354 Injector 5 - solenoid valve is open too long

Description:
The electronics monitor whether the solenoid valve shuts quickly enough after each injection. The error becomes ac-
tive if the solenoid valve stays open longer than scheduled during an injection. Injectors 1, 3 and 5 are disabled.
Possibile cause:
1. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Turn the starter switch to the "OFF" position and then back to "ON". Start the engine. If the error code continues
active, the cause of the problem lies in a faulty engine controller. Replace the engine controller.
(see chapter 2002A)

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EEM3 - 355 Injector 5 - solenoid valve error

Description:
The engine controller detects an error in the current flow to the solenoid valve of injector 5. The cause probably lies
in a transitory current spike in the solenoid valve. Injectors 1, 3 and 5 are disabled.
Possibile cause:
1. Faulty injector
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. The cause of the error can be a transitory current spike in the solenoid valve of the injector, caused by a short-
term malfunction of the solenoid valve. Clear the error code. Turn the starter switch to the "OFF" position and then
back to "ON". Start the engine.
a) If the error is no longer active, no further measures are required.
b) If the error is active, repeat the process several times. If the error is active after each engine start-up, replace
the injector. (see chapter 3001A)

EEM3 - 361 Injector 6 - solenoid valve short-circuit to ground

Description:
The engine controller detects a short-circuit to ground in the drive circuit to injector 6.
If the short-circuit is at cable C SL6 (low side), then injector 6 is disabled.
If the short-circuit is at cable C SH6 (high side), then injectors 2, 4 and 6 are disabled.
Possible causes:
1. Faulty connector or wiring
2. Faulty solenoid
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm. Depending on the cause, several injectors can be disabled.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the electrical connections of injector Y26 and the connector X16/1 of the engine controller.
a) Ensure the connector is connected, not damaged, the pins are in the correct position and that the fit is tight.
Repair or replace as required. Check the nuts of the injector connecting lead for the correct tightening torque of
1.5 Nm.
b) If the electrical connections are OK, continue with step 2.
2. Check for a short to ground.
a) Disconnect the electrical connections at the injector and the connector X16/1. Check for continuity between:
Cable C SH6 and ground
Cable C SL6 and ground
If a short-circuit to ground is displayed, repair or replace the cable.
b) If a short to ground is not indicated, continue to step 3.
3. Check the injector solenoid valve for a short-circuit to ground. Check both terminal studs for continuity against
ground .
a) If a short-circuit to ground is displayed, replace the injector.
b) If a short to ground is not indicated, continue to step 4.
4. Check the resistance of the coil: 0.2 - 0.25 Ohm at 20 °C.
a) If the resistance is not reached, replace the injector.

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EEM3 - 362 Injector 6 - solenoid valve short-circuit on +supply

Description:
The engine controller detects a short-circuit between the cables in the drive circuit to injector 6.
The short circuit is between the cable C SL6 (low side) and C SH6 (high side = battery +) Injectors 2, 4 and 6 are
disabled.
Possible causes:
1. Faulty connector or wiring
2. Faulty solenoid
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the electrical connections of injector Y26 and the connector X16/1 of the engine controller.
a) Ensure the connector is connected, not damaged, the pins are in the correct position and that the fit is tight.
Repair or replace as required. Check the nuts of the injector connecting lead for the correct tightening torque of
1.5 Nm.
b) If the electrical connections are OK, continue with step 2.
2. Check the cable C SL6 (low side) for a short-circuit to +supply.
a) Disconnect the electrical connections at the injector. Turn the starter switch to the "ON" position. Check for
voltage between:
Cable C SL6 and ground
If a short-circuit is displayed to +supply, repair or replace the cable.
b) If a short-circuit to +supply is displayed, continue with step 3.
3. Check the resistance of the coil: 0.2 - 0.25 Ohm at 20 °C.
a) If the resistance is not reached, replace the injector.

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EEM3 - 363 Injector 6 - solenoid valve open circuit

Description:
The engine controller detects an open circuit in the drive circuit to injector 6.
Possible causes:
1. Faulty connector or wiring
2. Faulty solenoid
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the electrical connections of injector Y26 and the connector X16/1 of the engine controller.
a) Ensure the connector is connected, not damaged, the pins are in the correct position and that the fit is tight.
Repair or replace as required. Check the nuts of the injector connecting lead for the correct tightening torque of
1.5 Nm.
b) If the electrical connections are OK, continue with step 2.
2. Check the wiring between the injector and the engine controller for an open circuit.
a) Disconnect the electrical connections at the injector and the connector X16/1. Check for continuity between:
Cable C SH6 and X16/1 PIN2
Cable C SL6 and X16/1 PIN15
If an open circuit is displayed, repair or replace the cable.
b) If an open circuit is not indicated, continue to step 3.
3. Check the resistance of the coil: 0.2 - 0.25 Ohm at 20 °C.
a) If the resistance is not reached, replace the injector.

EEM3 - 364 Injector 6 - solenoid valve is open too long

Description:
The electronics monitor whether the solenoid valve shuts quickly enough after each injection. The error becomes ac-
tive if the solenoid valve stays open longer than scheduled during an injection. Injectors 2, 4 and 6 are disabled.
Possibile cause:
1. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Turn the starter switch to the "OFF" position and then back to "ON". Start the engine. If the error code continues
active, the cause of the problem lies in a faulty engine controller. Replace the engine controller.
(see chapter 2002A)

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EEM3 - 365 Injector 6 - solenoid valve error

Description:
The engine controller dtects an error in the current flow to the solenoid valve of injector 6. The cause probably lies in
a transitory current spike in the solenoid valve. Injectors 2, 4 and 6 are disabled.
Possibile cause:
1. Faulty injector
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. The cause of the error can be a transitory current spike in the solenoid valve of the injector, caused by a short-
term malfunction of the solenoid valve. Clear the error code. Turn the starter switch to the "OFF" position and then
back to "ON". Start the engine.
a) If the error is no longer active, no further measures are required.
b) If the error is active, repeat the process several times. If the error is active after each engine start-up, replace
the injector. (see chapter 3001A)

EEM3 - 371 Battery voltage is too low

Description:
The supply voltage is less than 7.8 V.
Possible causes:
1. Voltage drop during starting procedure
2. Faulty wiring between battery and engine controller
3. Faulty alternator
Reaction:
EC is stored and the warning lamp is activated.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the battery charge.
a) If the battery charge is not OK, check the alternator charging voltage. If necessary replace the alternator or the
battery.
b) If the battery charge is OK, go to step 2.
2. Check the supply voltage to the engine controller.
a) Disconnect connector X89/1 from the engine controller and measure the voltage between:
X89/1 PIN40, 9, 8, 3, 2 and ground.
If the battery voltage is not reached at a pin, repair or replace the wiring.

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EEM3 - 372 Battery voltage is too high

Description:
The supply voltage is higher than 17 V.
Possibile cause:
1. Faulty alternator
Reaction:
EC is stored and the warning lamp is activated.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the alternator charging voltage. Replace the alternator if necessary.

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EEM3 - 381 Rail pressure too low

Description:
The error code is displayed if the rail pressure sensor gives a value of less than 200 bar (engine speed 900 rpm) or
400 bar (engine speed 2,300 rpm). The error typically occurs in the case of a delivery problem in the low-pressure
circuit.
Possible causes:
1. Fuel delivery pressure in the low-pressure circuit too low.
2. Leak in the high-pressure circuit.
3. High-pressure pump not working properly
4. Faulty connector or wiring
5. Faulty rail pressure sensor
6. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Check whether error code EEM3 - 446 (fuel delivery pressure too low) is active.
a) If the error code is active, remedy it first.
b) If the error code is not active, go to step 3.
ATTENTION: Carry out a visual inspection to see if there leaks at the high-pressure circuit.
High-pressure line connections must never be opened when the engine is running. The engine must be at a stand-
still for at least 30 seconds before opening. A fuel jet under high pressure (up to 1,100 bar) can cause penetrating
and serious injuries to the skin. In such a case a doctor must be consulted immediately.
a) If a leak is found, replace the appropriate component.
b) If no leaks are found, go to step 4.
3. Check the high-pressure pump with the "Test Function" in the service tool.
a) If the high-presure pump is not working correctly, it must be repaired by an authorized specialist service centre.
(Disassembly, installation - see chapter 3001A)
b) If the high-pressure pump is working correctly, go to step 5.
4. Check the connector X3/38 of sensor B38 and the connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 6.
5. Check the sensor using test adapter 380002718.
a) Connect the test adapter across the plug-in connection X3/38. Start the engine and check the signal voltage
between connection:
X3/38 PIN2 and PIN1
If a voltage of < 0.94 volt is displayed, replace the sensor.
b) If the signal voltage is OK, replace the engine controller. (see chapters 2002A und 3001A)

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EEM3 - 382 Rail pressure too high

Description:
The error code is displayed if the rail pressure sensor gives a reading higher than 1,700 bar. Under normal operation
the pressure relief valve opens above the critical pressure of 1,600 - 1,650 bar. If the pressure relief valve is faulty
and the rail pressure sensor permanantly returns a pressure of > 1,700 bar, the engine switches off immediately.
Possible causes:
1. High-pressure pump not working correctly
2. Faulty connector or wiring
3. Faulty rail pressure sensor
4. Pressure relief valve faulty
5. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine is shut down immediately.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Check the high-pressure pump with the "Test Function" in the service tool.
a) If the high-pressure pump is not working correctly, it must be repaired by an authorized specialist service cen-
tre. (Disassembly, installation - see chapter 3001A)
b) If the high-pressure pump is working correctly, go to step 3.
3. Check connector X3/38 of the rail pressure sensor B38 and connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 4.
4. Check the sensor using test adapter 380002718.
a) Insert the test adapter in the plug-in connection X3/38. Yurn the starter switch to the "ON" position and check
the signal voltage between connection:
X3/38 PIN2 und PIN1
The displayed signal voltage must be 0.5 volt. If a higher voltage is displayed, replace the sensor.
b) If the signal voltage is OK, replace the pressure relief valve on the rail. (see chapters 2002A and 3001A)
ATTENTION: High-pressure line connections must never be opened when the engine is running. The engine must
be at a standstill for at least 30 seconds before opening. A fuel jet under high pressure (up to 1,100 bar) can cause
penetrating and serious injuries to the skin. In such a case a doctor must be consulted immediately.
5. If the error continues active, replace the engine controller. (see chapter 2002A)

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EEM3 - 383 Rail pressure is lower than expected

Description:
The error code is displayed if the rail pressure sensor gives a smaller reading than expected.
Possible causes:
1. High-pressure pump not working correctly.
2. Faulty connector or wiring
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm. The engine functions that depend on the rail pressure are not active.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
NOTE: If error code EEM3 391 (pressure relief valve open) occurs, remedy it first.
2. Check the high-pressure pump using the "Test Function" in the service tool.
a) If the high-pressure pump is not working correctly, it must be repaired by an authorized specialist service cen-
tre. (Disassembly, installation - see chapter 3001A)
b) If the high-pressure pump is working correctly, go to step 3.
3. Check connector X3/38 of sensor B38 and connector X36/1 of the engine controller.
4. a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.

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EEM3 - 384 Rail pressure is higher than expected

Description:
The error code is displayed if the rail pressure is higher than expected.
Possible causes:
1. An injector is not working correctly
2. Leak in the high-pressure circuit
3. Faulty connector or wiring
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm. The engine functions that depend on rail pressure are not active.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
1. Carry out a visual inspection to see if there leaks at the high-pressure circuit.
ATTENTION: High-pressure line connections must never be opened when the engine is running. The engine must
be at a standstill for at least 30 seconds before opening. A fuel jet under high pressure (up to 1,100 bar) can cause
penetrating and serious injuries to the skin. In such a case a doctor must be consulted immediately.
a) If a leak is found, replace the appropriate component.
b) If no leaks are found, go to step 3.
2. Check the injectors using the "Test Function" in the service tool.
a) If the high-pressure pump is not working correctly, it must be repaired or replaced by an authorized specialist
service centre. (Disassembly, installation - see chapter 3001A)
b) If the injectors are working correctly, go to step 4.
3. Check connector X3/38 of sensor B38 and connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.

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EEM3 - 385 Rail pressure, leakage at no-load speed

Description:
The error code is displayed in no-load speed (900 rpm) in the case of too low rail pressure.
Possible causes:
1. An injector is not working correctly
2. Leakage in the high-pressure circuit
3. Faulty connector or wiring
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm. The engine functions that depend on rail pressure are not active.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Carry out a visual inspection to see if there are leaks in the high-pressure circuit.
ATTENTION: High-pressure line connections must never be opened when the engine is running. The engine must
be at a standstill for at least 30 seconds before opening. A fuel jet under high pressure (up to 1,100 bar) can cause
penetrating and serious injuries to the skin. In such a case a doctor must be consulted immediately.
a) If a leak is found, replace the appropriate component.
b) If no leaks are found, go to step 3.
3. Check the high-pressure pump with the "Test Function" in the service tool.
a) If an injector is not working correctly, it must be repaired or replaced by an authorized specialist service centre.
(Disassembly, installation - see chapter 3001A)
b) If the injectors are working correctly, go to step 4.
4. Check connector X3/38 of sensor B38 and connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.

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EEM3 - 386 Rail pressure, leakage

Description:
The error code is displayed when the control signal for the solenoid valve on the high-pressure pump is too high be-
cause of a leak.
Possible causes:
1. An injector is not working properly
2. Leak in the high-pressure circuit
3. Faulty connector or wiring
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm. The engine functions that depend on the rail pressure are not active.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Carry out a visual inspection for leaks in the high-pressure circuit.
ATTENTION: High-pressure line connections must never be opened when the engine is running. The engine must
be at a standstill for at least 30 seconds before opening. A fuel jet under high pressure (up to 1,100 bar) can cause
penetrating and serious injuries to the skin. In such a case a doctor must be consulted immediately.
a) If leaks are detected, replace the appropriate component.
b) If no leaks are detected, go to step 3.
3. Check the injectors with the "Test Funktion" in the service tool.
a) If an injector is not working correctly, it must be repaired or replaced by an authorized specialist service centre.
(Disassembly, installation - see chapter 3001A)
b) If the injectors are working correctly, go to step 4.
4. Check connector X3/38 of sensor B38 and connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.

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EEM3 - 387 Rail pressure signal, leaks during overspeed

Description:
The error code is displayed when the engine is run in the overspeed range and the rail pressure is too low.
Possible causes:
1. An injector is not working correctly.
2. Leak in the high-pressure circuit
3. Faulty connector or wiring
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm. The engine functions that depend on the rail pressure are not active.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Carry out a visual inspection to see if there are leaks in the high-pressure circuit.
ATTENTION: High-pressure line connections must never be opened when the engine is running. The engine must
be at a standstill for at least 30 seconds before opening. A fuel jet under high pressure (up to 1,100 bar) can cause
penetrating and serious injuries to the skin. In such a case a doctor must be consulted immediately.
a) If leaks are detected, replace the appropriate component.
b) If no leaks are detected, go to step 3.
3. Check the injectors with the "Test Function" in the service tool.
a) If an injector is not working correctly, it must be repaired or replaced by an authorized specialist service centre.
(Disassembly, installation - see chapter 3001A)
b) If the injectors are working correctly, go to step 4.
4. Check connector X3/38 of sensor B38 and connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.

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EEM3 - 391 Pressure relief valve open

Description:
The error code is displayed if the rail pressure rises above a critical value and the mechanical pressure relief valve
on the rail opens for reasons of safety. The pressure relief valve remains open until the engine is switched off.
The opening of the pressure relief valve can also be controlled for safety reasons by the engine electronics. If for ex-
ample the rail pressure sensor or the high-pressure pump solenoid valve break down, the pressure relief valve is ope-
ned by the "kick off" function.
This happens when the high-pressure pump is briefly controlled so that the maximum amount is delivered. This cau-
ses a rise in pressure in the rail and the pressure relief valve opens. After the pressure relief valve has opened, the
pressure drops to 600 - 700 bar. If the engine electronics do not detect this process, error code EEM3 - 392 (pressure
relief valve is stuck) becomes active.
The "kick off" function can only be active once during an engine operation. In order to be able to become active again,
the engine must be switched off and re-started.
Possibile cause:
1. Faulty solenoid valve - high-pressure pump
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm. The rail pressure is stabilized at 600 - 700 bar.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Check connector X2/21 of solenoid valve Y20 and connector X16/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the solenoid valve supply voltage with the test adapter 380002716.
a) Insert the test adapter in the plug-in connector X2/21. Turn the starter switch to the "ON" position and measure
the supply voltage between connector:
X2/21 and ground
The displayed voltage must be 12 volts.
b) If the voltage is not reached, go to step 4.
4. Check the wiring to the solenoid valve for breaks.
a) Disconnect connector X2/21 from the solenoid valve and connector X16/1 from the engine controller. Check
between connector:
X2/21 PIN1 and X16/1 PIN9
X2/21 PIN2 and X16/1 PIN10
If a break is displayed, repair or replace the cable.
b) If no break is displayed, go to step 5.
5. Check the coil resistance (2.6 - 3.2 Ohm at 20 °C) of the solenoid valve.
If the resistance is not reached, replace solenoid valve Y20.

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EEM3 - 392 Pressure relief valve is stuck

Description:
The engine electronics have initiated the "kick off" function. The "kick off" function (open the pressure relief valve) has
failed. (Description of "kick off" function - see error code EEM3 391)
Possibile cause:
1. Pressure relief valve faulty
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 50% and the engine speed limited to
1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
ATTENTION: Replace the pressure relief valve. (see chapter 2002A)
High-pressure line connections must never be opened when the engine is running. The engine must be at a stand-
still for at least 30 seconds before opening. A fuel jet under high pressure (up to 1,100 bar) can cause penetrating
and serious injuries to the skin. In such a case a doctor must be consulted immediately.

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EEM3 - 421 High-pressure pump solenoid valve, short-circuit to

ground
Description:
The drive circuit HP2 (low side) to the high-pressure pump solenoid valve Y20 has a short-circuit to ground.
Possible causes:
1. Faulty connector or wiring
2. Faulty high-pressure pump solenoid valve
Reaction:
EC is stored and the warning lamp is activated. Because of the error the high-pressure pump delivers the full injection
quantity and the pressure in the rail rises. This also activates error 391.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check connector X2/21 of solenoid valve Y20 and connector X16/1 of the engine controller.
a) The connectors must be connected and show no signs of damage. The pins must be in the correct position
and the connectors must fit securely. Repair or replace as required.
b) If the electrical connections are OK, continue with step 2.
2. Check control lead HP2 for a short-circuit to ground. Use test adapter 380002716.
a) Connect the adapter to connector X2/21 (solenoid valve unplugged). Disconnect connector X16/1 from the en-
gine controller. Check for continuity between:
X2/21 PIN2 and ground
If a short-circuit to ground is displayed, repair or replace the cable.
b) If a short to ground is not indicated, continue to step 3.
3. Check solenoid valve Y20 for a short-circuit to ground.
a) Check both pins for continuity against ground. If a short-circuit to ground is displayed, replace the solenoid
valve.
b) If a short to ground is not indicated, continue to step 4.
4. Check the resistance of solenoid valve Y20.
a) Measure the resistance of the solenoid valve. If the resistance at 20 °C is not between 2.6 and 3.15 Ohm, re-
place the solenoid valve.

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EEM3 - 422 High-pressure pump solenoid valve, short-circuit to

+supply
Description:
The drive circuit HP2 (low side) to the high-pressure pump solenoid valve Y20 has a short-circuit to + supply.
Possible causes:
1. Faulty connector or wiring
2. Faulty high-pressure pump solenoid valve
Reaction:
EC is stored and the warning lamp is activated. Because of the error the high-pressure pump delivers the full injection
quantity and the pressure in the rail rises. This also activates error 391.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the connector X2/21 of solenoid valve Y20 and connector X16/1 of the engine controller.
a) The connectors must be connected and show no signs of damage. The pins must be in the correct position
and the connectors must fit securely. Repair or replace as required.
b) If the electrical connections are OK, continue with step 2.
2. Check control lead HP2 for a short circuit to + supply. Use test adapter 380002716.
a) Connect the adapter to connector X2/21 (solenoid valve unplugged). Disconnect connector X16/1 from the en-
gine controller. Check for voltage between:
X2/21 PIN2 and ground
If a short-circuit to + supply is displayed, repair or replace the cable.
b) If no short-circuit to + supply is displayed, continue with step 3.
3. Check the resistance of solenoid valve Y20.
a) Measure the resistance of the solenoid valve. If the resistance at 20 °C is not between 2.6 and 3.15 Ohm, re-
place the solenoid valve.

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EEM3 - 423 High-pressure pump solenoid valve open circuit

Description:
The engine controller detects an open circuit in the drive circuit HP2 (low side) to high-pressure pump solenoid valve
Y20.
Possible causes:
1. Faulty controller or wiring
2. Faulty high-pressure pump solenoid valve
Reaction:
EC is stored and the warning lamp is activated. Because of the error the high-pressure pump delivers the full injection
quantity and the pressure in the rail rises. This also activates error 391.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check connector X2/21 of solenoid valve Y20 and connector X16/1 of the engine controller.
a) The connectors must be connected and show no signs of damage. The pins must be in the correct position
and the connectors must fit securely. Repair or replace as required.
b) If the electrical connections are OK, continue with step 2.
2. Check control lead HP2 for an open circuit. Use test adapter 380002716.
a) Connect the adapter to controller X2/21 (solenoid valve unplugged). Disconnect connector X16/1 from the en-
gine controller. Check for continuity between:
X2/21 PIN2 and X16/1 PIN10
If an open circuit is displayed, repair or replace the cable.
b) If an open circuit is not indicated, continue to step 3.
3. Check the resistance of solenoid valve Y20.
a) Measure the resistance of the solenoid valve. If the resistance at 20 °C is not between 2.6 and 3.15 Ohm, re-
place the solenoid valve.

EEM3 - 424 High-pressure pump solenoid valve, driving circuit

overtemperature
Description:
The engine controller detects an overtemperature in the driving circuit to high-pressure pump solenoid valve Y20.
Possible causes:
1. Short-circuit of the driving circuit (to the high-pressure circuit) at the battery +
2. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. Because of the error the high-pressure pump delivers the full injection
quantity and the pressure in the rail rises. This also activates error 391.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check whether error code 422 is active.
a) If the error is active, remedy this first.
b) If the error is not active, go to step 2.
2. Turn the starter switch to the "OFF" position and "ON". Then start the engine. If the error is active, replace the
engine controller. (see chapter 2002A)

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EEM3 - 441 Fuel delivery pressure, value fluctuates

Description:
The engine controller detects a fluctuating fuel delivery pressure.
Possible causes:
1. Too little fuel in the tank
2. Leak in the fuel delivery system (after the fuel pump)
3. Faulty fuel pump
4. Faulty connector or wiring
5. Faulty fuel delivery pressure sensor
6. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the mechanical components of the fuel delivery system for proper functioning. (Fuel level in the tank, fuel
filter, fuel pump, hoses and tubes) Check the fuel delivery pressure and then vent the system. (see chapter
3001A)
a) If the cause of the fluctuating delivery pressure is a mechanical component, remedy the error.
b) If the mechanical components are OK, the error lies in the electrical system. Go to step 2
2. Check connector X3/39 of the fuel delivery pressure sensor B39 and connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the sensor supply using test adapter 380002717.
a) Connect the test adapter to connector X3/39. (Sensor unplugged) Turn the starter switch to the "ON" position
and measure the supply voltage between connector:
X3/39 PIN3 and PIN1.
The displayed voltage must be 5 volts. If the voltage is not reached, go to step 4.
b) If the supply voltage is correct, go to step 5.
4. Check the wiring to the sensor for short-circuit to ground and for breaks.
a) Disconnect connector X36/1 from the engine controller. Check between connector:
X3/39 PIN2 and ground
X3/39 PIN3 and ground
X3/39 PIN1 and X36/1 PIN17
X3/39 PIN2 and X36/1 PIN21
X3/39 PIN3 and X36/1 PIN31
If a short-circuit to ground or a break is displayed, repair or replace the cable.
5. Check the sensor.
a) Connect the connector X36/1 to the engine controller and the sensor to the test adapter. Turn the starter switch
to the "ON" position and check the signal voltage between connector:
X3/39 PIN2 and PIN1
The displayed signal voltage must be about 1.9 volts. If the voltage is not reached, replace the sensor.
If the signal voltage is OK, replace the engine controller. (see chapter 2002A)

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EEM3 - 442 Fuel delivery pressure sensor, drop-out

Description:
The fuel delivery pressure sensor B39 signal voltage changes too rapidly.
Possible causes:
1. Faulty supply voltage
2. Faulty connector or wiring
3. Faulty fuel delivery pressure sensor
4. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not indicated, check that the system is operating correctly.
b) If the error code is displayed, continue to step 2.
2. Check connector X3/39 of the fuel delivery pressure sensor B39 and connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the sensor supply using test adapter 380002717.
a) Connect the test adapter to connector X3/39. (Sensor unplugged) Turn the starter switch to the "ON" position
and measure the supply voltage between connector:
X3/39 PIN3 and PIN1.
The displayed voltage must be 5 volts. If the voltage is not reached, repair or replace the cable.
b) If the supply voltage is correct, go to step 4.
4. Check the sensor.
a) Connect the sensor to the test adapter. Start the engine and check the signal voltage between connector:
X3/39 PIN2 and PIN1
The displayed signal voltage must be about 3 volts (at 900 rpm). If drop-outs can be detected on the signal volta-
ge, replace the sensor.
If the signal voltage is OK, replace the engine controller. (see chapter 2002A).

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EEM3 - 445 Fuel delivery pressure, too high

Description:
The fuel delivery pressure is higher than 2.5 bar.
Possible causes:
1. Faulty fuel delivery system (fuel pump, return pipes kinked, squashed or clogged)
2. Faulty connector or wiring
3. Faulty fuel delivery pressure sensor
4. Faulty engine controller
Reaction:
EC is stores.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check if return pipes are kinked, squashed or clogged. Check the fuel delivery pump for proper operation. Check
the fuel delivery pressure and then vent the system. (see chapter 3001A)
a) If the delivery pressure is > 2.5 bar, replace the fuel pump.
b) If the delivery pressure is OK, the fault lies in the electrical system. Go to step 2
2. Check connector X3/39 of the fuel delivery pressure sensor B39 and connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the sensor supply using test adapter 380002717.
a) Connect the test adapter to connector X3/39. (Sensor unplugged) Turn the starter switch to the "ON" position
and measure the supply voltage between connector:
X3/39 PIN3 and PIN1.
The displayed voltage must be 5 volts. If the voltage is higher than 5 volts, there is a short-circuit at + 12 volts.
Repair or replace the cable.
b) If the supply voltage is correct, go to step 4.
4. Check the signal cable for short-circuit to + supply.
a) Check between connector:
X3/39 PIN2 and PIN1
If a short-circuit at +supply is displayed, repair or replace the cable.
b) If no short-circuit is displayed, go to step 5.
5. Check the sensor.
a) Connect the sensor to the test adapter. Turn the starter switch to the "ON" position and check the signal voltage
between connector:
X3/39 PIN2 and PIN1
The displayed signal voltage must be about 1.9 volts. If a higher voltage is displayed, replace the sensor.
If the signal voltage is OK, replace the engine controller. (see chapter 2002A).

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EEM3 - 446 Fuel delivery pressure, too low

Description:
The fuel delivery pressure is lower than 0.75 bar.
Possible causes:
1. No fuel in the tank
2. Fuel filter is clogged
3. Air in the delivery circuit
4. Faulty fuel delivery system (fuel pump)
5. Faulty connector or wiring
6. Faulty fuel delivery pressure
7. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The engine power is reduced to 75% and the engine speed limited to
1,800 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the mechanical components of the fuel delivery system for proper function. (fuel level in the tank, fuel filter,
fuel pump, hoses and pipes) Check the fi=uel delivery pressure and then vent the system. (see chapter 3001A)
a) If the cause of the delivery pressure being too low lies in a mechanical component, remedy this fault.
b) If the mechanical components are OK, the fault lies in the electrical sysem. Go to step 2
2. Check connector X3/39 of the fuel delivery pressure sensor B39 and connector X36/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the sensor supply using test adapter 380002717.
a) Connect the test adapter to the connector X3/39. (Sensor unplugged) Turn the starter switch to the "ON" po-
sition and measure the suppply voltage between connection:
X3/39 PIN3 and PIN1.
The displayed voltage must be 5 volts. If the voltage is not reached, go to step 4.
b) If the supply voltage is correct, go to step 5.
4. Check the wiring to the sensor for short-circuit to ground and for breaks.
a) Disconnect connector X36/1 from the engine controller. Check between connector:
X3/39 PIN2 and ground
X3/39 PIN3 and ground
X3/39 PIN1 and X36/1 PIN17
X3/39 PIN2 and X36/1 PIN21
X3/39 PIN3 and X36/1 PIN31
If a short-circuit to ground or a break is displayed, repair or replace the cable.
5. Check the sensor.
a) Connect the connector X36/1 to the engine controller and the sensor to the test adapter. Turn the starter switch
to the "ON" position and check the signal voltage between connector:
X3/39 PIN2 and PIN1
The displayed signal voltage must be about 1.9 volts. If the voltage is not reached, replace the sensor.
If the signal voltage is OK, replace the engine controller. (see chapter 2002A)

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EEM3 - 451 Incorrect engine specification

Description:
The specification number in the engine controller is incorrect for this engine type. The error is active when an engine
controller of another engine type is used or incorrect software has been loaded.
Possible causes:
1. Installation of an engine controller from a vehicle of a different output class.
2. Incorrect software in the engine controller
Reaction:
EC is stored and the warning lamp is activated. The injection quantity is fixed at 50 mg and the maximum engine
speed is 1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Load the current engine software version using the service ool.
2. Install a new engine controller. Using the service tool, connect the ID module to the new engine controller. (Di-
sassembly. installation of the engine controller - see chapter 2002A)

EEM3 - 452 Incorrect serial number

Description:
The engine serial number in the engine controller does not match the engine.
Possibile cause:
1. Installation of an engine controller from a vehicle with a different output class.
Reaction:
EC is stored and the warning lamp is activated. The injection quantity is fixed at 50 mg and the maximum engine
speed is 1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Install a new engine controller. Using the service tool, connect the ID module to the new engine controller. (Di-
sassembly, installation of the engine controller - see chapter 2002A)

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EEM3 - 453 ID module, no communication

Description:
The engine controller does not detect the ID module.
Possible causes:
1. Connecting cable short-circuit to ground
2. Connecting cable break
3. Bent, broken or corroded connector contacts
4. Faulty ID module
5. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated. The injection quantity is fixed at 50 mg and the maximumengine speed
is 1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check connector X4/4 of the ID module and connector X89/1 of the engine controller.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 2.
2. Check the ID module supply voltage. Use test adapter 380000062.
a) Insert the test adapter in the plug-in connection X4/4. Turn the starter switch to the "ON" position. Measure the
voltage between connector X4/4 PIN4 and PIN1. If the displayed voltage is about +12 volts, continue with step 3.
b) If a short-circuit or a break is displayed, the wiring must be repaired or replaced.
3. Check the CAN BUS between the ID module and the engine controller.
a) Insert the test adapter in the plug-in connection X4/4. Turn the starter switch to the "ON" position.
Measure the voltage between connector X4/4 PIN2 and PIN1. The displayed voltage must be about 2.5 V.
Measure the voltage between connector X4/4 PIN3 and PIN1. The displayed voltage must be about 2.5 V.
If the voltages are not reached, go to step 4.
b) If the voltages are reached, go to step 6.
4. Check the CAN BUS wiring between the ID module and the engine controller.
a) If the wiring is damaged, repair or replace it.
b) If the wiring is OK, go to step 5.
5. Check the terminating resistances in the ID module and the engine controller.
a) Disconnect the engine controller from the test adapter. Measure the resistance at the connector X4/4 between
PIN2 and 3. The displayed value must be 120 Ohm. If the value is not reached, replace the ID module.
b) Unplug the ID module from X4/4 and establish the connection to the engine controller. Measure the resistance
at connector X4/4 between PIN2 and 3. The displayed value must be 120 Ohm. If the value is not reached, re-
place the engine controller.
6. Replace the ID module. If the error persists, replace the engine controller. (Disassembly, installation of engine
controller - see chapter 2002A)
NOTE: By activating the "by pass" function in the service tool you can by pass the restrictions (injection quantity /
engine speed) of error code EEM3 - 453 for a maximumof 200 operating hours.

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EEM3 - 454 ID module, not compatible

Description:
The engine controller detects a conflict between the ID module and the engine controller version. The ID module cor-
responds to a newer version than the engine controller. The error becomes active when an engine controller with an
equivalent specification but an older software version is used.
Possibile cause:
1. Engine controller with incorrect software
Reaction:
EC is stored and the warning lamp is activated. The injection quantity is fixed at 50 mg and the maximum engine
speed is 1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
Using the service tool, load the current engine software version.

EEM3 - 455 ID module, memory 1 faulty

Description:
The engine controller detects a problem in the ID module memory 1.
Possibile cause:
1. Faulty ID module
Reaction:
EC is stored and the warning lamp is activated. The injection quantity is fixed at 50 mg and the maximum engine
speed is 1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Turn the starter switch to the "ON" position. If the error becomes active
again, replace the ID module.
NOTE: By activating the "by pass" function in the service tool you can by pass the restrictions (injection quantity,
engine speed) for a maximum of 200 operating hours. The "by pass" function can only be activated by active error
EEM3 - 453. To do this unplug the ID module at connector X4/4!

EEM3 - 456 ID module, supply voltage too high

Description:
The ID module supply voltage stays above the permiited value (>32 V) for longer than 1 second.
Possible causes:
1. Faulty alternator
2. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Check the alternator charging voltage. (see error code EEM3 - 18)
2. If the charging voltage is OK, you can load the current engine software version. If fault re-occurs, remove and
replace the engine controller. (see chapter 2002A)

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EEM3 - 457 ID module, supply voltage too low

Description:
The ID module supply voltage remains below the permitted value (8V) for longer than 1 second.
The error can also be initiated by too high a battery voltage drop during the start-up process.
Possible causes:
1. Low battery charge
2. Faulty connector
3. Faulty harness
4. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. The error can occur during engine start-up or even with the starter switch in the "ON" position. Before proceeding
clear the error code and turn the starter switch to the "OFF" position.
a) Turn the starter back to the "ON" position. If the error code is displayed, continue to step 2.
b) If the error code is not active, start the engine. If the error is active, the cause lies in too high a battery voltage
drop durin the start-up process. Check battery charge level. (see also error code EEM3 - 371)
2. Check connector X4/4 of the ID module A7.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are okay, continue to step 3.
3. Check the ID module supply voltage. Use test adapter 380000062.
a) Insert the test adapter in the plug-in connection X4/4. Turn the starter switch to the "ON" position. Measure the
voltage between connector X4/4 PIN4 and PIN1.
If a short-circuit or a break is displayed, repair or replace the wiring.
b) If the displayed voltage is about + 12 volts, load the current engine software version. If fault re-occurs, replace
the engine controller. (see chapter 2002A)

EEM3 - 458 ID module, temperature too high

Description:
The engine controller detects a temperature above 110 °C for longer than 30 seconds in the ID module.
Possibile cause:
1. Ambient temperature too high
Reaction:
EC is stored and the warning lamp is activated.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Clean dirt from the ID module environment and then carry out a test run. If the error occurs again, replace the ID
module.

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EEM3 - 459 ID module, memory 2 faulty

Description:
The engine controller detects a problem in the ID module memory 2.
Possibile cause:
1. Faulty ID module
Reaction:
EC is stored and the warning lamp is activated.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Turn the starter switch to the "ON" position. If the error occurs again, re-
place the ID module.

EEM3 - 461 ID module, internal error 1

Description:
The engine controller detects a problem in the ID module software.
Possibile cause:
1. Faulty ID module
Reaction:
EC is stored and the warning lamp is activated.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
Replace the ID module.

EEM3 - 462 ID module, start error

Description:
The engine controller detects a problem with the ID module supply voltage. The most likely cause is a voltage drop
during the starting preocedure.
Possibile cause:
1. Voltage drop during the starting procedure
2. Faulty connector
3. Faulty ID module
Reaction:
EC is stored and the warning lamp is activated.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. If the error occurs during the start procedure, the cause lies in a too high battery voltage drop. Check battery char-
ge level. (see also error code EEM3 - 371)
2. Check connector X4/4 of the ID module.
a) Check whether the connectors are plugged in, there is no damage, the pins are in the right position and the
connectors are secure. Repair or replace as required.
b) If the connectors are OK, load the current engine software version. If the fault re-occurs, replace the ID module.

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EEM3 - 463 Missing engine specification

Description:
The engine controller detects a missing or invalid engine specification in the ID module.
Possibile cause:
1. Installation of an ID module with missing or invalid engine specification.
Reaction:
EC is stored and the warning lamp is activated. The injection quantity is fixed at 50 mg and the maximum engine
speed is 1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
Replace the ID module.

EEM3 - 464 Missing serial number

Description:
The engine controller detects a missing or invalid serial number in the ID module.
Possibile cause:
Installation of an ID module with a missing or invalid engine serial number.
Reaction:
EC is stored and the warning lamp is activated. The injection quantity is fixed at 50 mg and the maximum engine
speed is 1,500 rpm.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
Replace the ID module.

EEM3 - 465 Missing ID module, by pass function activated

Description:
The "by pass" function is activated. The specified time limit (max. 200 operating hours) has not yet expired.
Possibile cause:
1. "by pass" function was activated with the service tool.
Reaction:
EC is stored and the warning lamp is activated.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
Replace the ID module.

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EEM3 - 466 Missing ID module, by pass function deactivated

Description:
The "by pass" function is deactivated because the specified time limit has expired.
Possibile cause:
1. Specified time limit of the "by pass" function has expired.
Reaction:
EC is stored and the warning lamp is activated.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
Replace the ID module or re-activate the "by pass" function.
NOTE: The "by pass" function can be activated for a maximum of 200 operating hours!

EEM3 - 467 Missing ID module, by pass function time expired

Description:
The "by pass" function is switched off because the absolute time limit of 200 operating hours has expired.
Possibile cause:
1. The absolute time limit has expired.
Reaction:
EC is stored and the warning lamp is activated.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
Replace the ID module.

EEM3 - 471 Air pressure sensor in engine controller, signal voltage

too low
Description:
The engine controller detects an invalid internal air pressure sensor voltage. The cause is probably an engine con-
troller hardware error.
Possibile cause:
1. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not displayed, no further measures are necessary.
b) If the error code is displayed, continue to step 2.
2. Load the current engine software version. If fault re-occurs, replace the engine controller. (see chapter 2002A)

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EEM3 - 472 Air pressure sensor in the engine controller, signal

voltage too high
Description:
The engine controller detects an invalid internal air pressure sensor voltage. The cause is probably an engine con-
troller hardware error.
Possibile cause:
1. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not displayed, no further measures are necessary.
b) If the error code is displayed, continue to step 2.
2. Load the current engine software version. If fault re-occurs, replace the engine controller. (see chapter 2002A)

EEM3 - 473 Air pressure too high

Description:
The engine controller detects an air pressure of > 2 bar. The cause is probably an engine controller hardware error.
Possibile cause:
1. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not displayed, no further measures are necessary.
b) If the error code is displayed, continue to step 2.
2. Load the current engine software version. If fault re-occurs, replace the engine controller. (see chapter 2002A)

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EEM3 - 474 Air pressure sensor in the engine controller, no signal

Description:
The engine controller does not detect the internal air pressure sensor signal. The cause is probably an engine con-
troller hardware error.
Possibile cause:
1. Faulty engine controller
Reaction:
EC is stored and the warning lamp is activated.
Solution:
NOTE: As soon as the cause of the error code has been removed, you must delete the error code and check the
system for proper functioning.
1. Before proceeding clear the error code. Run the tractor under normal conditions and repeat the test.
a) If the error code is not displayed, no further measures are necessary.
b) If the error code is displayed, continue to step 2.
2. Load the current engine software version. If fault re-occurs, replace the engine controller. (see chapter 2002A)

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COMPONENTS SUMMARY
(2) Screw connection for ground point, engine control unit.....................................................................Fig. 1
(11) Ground point engine cable carrier, rear ............................................................................................Fig. 2
A3 EEM3 control unit ..............................................................................................................................Fig. 3
A7 ID module ..........................................................................................................................................Fig. 4
B20 Engine speed sensor .........................................................................................................................Fig. 4
B22 Engine temperature sensor ...............................................................................................................Fig. 5
B23 ’Water in fuel’ sensor ........................................................................................................................Fig. 5
B29 Charge-air pressure / temperature sensor ........................................................................................Fig. 6
B36 Fuel temperatur sensor .....................................................................................................................Fig. 6
B37 Oil pressure sensor ..........................................................................................................................Fig. 7
B38 Rail pressure sensor..........................................................................................................................Fig. 7
B39 Fuel delivery pressure sensor ...........................................................................................................Fig. 8
B40 Camshaft position sensor ..................................................................................................................Fig. 8
G2/2 Generator, Bosch, 120A ....................................................................................................................Fig. 9
G2/2/2 2nd Generator Magneton 95A ...........................................................................................................Fig. 9
R8 Potentiometer, accelerator pedal ....................................................................................................Fig. 10
X1/30/EEMScrew connection, engine print potential 30 ............................................................................... Fig. 11
X2/21 Plug connection, solenoid valve, high-pressure pump ...................................................................Fig. 12
X2/22 Plug connection, coolant temperature sensor .................................................................................Fig. 13
X2/28 Plug connection, engine speed sensor............................................................................................Fig. 14
X2/36 Plug connection, fuel temperature sensor .......................................................................................Fig. 15
X3/10 Plug connection, terminating resistor ..............................................................................................Fig. 16
X3/12 Plug connection, ’Water in fuel’ sensor............................................................................................Fig. 17
X3/37 Plug connection, oil pressure sensor ..............................................................................................Fig. 18
X3/38 Plug connection, rail pressure sensor .............................................................................................Fig. 19
X3/39 Plug connection, fuel delivery pressure sensor ...............................................................................Fig. 20
X3/40 Plug connection, camshaft position sensor .....................................................................................Fig. 21
X4/4 Plug connection, ID module ............................................................................................................Fig. 22
X4/29 Plug connection, charge-air pressure/charge-air temperature sensor ...........................................Fig. 23
X4/70 Plug connection, accelerator pedal [70] .........................................................................................Fig. 24
X12/1 Plug connection, engine wiring harness - engine print ..................................................................Fig. 25

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X16/1 Plug connection, EEM3 engine control unit - engine injection nozzles wiring harness .................. Fig. 26
X36/1 Plug connection, EEM3 engine control unit - engine sensors wiring harness ............................... Fig. 27
X89/1 Plug connection, EEM3 engine control unit - engine wiring harness EEM3 ................................... Fig. 28
Y20 Solenoid valve, high-pressure pump ............................................................................................. Fig. 10
Y21 Screw connection, injector, 1st cylinder.......................................................................................... Fig. 29
Y22 Screw connection, injector, 2nd cylinder......................................................................................... Fig. 30
Y23 Screw connection, injector, 3rd cylinder ......................................................................................... Fig. 31
Y24 Screw connection, injector, 4th cylinder.......................................................................................... Fig. 32
Y25 Screw connection, injector, 5th cylinder.......................................................................................... Fig. 33
Y26 Screw connection, injector, 6th cylinder.......................................................................................... Fig. 34

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Fig. 1 Fig. 5

Fig. 2 Fig. 6

Fig. 3 Fig. 7

Fig. 4 Fig. 8

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Fig. 9 Fig. 13

Fig. 10 Fig. 14

Fig. 11 Fig. 15

Fig. 12 Fig. 16

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Fig. 17 Fig. 21

Fig. 18 Fig. 22

Fig. 19 Fig. 23

Fig. 20 Fig. 24

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Fig. 25 Fig. 28

Fig. 26

Fig. 29

Fig. 27

Fig. 30

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Fig. 31

Fig. 32

Fig. 33

Fig. 34

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FUNCTIONAL SCHEMATIC DIAGRAM FOR EEM3

A14
X12/1 F207 5A
2 +15

X1/30/EEM F203 30A

A12 +30
F19 5A

F20 5A
+15/1

ARMREST X89/1 40 9 8 3 2 11 10 5 6
17 18 X24/2 A3 EEM3
(11) CAN H (2)
A30 PRINT ARU 35
X30/1 X18/4 CAN L Supply F208 10A
34 +30
8 10 (11)
X30/3 7 13
B28 M13
1 9 9 X12/1
5V 12V
X30/7 Pre-glowing and K5/LP 9 3 M 1
0.4V to 4.7V fuel delivery pump 4
X 2 2 16 3 5
3
CAN H X89/1
17 1 2
CAN L 55 4 GND
GND 4 4 18 X12/1
(11)

X1/30/1 E10/1
+30
P8/1 4 3
P8 ICU + -
P8/2
3 K8/2
4 3 5
(12)

1 2
X36/1 X2/19 X2/19
4
A1 ADIC CN3 5
26
25
A1 ADIC X4/4 4-pin plug connection
A3 EEM3 X4/70 4-pin plug connection
A7 ID module X10/18 10-pin plug connection
A12 Central print X12/1 12-pin plug connection
Emergency signal A14 Engine print X18/4 18-pin plug connection
R8 X4/70 X24/3 X10/18 X89/1 A30 Print ARU X24/2 24-pin plug connection
4 16 10 79 0.8 to 4.4 V B28 Manual throttle X24/3 24-pin plug connection
CN3 26-pin plug connection X30/1 14-pin plug connection
E10/1 Heating flange X30/3 4-pin plug connection
K5/LP Relay, fuel delivery pump X30/7 4-pin plug connection
K8/2 Relay, heating flange X36/1 36-pin plug connection
M13 Fuel delivery pump X89/1 89-pin plug connection
P8 ICU (2) Ground point, EEM3 control unit
A7 ID module Engine identification P8/1 4-pin plug connection (11) Ground point, engine cable carrier,
X4/4 X89/1
12V P8/2 4-pin plug connection rear
4 21 R8 Potentiometer, accelerator pedal (12) Ground point, engine cable carrier,
GND front
120 Ω 1 29 120 Ω
X1/30/1 Screw connection
CAN L X1/30/EEM Screw connection
2 52
CAN H X2/19 2-pin plug connection
3 53

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A3 EEM3
B23 X3/12 X89/1 X16/1 X2/21
12V HP1
R A 50 9 1
Fuel OK = 12 V Y20
B 47 Water in fuel = 0 V
U GND HP2
C 65 10 2

C SH1
X4/29 X36/1 4
GND Y21
1 25
p,t 2.5 kOhm with 20° C C SL1
2 29 13
B29 5V
3 33
U,R 4 34 1.07 V with 1 bar 11
C SH2
atmospheric pressure Y22
C SL2
X2/22 X36/1 6
t 1 15
B22 GND 2.5 kOhm with 20° C C SH3
R 2 26 5
Y23
C SL3
X2/36 X36/1 12
t 1 35
B36 GND 2.5 kOhm with 20° C C SH4
R 2 8 3
Y24
C SL4
X3/37 X36/1 14
GND
p 1 24
C SH5
B37 2 27 0.5 to 4.5 V 1
U,R 3 5V
32 Y25
C SL5
16
X3/38 X36/1
GND C SH6
p 1 12 2
B38 2 14 0.5 to 4.5 V Y26
U,R 3 5V
13 15
C SL6

X3/39 X36/1
GND
p 1 17
A3 EEM3 X3/37 3-pin plug connection
B39 2 21 0.5 to 4.5 V
B20 Engine speed sensor X3/38 3-pin plug connection
U,R 3 5V
31 B22 Coolant temperature sensor X3/39 3-pin plug connection
B23 'Water in fuel' sensor X3/40 3-pin plug connection
B29 Sensor for charger pressure, X4/29 4-pin plug connection
X2/28 X36/1 charge-air temperature X16/1 16-pin plug connection
n GND B36 Fuel temperature sensor X36/1 36-pin plug connection
1 19
B20 approx. 855 Hz at 900 rpm B37 Oil pressure sensor X89/1 89-pin plug connection
f 2 23 B38 Rail pressure sensor Y20 Solenoid valve, high-pressure pump
B39 Fuel delivery pressure sensor Y21 Injector 1
B40 Camshaft position sensor Y22 Injector 2
X3/40 X36/1 X2/21 2-pin plug connection Y23 Injector 3
n 1 9 X2/22 2-pin plug connection Y24 Injector 4
GND approx. 52 Hz at 900 rpm
B40 2 10 X2/28 2-pin plug connection Y25 Injector 5
f X2/36 2-pin plug connection Y26 Injector 6
3 X3/12 3-pin plug connection

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FAULTCODES FMGR
FMGR - 1 Controller fault (Arithmetic, Push, Pop, Stack) ................................................................................. 473
FMGR - 2 Controller fault (Register) ................................................................................................................. 473
FMGR - 3 Controller fault (internal Watchdog) .................................................................................................. 474
FMGR - 5 Controller fault (external Watchdog) ................................................................................................. 474
FMGR - 7 FMGR in shipment condition, without valid parameters ................................................................... 475
FMGR - 8 Controller memory fault (Flash Checksum) at init ............................................................................ 475
FMGR - 9 Controller memory fault (Flash Checksum) at run ............................................................................ 476
FMGR - 12 Controller memory fault (RAM addressing) internal at init .............................................................. 476
FMGR - 13 Controller memory fault (RAM addressing) internal at run ............................................................. 477
FMGR - 14 Controller memory fault (RAM addressing) external at init ............................................................. 477
FMGR - 15 Controller memory fault (RAM addressing) external at runtime ..................................................... 478
FMGR - 16 Controller memory fault (EEPROM checksum 0 manufacture- and ISO-data incorrect) ............... 478
FMGR - 17 Controller memory fault (EEPROM checksum 1 vehicle data incorrect) ........................................ 479
FMGR - 18 Controller memory fault (EEPROM checksum 2 history track incorrect) ........................................ 479
FMGR - 24 Controller fault (ILLBUS illegal external bus access) ..................................................................... 480
FMGR - 25 Controller fault (ILLINA illegal instruction access) .......................................................................... 480
FMGR - 26 Controller fault (ILLOPA illegal word operand access) ................................................................... 481
FMGR - 27 Controller fault (PRTFLT Protection fault flag) ............................................................................... 481
FMGR - 28 Program fault (UNDOPC no valid C167 instruction) ...................................................................... 482
FMGR - 29 Controller fault (STKUF Stack underflow) ...................................................................................... 482
FMGR - 30 Controller fault (STKOF Stack overflow) ........................................................................................ 483
FMGR - 31 Non maskable interrupt (NMI) incorrect ......................................................................................... 483
FMGR - 32 Receive of local CAN Bussignal TR2 is failed (register 0) ............................................................. 484
FMGR - 33 Receive of local CAN Bussignal TR3 is failed (register 1) ............................................................. 485
FMGR - 34 Receive of local CAN Bussignal TR4 is failed (register 2) ............................................................. 486
FMGR - 37 Receive of local CAN Bussignal TR4 is failed (register 5) ............................................................. 487
FMGR - 47 CAN Bus OFF (transmission Bus) .................................................................................................. 488
FMGR - 48 Supply voltage (potential 30) too low ............................................................................................. 489
FMGR - 49 Supply voltage (potential 30) too high ............................................................................................ 489
FMGR - 50 Internal main switch not switchable ................................................................................................ 490
FMGR - 51 Internal main switch permanent on ................................................................................................ 490
FMGR - 63 Communication between FMGR/SGR is incorrect ......................................................................... 491
FMGR - 64 Engine false power classification up to DBD100000 ...................................................................... 491
FMGR - 64 Engine false power classification from DBD100001 ....................................................................... 492
FMGR - 69 Engine variation impossible ............................................................................................................ 492
FMGR - 84 Accelerator pedal potentiometer R8 - signal voltage (Analogue 1) above permissible range ........ 493
FMGR - 85 Accelerator pedal potentiometer R8 - signal faulty ......................................................................... 494
FMGR - 87 Accelerator pedal potentiometer R8 - signal voltage (Analogue 1) below permissible range ........ 495
FMGR - 93 Hand throttle sensor - signal incorrect ............................................................................................ 496
FMGR - 100 Clutch pedal angle of rotation sensor B17 - signal voltage above permissible range .................. 497
FMGR - 103 Clutch pedal angle of rotation sensor B17 - signal voltage below permissible range .................. 498
FMGR - 104 Signal of plus key (+) present for too long .................................................................................... 499
FMGR - 105 Signal of minus key (-) present for too long .................................................................................. 499
FMGR - 106 Signal of cruise control OFF/resume key present for too long ..................................................... 500
FMGR - 109 Signal of forwards/reverse key present for too long ..................................................................... 500
FMGR - 112 Signal of seat switch S8 is interrupted ......................................................................................... 501
FMGR - 114 Seat switch S8 - signal permanently at + ..................................................................................... 501
FMGR - 115 Seat switch S8 - incorrect phase angle of input signal ................................................................. 502

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FMGR - 116 Steering brake inductive switch - signal doesn't change .............................................................. 502
FMGR - 118 Steering brake inductive switch - signal permanent On (instead PWM) ....................................... 503
FMGR - 119 Steering brake inductive switch - input signal with wrong circuit .................................................. 504
FMGR - 120 Stop light switch - signal doen't change ....................................................................................... 505
FMGR - 122 Stop switch - signal permanent On instead of press ratio (PWM) ................................................ 506
FMGR - 123 Stop switch - input signal On with wrong circuit ........................................................................... 507
FMGR - 124 Parking brake switch S21 - signal permanently present ............................................................... 508
FMGR - 126 Parking brake switch S21 - signal permanently at + .................................................................... 508
FMGR - 127 Parking brake switch S21 - incorrect phase angle of input signal ................................................ 509
FMGR - 130 Manual mode switch - signal permanently at + ............................................................................ 509
FMGR - 131 Manual mode switch - incorrect phase angle of input signal ........................................................ 510
FMGR - 138 Switch MFD Management - Signal permanent On (instead PWM) .............................................. 511
FMGR - 139 Switch MFD Management - Input Siganl with wrong circuit ......................................................... 512
FMGR - 142 Switch MFD ON - signal permanent On (instead PWM) .............................................................. 513
FMGR - 143 Switch MFD ON - input signal with wrong circuit .......................................................................... 514
FMGR - 150 Reversible seat switch S8/2 (with reversing facility) - signal permanently at + ............................ 515
FMGR - 151 Reversible seat switch S8/2 (with reversing facility) - incorrect phase angle of input signal ........ 515
FMGR - 156 Clutch switch 80% signal doesn't change .................................................................................... 516
FMGR - 157 Clutch switch 80% plausibility with clutch sensor not provided .................................................... 517
FMGR - 158 Clutch switch 75% signal permanent on (instead PWM) .............................................................. 518
FMGR - 159 Clutch switch 75% input signal with wrong circuit ........................................................................ 519
FMGR - 160 Engine back pressure brake switch S20 - signal permanently present ........................................ 520
FMGR - 162 Engine back pressure brake switch S20 - signal permanently at + .............................................. 520
FMGR - 163 Engine back pressure brake switch S20 - incorrect phase angle of input signal .......................... 521
FMGR - 164 Parklock ON - signal On too long ................................................................................................. 521
FMGR - 166 Parklock ON - signal permanent On (instead PWM) .................................................................... 522
FMGR - 167 Parklock ON - input signal with wrong circuit ............................................................................... 523
FMGR - 168 Signal of "Forward driving direction" shuttle lever present for too long ........................................ 524
FMGR - 170 Switch forward - signal permanent On (instead PWM) ................................................................. 525
FMGR - 171 Switch forward - input signal with wrong circuit ............................................................................ 526
FMGR - 172 Signal of "Reverse driving direction" shuttle lever present for too long ........................................ 527
FMGR - 174 Switch reverse - signal permanent On (instead PWM) ................................................................. 528
FMGR - 175 Switch reverse - input signal with wrong circuit ............................................................................ 529
FMGR - 176 Signal of "neutral button" on the shuttle lever present for too long ............................................... 530
FMGR - 178 Switch neutral - signal permanent On (instead PWM) .................................................................. 531
FMGR - 179 Switch neutral - input signal with wrong circuit ............................................................................. 532
FMGR - 180 Signal of "Shuttle lever raised" present for too long ..................................................................... 533
FMGR - 182 Switch deadman - signal permanent On (instead PWM) .............................................................. 534
FMGR - 183 Switch deadman - input signal with wrong circuit ......................................................................... 535
FMGR - 186 Speed range switch - signal permanently at plus in position I ...................................................... 536
FMGR - 187 Speed range switch - incorrect phase angle of input signal in position I ...................................... 536
FMGR - 190 Speed range switch - signal permanently at plus in position II ..................................................... 537
FMGR - 191 Speed range switch - incorrect phase angle of input signal in position II ..................................... 537
FMGR - 200 Accelerator pedal potentiometer R8 - supply voltage too low (<4.5V) ......................................... 538
FMGR - 201 Accelerator pedal potentiometer R8 - supply voltage too high (>6.5V) ........................................ 538
FMGR - 202 Accelerator pedal potentiometer R8 - supply voltage shorted to + ............................................... 539
FMGR - 203 Accelerator pedal potentiometer R8 - supply voltage shorted to ground ...................................... 539
FMGR - 204 Full-load potentiometer - supply voltage too low (<4.5V) ............................................................. 540
FMGR - 205 Full-load potentiometer - supply voltage too high (>6.5V) ............................................................ 540
FMGR - 206 Full-load potentiometer - supply voltage shorted to + .................................................................. 540

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FMGR - 207 Full-load potentiometer - supply voltage shorted to ground ......................................................... 541
FMGR - 208 Clutch pedal angle of rotation sensor B17 - supply voltage too low (<4.5V) ................................ 541
FMGR - 209 Clutch pedal angle of rotation sensor B17 - supply voltage too high (>6.5V) .............................. 542
FMGR - 210 Clutch pedal angle of rotation sensor B17 - supply voltage shorted to + ..................................... 542
FMGR - 211 Clutch pedal angle of rotation sensor B17 - supply voltage shorted to ground ............................ 543
FMGR - 213 Supply switches pulsed GSV 1 - short-circuit to other circuit ....................................................... 543
FMGR - 214 Supply switches pulsed GSV1 - short-circuit to power ................................................................. 544
FMGR - 215 Supply switches pulsed GSV1 - short circuit, or short-circuit to ground ....................................... 545
FMGR - 217 Supply Switches pulsed GSV2 - short-circuit to other circuit ....................................................... 546
FMGR - 218 Supply switches pulsed GSV2 - short-circuit to power ................................................................. 547
FMGR - 219 Supply switches pulsed GSV2 - short circuit, or short to ground ................................................. 548
FMGR - 221 Clocked switch supply (GSV3) - short-circuit to other phase ....................................................... 549
FMGR - 222 Clocked switch supply (GSV3) - short-circuit to + ........................................................................ 550
FMGR - 223 Clocked switch supply (GSV 3) - short to ground ......................................................................... 550
FMGR - 232 Solenoid valve 2, brake oil cooling - control interruption up to DBD100000 ................................ 551
FMGR - 232 Solenoid valve 1, brake oil cooling - control interruption from DBD100001 ................................. 551
FMGR - 234 Solenoid valve 2, brake oil cooling - short-circuit to + up to DBD100000 .................................... 552
FMGR - 234 Solenoid valve 1, brake oil cooling - short-circuit to + from DBD100001 ..................................... 552
FMGR - 235 Solenoid valve 2, brake oil cooling - short-circuit to ground up to DBD100000 ........................... 553
FMGR - 235 Solenoid valve 1, brake oil cooling - short-circuit to ground from DBD100001 ............................ 553
FMGR - 236 Solenoid valve 1, brake oil cooling - control interruption up to DBD100000 ................................ 554
FMGR - 236 Solenoid valve 2, brake oil cooling - control interruption from DBD100001 ................................. 554
FMGR - 238 Solenoid valve 1, brake oil cooling - short-circuit to + up to DBD100000 .................................... 555
FMGR - 238 Solenoid valve 2, brake oil cooling - short-circuit to + from DBD100001 ..................................... 555
FMGR - 239 Solenoid valve 1, brake oil cooling - short-circuit to ground up to DBD100000 ........................... 556
FMGR - 239 Solenoid valve 2, brake oil cooling - short-circuit to ground from DBD100001 ............................ 556
FMGR - 240 Reception of motor (EHS) CAN bus signal on vehicle side in register 0
is faulty up to DBD100000 ................................................................................................................................ 557
FMGR - 240 Reception of motor (EHS) CAN bus signal on vehicle side in register 0
is faulty from DBD100001 ................................................................................................................................. 558
FMGR - 241 Reception of vehicle side CAN bus signal EEC2 in register 1 is faulty up to DBD100000 ........... 560
FMGR - 241 Reception of vehicle side CAN bus signal EEC2 in register 1 is faulty from DBD100001 ........... 561
FMGR - 242 Reception of vehicle side CAN bus signal EEC1 in register 2 is faulty up to DBD100000 ........... 563
FMGR - 242 Reception of vehicle side CAN bus signal EEC1 in register 2 is faulty from DBD100001 ........... 564
FMGR - 243 Reception of vehicle side CAN bus signal DRVST in register 3 is faulty up to DBD100000 ........ 566
FMGR - 243 Reception of vehicle side CAN bus signal DRVST in register 3 is faulty from DBD100001 ......... 567
FMGR - 245 Reception of vehicle side CAN bus signal AUX1 in register 5 is faulty up to DBD100000 ........... 569
FMGR - 245 Reception of vehicle side CAN bus signal AUX1 in register 5 is faulty from DBD100001 ........... 570
FMGR - 246 Reception of vehicle side CAN bus signal AUX2 in register 6 is faulty up to DBD100000 ........... 572
FMGR - 246 Reception of vehicle side CAN bus signal AUX2 in register 6 is faulty from DBD100001 ........... 573
FMGR - 247 Reception of vehicle side CAN bus signal AUX3 in register 7 is faulty up to DBD100000 ........... 575
FMGR - 247 Reception of vehicle side CAN bus signal AUX3 in register 7 is faulty from DBD100001 ........... 576
FMGR - 248 Reception of vehicle side CAN bus signal AUX4 in register 8 is faulty up to DBD100000 ........... 578
FMGR - 248 Reception of vehicle side CAN bus signal AUX4 in register 8 is faulty from DBD100001 ........... 579
FMGR - 249 Reception of vehicle side CAN bus signal AUX5 in register 9 is faulty up to DBD100000 ........... 581
FMGR - 249 Reception of vehicle side CAN bus signal AUX5 in register 9 is faulty from DBD100001 ........... 582
FMGR - 250 Reception of vehicle side CAN bus signal ICU in register 10 is faulty up to DBD100000 ............ 584
FMGR - 250 Reception of vehicle side CAN bus signal ICU in register 10 is faulty from DBD100001 ............. 585
FMGR - 251 Reception of vehicle side CAN bus signal ECCU1 in register 11 is faulty up to DBD100000 ...... 587
FMGR - 251 Reception of vehicle side CAN bus signal ECCU1 in register 11 is faulty from DBD100001 ....... 588

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FMGR - 252 Reception of vehicle side CAN bus signal ECCU2 in register 12 is faulty up to DBD100000 ...... 590
FMGR - 252 Reception of vehicle side CAN bus signal ECCU2 in register 12 is faulty from DBD100001 ....... 591
FMGR - 253 Reception of vehicle side CAN bus signal ECCU3 in register 13 is faulty up to DBD100000 ...... 593
FMGR - 253 Reception of vehicle side CAN bus signal ECCU3 in register 13 is faulty from DBD100001 ....... 594
FMGR - 255 CAN bus OFF up to DBD100000 ................................................................................................. 596
FMGR - 255 CAN bus OFF from DBD100001 .................................................................................................. 597
COMPONENTS SUMMARY ............................................................................................................................. 598
FUNCTIONAL SCHEMATIC DIAGRAM FOR FMGR - SGR UP TO DBD100000 ............................................ 617
FUNCTIONAL SCHEMATIC DIAGRAM FOR FMGR - SGR FROM DBD100001 ............................................ 621
FUNCTIONAL SCHEMATIC DIAGRAM FOR FMGR REVERSING FACILITY UP TO DBD100000 ................ 625
FUNCTIONAL SCHEMATIC DIAGRAM FOR FMGR REVERSING FACILITY FROM DBD100001 ................ 627

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FMGR - 1 Controller fault (Arithmetic, Push, Pop, Stack)

Cause:
Controller processor error: Controller internal component defective.
Possible reasons:
1. Memory defect.
2. Problem during reprogramming.
3. Intermittent voltage supply of controller.
4. EMC (Electro Magnetic Compatibility) Problem.
Solution:
Make sure that the FMGR (A4) has a good connection to the battery (A4/3 PIN10 fuse F51 (15/1) 10A and PIN14
fuse F14 (+30) 7.5A) and is properly grounded (A4/3 PIN13).

Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.

FMGR - 2 Controller fault (Register)

Cause:
Controller memory error: Controller internal component defective.
Possible reasons:
1. Memory defect.
2. Problem during reprogramming.
3. Intermittent voltage supply of controller.
4. EMC (Electro Magnetic Compatibility) Problem.
Solution:
Make sure that the FMGR (A4) has a good connection to the battery (A4/3 PIN10 fuse F51 (15/1) 10A and PIN14
fuse F14 (+30) 7.5A) and is properly grounded (A4/3 PIN13).

Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.

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FMGR - 3 Controller fault (internal Watchdog)

Cause:
Controller memory error: Controller internal component defective.
Possible reasons:
1. Memory defect.
2. Problem during reprogramming.
3. Intermittent voltage supply of controller.
4. EMC (Electro Magnetic Compatibility) Problem.
Solution:
Make sure that the FMGR (A4) has a good connection to the battery (A4/3 PIN10 fuse F51 (15/1) 10A and PIN14
fuse F14 (+30) 7.5A) and is properly grounded (A4/3 PIN13).

Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.

FMGR - 5 Controller fault (external Watchdog)

Cause:
Controller memory error: Controller internal component defective.
Possible reasons:
1. Memory defect.
2. Problem during reprogramming.
3. Intermittent voltage supply of controller.
4. EMC (Electro Magnetic Compatibility) Problem.
Solution:
Make sure that the FMGR (A4) has a good connection to the battery (A4/3 PIN10 fuse F51 (15/1) 10A and PIN14
fuse F14 (+30) 7.5A) and is properly grounded (A4/3 PIN13).

Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.

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FMGR - 7 FMGR in shipment condition, without valid parameters

Cause:
The FMGR as sparepart is normally shipped without valid parameters from factory. This will be indicated to the cu-
stomer by setting this error.
Solution:
Strictly spoken it is not a fault. Failure will be stored and signaled with a warning triangle on the instrument panel.
Follow the installation instructions for a controller replacement, how to setup new parameters.

FMGR - 8 Controller memory fault (Flash Checksum) at init

Cause:
Controller memory error: Programm memory lost defective.
Possible reasons:
1. Memory defect.
2. Problem during reprogramming.
3. Intermittent voltage supply of controller.
4. EMC (Electro Magnetic Compatibility) Problem.
Solution:
Make sure that the FMGR (A4) has a good connection to the battery (A4/3 PIN10 fuse F51 (15/1) 10A and PIN14
fuse F14 (+30) 7.5A) and is properly grounded (A4/3 PIN13).

Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.

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FMGR - 9 Controller memory fault (Flash Checksum) at run

Cause:
Controller memory error: Programm memory lost defective.
Possible reasons:
1. Memory defect.
2. Problem during reprogramming.
3. Intermittent voltage supply of controller.
4. EMC (Electro Magnetic Compatibility) Problem.
Solution:
Make sure that the FMGR (A4) has a good connection to the battery (A4/3 PIN10 fuse F51 (15/1) 10A and PIN14
fuse F14 (+30) 7.5A) and is properly grounded (A4/3 PIN13).

Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.

FMGR - 12 Controller memory fault (RAM addressing)

internal at init
Cause:
Controller memory error: Controller data memory defective.
Possible reasons:
1. Memory defect.
2. Intermittent voltage supply of controller.
3. EMC (Electro Magnetic Compatibility) Problem.
Solution:
Make sure that the FMGR (A4) has a good connection to the battery (A4/3 PIN10 fuse F51 (15/1) 10A and PIN14
fuse F14 (+30) 7.5A) and is properly grounded (A4/3 PIN13).

Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.

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FMGR - 13 Controller memory fault (RAM addressing)

internal at run
Cause:
Controller memory error: Controller data memory defective.
Possible reasons:
1. Memory defect.
2. Intermittent voltage supply of controller.
3. EMC (Electro Magnetic Compatibility) Problem.
Solution:
Make sure that the FMGR (A4) has a good connection to the battery (A4/3 PIN10 fuse F51 (15/1) 10A and PIN14
fuse F14 (+30) 7.5A) and is properly grounded (A4/3 PIN13).

Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.

FMGR - 14 Controller memory fault (RAM addressing)

external at init
Cause:
Controller memory error: Controller data memory defective.
Possible reasons:
1. Memory defect.
2. Intermittent voltage supply of controller.
3. EMC (Electro Magnetic Compatibility) Problem.
Solution:
Make sure that the FMGR (A4) has a good connection to the battery (A4/3 PIN10 fuse F51 (15/1) 10A and PIN14
fuse F14 (+30) 7.5A) and is properly grounded (A4/3 PIN13).

Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.

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FMGR - 15 Controller memory fault (RAM addressing)

external at runtime
Cause:
Controller memory error: Controller data memory defective.
Possible reasons:
1. Memory defect.
2. Intermittent voltage supply of controller.
3. EMC (Electro Magnetic Compatibility) Problem.
Solution:
Make sure that the FMGR (A4) has a good connection to the battery (A4/3 PIN10 fuse F51 (15/1) 10A and PIN14
fuse F14 (+30) 7.5A) and is properly grounded (A4/3 PIN13).

Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.

FMGR - 16 Controller memory fault (EEPROM checksum 0 manu-

facture- and ISO-data incorrect)
Cause:
Controller memory error: Loss of controller manufacturer and diagnostic tester factory settings data. This fault has no
effect to the drive function.
Possible reasons:
1. Memory defect.
2. Intermittent voltage supply of controller.
3. Incorrect terminated parameter download after software reprogramming or controller replacement.
Solution:
Make sure that the FMGR (A4) has a good connection to the battery (A4/3 PIN10 fuse F51 (15/1) 10A and PIN14
fuse F14 (+30) 7.5A) and is properly grounded (A4/3 PIN13).
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Correct checksums with configuration screen "TRANSMISSION - CLEAR NON-CRITICAL CHECKSUM
FAULTS" of the servicetool.
4. If error occurs again then replace FMGR.

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FMGR - 17 Controller memory fault (EEPROM checksum 1 vehicle

data incorrect)
Cause:
Controller memory error: Loss of transmission manufacturer data and vehicle manufacturer factory settings data.
Possible reasons:
1. Memory defect.
2. Intermittent voltage supply of controller.
3. Incorrect terminated parameter download after software reprogramming or controller replacement.
Solution:
Make sure that the FMGR (A4) has a good connection to the battery (A4/3 PIN10 fuse F51 (15/1) 10A and PIN14
fuse F14 (+30) 7.5A) and is properly grounded (A4/3 PIN13).
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. If error occurs again then replace FMGR.

FMGR - 18 Controller memory fault (EEPROM checksum 2 history

track incorrect)
Cause:
Controller memory error: Loss of service data. This fault has no effect to the drive function.
Possible reasons:
1. Memory defect.
2. Intermittent voltage supply of controller.
3. Battery main switch switched off, or battery terminal was disconnected before ignition was switched off.
4. Incorrect terminated parameter download after software reprogramming or controller replacement.
Solution:
Make sure that the FMGR (A4) has a good connection to the battery (A4/3 PIN10 fuse F51 (15/1) 10A and PIN14
fuse F14 (+30) 7.5A) and is properly grounded (A4/3 PIN13).

Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error, switch ignition OFF and ON again. All old service information is possibly lost, but this doesn't influence
the controller function.
4. Correct checksums with configuration screen "TRANSMISSION - CLEAR NON-CRITICAL CHECKSUM
FAULTS" of the servicetool.
5. If error occurs again and is not due to mishandling of the vehicle, then replace FMGR.

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FMGR - 24 Controller fault (ILLBUS illegal external bus access)

Cause:
Controller memory error: Controller internal component defective.
Possible reasons:
1. Memory defect.
2. Problem during reprogramming.
3. Intermittent voltage supply of controller.
4. Software problem.
5. EMC (Electro Magnetic Compatibility) Problem.
Solution:
Make sure that the FMGR (A4) has a good connection to the battery (A4/3 PIN10 fuse F51 (15/1) 10A and PIN14
fuse F14 (+30) 7.5A) and is properly grounded (A4/3 PIN13).

Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.

FMGR - 25 Controller fault (ILLINA illegal instruction access)

Cause:
Controller memory error: Controller internal component defective.
Possible reasons:
1. Memory defect.
2. Problem during reprogramming.
3. Intermittent voltage supply of controller.
4. Software problem.
5. EMC (Electro Magnetic Comaptibility) Problem.
Solution:
Make sure that the FMGR (A4) has a good connection to the battery (A4/3 PIN10 fuse F51 (15/1) 10A and PIN14
fuse F14 (+30) 7.5A) and is properly grounded (A4/3 PIN13).

Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.

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FMGR - 26 Controller fault (ILLOPA illegal word operand access)

Cause:
Controller memory error: Controller internal component defective.
Possible reasons:
1. Memory defect.
2. Problem during reprogramming.
3. Intermittent voltage supply of controller.
4. Software problem.
5. EMC (Electro Magnetic Compatibility) Problem.
Solution:
Make sure that the FMGR (A4) has a good connection to the battery (A4/3 PIN10 fuse F51 (15/1) 10A and PIN14
fuse F14 (+30) 7.5A) and is properly grounded (A4/3 PIN13).

Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.

FMGR - 27 Controller fault (PRTFLT Protection fault flag)

Cause:
Controller memory error: Controller internal component defective.
Possible reasons:
1. Memory defect.
2. Problem during reprogramming.
3. Intermittent voltage supply of controller.
4. Software problem.
5. EMC (Electro Magnetic Compatibility) Problem.
Solution:
Make sure that the FMGR (A4) has a good connection to the battery (A4/3 PIN10 fuse F51 (15/1) 10A and PIN14
fuse F14 (+30) 7.5A) and is properly grounded (A4/3 PIN13).

Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.

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FMGR - 28 Program fault (UNDOPC no valid C167 instruction)

Cause:
Controller memory error: Controller internal component defective.
Possible reasons:
1. Memory defect.
2. Problem during reprogramming.
3. intermittent voltage supply of controller.
4. Software problem.
5. EMC (Electro Magnetic Compatibility) Problem.
Solution:
Make sure that the FMGR (A4) has a good connection to the battery (A4/3 PIN10 fuse F51 (15/1) 10A and PIN14
fuse F14 (+30) 7.5A) and is properly grounded (A4/3 PIN13).

Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.

FMGR - 29 Controller fault (STKUF Stack underflow)

Cause:
Controller memory error: Controller internal component defective.
Possible reasons:
1. Memory defect.
2. Problem during reprogramming.
3. Intermittent voltage supply of controller.
4. Software problem.
5. EMC (Electro Magnetic Compatibility) Problem.
Solution:
Make sure that the FMGR (A4) has a good connection to the battery (A4/3 PIN10 fuse F51 (15/1) 10A and PIN14
fuse F14 (+30) 7.5A) and is properly grounded (A4/3 PIN13).

Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.

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FMGR - 30 Controller fault (STKOF Stack overflow)

Cause:
Controller memory error: Controller internal component defective.
Possible reasons:
1. Memory defect.
2. Problem during reprogramming.
3. Intermittent voltage supply of controller.
4. Software problem.
5. EMC (Electro Magnetic Compatibility) Problem.
Solution:
Make sure that the FMGR (A4) has a good connection to the battery (A4/3 PIN10 fuse F51 (15/1) 10A and PIN14
fuse F14 (+30) 7.5A) and is properly grounded (A4/3 PIN13).

Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.

FMGR - 31 Non maskable interrupt (NMI) incorrect

Cause:
Controller memory error: Controller internal component defective.
Possible reasons:
1. Memory defect.
2. Problem during reprogramming.
3. Intermittent voltage supply of controller.
4. Software problem.
5. EMC (Electro Magnetic Compatibility) Problem.
Solution:
Make sure that the FMGR (A4) has a good connection to the battery (A4/3 PIN10 fuse F51 (15/1) 10A and PIN14
fuse F14 (+30) 7.5A) and is properly grounded (A4/3 PIN13).

Failure will be stored and signaled with a warning triangle on the monitor.
1. Check potential 15/1 via A4/3 PIN10 and X24/2 (A12) to fuse F51 if the supply voltage is correct.
2. Check also potential 30 via A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 if the supply voltage is correct.
3. Clear error record, switch ignition OFF and ON again.
4. If error occurs periodically again then replace FMGR.
5. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro Magnetic Compatibility) problem.

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FMGR - 32 Receive of local CAN Bussignal TR2 is failed (register 0)

Cause:
The controller detects a timeout of a periodical data exchange between FMGR (A4) and SGR (A21).
Possible reasons:
1. Intermittant CAN Problems between FMGR and SGR.
2. Short circuit in the CAN Bus.
3. Controller Hardware failure of FMGR or SGR.
4. Wrong or missing Bus terminating resistor.
5. Bent, broken or corroded pins on the Bus connectors.
6. Wrong program in the FMGR or SGR.
Solution:
Make sure that FMGR (A4) and SGR (A21) are correctly power supplied, and the SGR is online on the Bus. Check
for additional stored errors of the FMGR and the SGR to limit the possible reasons.
Failure will be stored and signaled with a warning triangle on the monitor.
1. Check supply from FMGR and SGR:
• Check FMGR potential 15/1 over A4/3 PIN10 and X24/2 (A12) PIN1 to fuse F51 10A.
• Check FMGR potential 30 over A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 7.5A and ground A4/3
PIN13.
• Check SGR potential 15/1 on X16/21 PIN13 and X24/2 (A12) PIN21 to fuse F18 5A.
• Check SGR potential 30 on X16/21 PIN12 and X24/2 (A12) PIN23 to fuse F9 (30) 10A and ground X16/21
PIN3.
• If the failure occured only one time, and the error was not recorded after deleting and not detected after a
testdrive again, there is no additional check required. The operation of the vehicle is not limited.
2. If Errorcode FMGR - 63 is permanent active refer to description of FMGR - 63.
3. If several errorcodes FMGR - 32, 34 and 37 are recorded and errorcode FMGR - 47 is not active, check the SGR
for correct operation. If errorcode FMGR - 47 is active refer to description of FMGR - 47.
4. If the SGR works correctly, check the CAN Bus connection between SGR and FMGR. Please check terminals
and also the wire between FMGR connector A4/4 PIN17 (CANH) and SGR connector X16/21 PIN1 (CANH) and
A4/4 PIN18 (CANL) to SGR connector X16/21 PIN2 (CANL).
5. Check if messages of FMGR and SGR are on the local bus.
6. Check the program version of FMGR and the SGR for correct application.
7. Was a reprogramming of the SGR or FMGR terminated incorrectly, or was a controller unit changed to a wrong
program version, repeat the reprograming or replace the FMGR or SGR if required.

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FMGR - 33 Receive of local CAN Bussignal TR3 is failed (register 1)

Cause:
The controller detects a timeout of a periodical data exchange between FMGR (A4) and SGR (A21).
Possible reasons:
1. Intermittant CAN Problems between FMGR and SGR.
2. Short circuit in the CAN Bus.
3. Controller Hardware failure of FMGR or SGR.
4. Wrong or missing Bus terminating resistor.
5. Bent, broken or corroded pins on the Bus connectors.
6. Wrong program in the FMGR or SGR.
Solution:
Make sure that FMGR (A4) and SGR (A21) are correctly power supplied, and the SGR is online on the Bus. Check
for additional stored errors of the FMGR and the SGR to limit the possible reasons.
Failure will be stored and signaled with a warning triangle on the monitor.
1. Check supply from FMGR and SGR:
• Check FMGR potential 15/1 over A4/3 PIN10 and X24/2 (A12) PIN1 to fuse F51 10A.
• Check FMGR potential 30 over A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 7.5A and ground A4/3
PIN13.
• Check SGR potential 15/1 on X16/21 PIN13 and X24/2 (A12) PIN21 to fuse F18 5A.
• Check SGR potential 30 on X16/21 PIN12 and X24/2 (A12) PIN23 to fuse F9 (30) 10A and ground X16/21
PIN3. I
• If the failure occured only one time, and the error was not recorded after deleting and not detected after a
testdrive again, there is no additional check required. The operation of the vehicle is not limited.
2. If Errorcode FMGR - 63 is permanent active refer to description of FMGR - 63.
3. If several errorcodes FMGR - 32, 34 and 37 are recorded and errorcode FMGR - 47 is not active, check the SGR
for correct operation. If errorcode FMGR - 47 is active refer to description of FMGR - 47.
4. If the SGR works correctly, check the CAN Bus connection between SGR and FMGR. Please check terminals
and also the wire between FMGR connector A4/4 PIN17 (CANH) and SGR connector X16/21 PIN1 (CANH) and
A4/4 PIN18 (CANL) to SGR connector X16/21 PIN2 (CANL).
5. Check if messages of FMGR and SGR are on the local bus.
6. Check the program version of FMGR and the SGR for correct application.
7. Was a reprogramming of the SGR or FMGR terminated incorrectly, or was a controller unit changed to a wrong
program version, repeat the reprograming or replace the FMGR or SGR if required.

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FMGR - 34 Receive of local CAN Bussignal TR4 is failed (register 2)

Cause:
The controller detects a timeout of a periodical data exchange between FMGR (A4) and SGR (A21).
Possible reasons:
1. Intermittant CAN Problems between FMGR and SGR.
2. Short circuit in the CAN Bus.
3. Controller Hardware failure of FMGR or SGR.
4. Wrong or missing Bus terminating resistor.
5. Bent, broken or corroded pins on the Bus connectors.
6. Wrong program in the FMGR or SGR.
Solution:
Make sure that FMGR (A4) and SGR (A21) are correctly power supplied, and the SGR is online on the Bus. Check
for additional stored errors of the FMGR and the SGR to limit the possible reasons.
Failure will be stored and signaled with a warning triangle on the monitor.
1. Check supply from FMGR and SGR:
• Check FMGR potential 15/1 over A4/3 PIN10 and X24/2 (A12) PIN1 to fuse F51 10A.
• Check FMGR potential 30 over A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 7.5A and ground A4/3
PIN13.
• Check SGR potential 15/1 on X16/21 PIN13 and X24/2 (A12) PIN21 to fuse F18 5A.
• Check SGR potential 30 on X16/21 PIN12 and X24/2 (A12) PIN23 to fuse F9 (30) 10A and ground X16/21
PIN3.
If the failure occured only one time, and the error was not recorded after deleting and not detected after a testdrive
again, there is no additional check required. The operation of the vehicle is not limited.
2. If Errorcode FMGR - 63 is permanent active refer to description of FMGR - 63.
3. If several errorcodes FMGR - 32, 34 and 37 are recorded and errorcode FMGR - 47 is not active, check the SGR
for correct operation. If errorcode FMGR - 47 is active refer to description of FMGR - 47.
4. If the SGR works correctly, check the CAN Bus connection between SGR and FMGR. Please check terminals
and also the wire between FMGR connector A4/4 PIN17 (CANH) and SGR connector X16/21 PIN1 (CANH) and
A4/4 PIN18 (CANL) to SGR connector X16/21 PIN2 (CANL).
5. Check if messages of FMGR and SGR are on the local bus.
6. Check the program version of FMGR and the SGR for correct application.
7. Was a reprogramming of the SGR or FMGR terminated incorrectly, or was a controller unit changed to a wrong
program version, repeat the reprograming or replace the FMGR or SGR if required.

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FMGR - 37 Receive of local CAN Bussignal TR4 is failed (register 5)

Cause:
The controller detects a timeout of a periodical data exchange between FMGR (A4) and SGR (A21).
Possible reasons:
1. Intermittant CAN Problems between FMGR and SGR.
2. Short circuit in the CAN Bus.
3. Controller Hardware failure of FMGR or SGR.
4. Wrong or missing Bus terminating resistor.
5. Bent, broken or corroded pins on the Bus connectors.
6. Wrong program in the FMGR or SGR.
Solution:
Make sure that FMGR (A4) and SGR (A21) are correctly power supplied, and the SGR is online on the Bus. Check
for additional stored errors of the FMGR and the SGR to limit the possible reasons.
Failure will be stored and signaled with a warning triangle on the monitor.
1. Check supply from FMGR and SGR:
• Check FMGR potential 15/1 over A4/3 PIN10 and X24/2 (A12) PIN1 to fuse F51 10A.
• Check FMGR potential 30 over A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 7.5A and ground A4/3
PIN13.
• Check SGR potential 15/1 on X16/21 PIN13 and X24/2 (A12) PIN21 to fuse F18 5A.
• Check SGR potential 30 on X16/21 PIN12 and X24/2 (A12) PIN23 to fuse F9 (30) 10A and ground X16/21
PIN3.
If the failure occured only one time, and the error was not recorded after deleting and not detected after a testdrive
again, there is no additional check required. The operation of the vehicle is not limited.
2. If Errorcode FMGR - 63 is permanent active refer to description of FMGR - 63.
3. If several errorcodes FMGR - 32, 34 and 37 are recorded and errorcode FMGR - 47 is not active, check the SGR
for correct operation. If errorcode FMGR - 47 is active refer to description of FMGR - 47.
4. If the SGR works correctly, check the CAN Bus connection between SGR and FMGR. Please check terminals
and also the wire between FMGR connector A4/4 PIN17 (CANH) and SGR connector X16/21 PIN1 (CANH) and
A4/4 PIN18 (CANL) to SGR connector X16/21 PIN2 (CANL).
5. Check if messages of FMGR and SGR are on the local bus.
6. Check the program version of FMGR and the SGR for correct application.
7. Was a reprogramming of the SGR or FMGR terminated incorrectly, or was a controller unit changed to a wrong
program version, repeat the reprograming or replace the FMGR or SGR if required.

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FMGR - 47 CAN Bus OFF (transmission Bus)

Cause:
The controller detects the termination of dataexchange between FMGR and SGR
Possible reasons:
1. Intermittant Problems between FMGR and SGR.
2. Short circuit in the Bus.
3. Controller Hardware failure of FMGR or SGR.
4. Wrong or missing Bus terminating resistor.
5. Bent, broken or corroded pins on the Bus connectors.
Solution:
Make sure that FMGR and SGR are correctly power supplied. If this error is aktive, the SGR will not be shown as
online on the bus.
Failure will be stored and signaled with a warning triangle on the monitor.
1. Check supply from FMGR and SGR:
• Check FMGR potential 15/1 over A4/3 PIN10 and X24/2 (A12) PIN1 to fuse F51 10A.
• Check FMGR potential 30 over A4/3 PIN14 and X24/2 (A12) PIN6 to fuse F14 7.5A and ground A4/3
PIN13.
• Check SGR potential 15/1 on X16/21 PIN13 and X24/2 (A12) PIN21 to fuse F18 5A.
• Check SGR potential 30 on X16/21 PIN12 and X24/2 (A12) PIN23 to fuse F9 10A and ground X16/21
PIN3.
Check the connections between FMGR und SGR. Check if messages of FMGR and SGR are on the local bus.
• Check with Service Tool, if FMGR and SGR is online.
• Please check terminals and also the wire between FMGR
A4/4 PIN17 (CANH) and SGR X16/21 PIN1
(CANH) ad FMGR A4/4 PIN18 (CANL) on SGR X16/21 PIN2 (CANL).
• Remove SGR connector A21/1 and check with Service Tool if the messages of FMGR will be correct then.
If yes, local bus wire or SGR controller is defect. If not, remove the FMGR box.
2. Check the SGR for correct working and replace if required.

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FMGR - 48 Supply voltage (potential 30) too low

Cause:
The controller detects low voltage on the permanent power supply potential 30 below 9V.
Possible reasons:
1. Battery voltage low.
2. A fuse is burned.
3. Alternator regulator malfunction.
4. The controller has a bad connection to power or is not grounded properly.
Solution:
Check for fuse faults, battery voltage, alternator regulator output and the controller connection to power and ground.
Failure will be stored and signaled with a warning triangle on the monitor.
1. Check fuse F14 (30) 7.5 A at central print A12.
2. Check other ECU's for stored errors concerning low voltage.
If yes:
• Check for actual Battery voltage directly on the batterie.
• Check alternator output voltage directly on the generator terminal (B+).
If no:
• Unplug connector A4/3 of FMGR, mount adapter, measure voltage and connect a lamp (21W) between
PIN14 and PIN13 (GND) (switch ignition OFF).
• The voltage should not be under 11V. If so, switch on big electrical consumers like workinglights or fans.
If the voltage drops unter 9V, the error occured due to a low charged battery.
• If the voltage is already without extra consumers below 9V, measure voltage between PIN14 and chassis
ground. If the voltage is higher, then the failure can be found in the ground line (PIN13) else look in sup-
ply ptential 30 to PIN14. For this check harness from A4/3 PIN14 over central print connector X24/2 PIN6
to fuse F14 (30) 7.5A.

FMGR - 49 Supply voltage (potential 30) too high

Cause:
The controller detects overvoltage of more than 15V on the supply input.
Possible reasons:
1. Battery voltage over 15 V.
2. Alternator regulator malefunction.
3. The battery positive wiring is accidentially connected to external higher voltage source.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor.
• Test the alternator output and check for external power source.
• Check other ECU's for stored errorcodes.
• Check all ECU's for their proper function.
Check voltage between PIN14 (30) and PIN13 (GND) of connector A4/3 of FMGR.
If voltage isn´t higher, the FMGR is defective and has to be changed.

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FMGR - 50 Internal main switch not switchable

Cause:
The controller has a internal solid state relay. The controller tries to activate this relay, but cannot measure any voltage
on the output although there is supply voltage of more than 9V.
Possible reasons:
1. Defect of the solid state relay.
2. Shortcut of another internal part that pulls the voltage down.
Solution:
The FMGR has to be replaced, but it has to be checked that the defect was not due to external influences. Failure will
be stored and signaled with a warning triangle on the monitor.
1. Disconnect all connectors of FMGR. Measure the resistance for posiible shortcuts from all FMGR pins to ground.
There should be no direct ground connection except A4/3 PIN13. PIN10 (15/1) and PIN14 (30) can have low re-
sistance. All other should be much higher.
2. If you found a short circuit, you can try again if the FMGR is working. If not, change the FMGR.

FMGR - 51 Internal main switch permanent on

Cause:
The controller has a internal solid state relay. The controller tests before activating this relay that it is switched off.
Possible reasons:
1. Defect of the solid state relay.
2. A battery positive wiring is accidentally connected to an output.
Solution:
Before replacing the FMGR it has to be checked that the error was not due to an external fault.
Failure will be stored and signaled with a warning triangle on the monitor.
1. Check for errors FMGR 214, 218, 222 are active. If yes:
2. Unplug connectors A4/1 and A4/2 of FMGR. Clear errors, switch ignition ON again. If errors are not displayed
again, the reason can be found in the supply lines of the switches. See for description FMGR 214, 218 or 222.
3. Check for errors FMGR 202, 206, 210 or 214 are active. If yes:
4. Unplug connector A4/4 of FMGR. Clear errors, switch ignition ON again. If errors are not displayed again, the
reason can be found in the supply lines of the sensors. See for description FMGR 202, 206, 210 or 214. If these
tests are ok:
5. Unplug all connectors from FMGR and measure the voltage of all used pins to cabine ground with ignition ON.
Only A4/3 PIN10 und PIN14 should show battery voltage. On A4/3 PIN2, PIN3 and PIN4, also on A4/4 PIN17 and
PIN18 is a signal voltage. On A4/2 PIN3, PIN12, PIN15 and PIN18 is also a voltage.
6. If there is a voltage on any other line the reason has to be searched in that line according the circuit diagram.
7. Else replace the FMGR.

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FMGR - 63 Communication between FMGR/SGR is incorrect

Cause:
The FMGR (A4) and the SGR (A21) are testing each other periodically with a small calculation task. The SGR ans-
wers, but the result is different from the expected one. There is no effect to the drive function if fault occurres only
sometimes.
Possible reasons:
1. SGR has a wrong program version.
2. FMGR has a wrong program version.
3. SGR has an internal defect.
4. FMGR has an internal defect.
5. CAN Bus Problem.
6. EMC (Electro Magnetic Compatibility) Disturbance.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Because of no effect to drive function if fault
occurres only sometimes, there is no need to do something till permanent occurrence of the fault. Switch on ignition
and check with the servicetool the version numbers of the FMGR and SGR software. Make sure that they are com-
patible (same identification number).
1. SGR programmversion is too old: Reprogramming (to latest version) of SGR with the Service Tool: "Programming
Screen".
2. FMGR programmversion is too old: Reprogrammierung (to latest version) of FMGR with the Service Tool: "Pro-
gramming Screen".
3. If the program versions are correct, so check the SGR and the FMGR for additional stored faultcodes, to decide
which ECU has to be replaced: At the occurence of one of the following errors FMGR001, 002, 003, 004, 005,
008, 009, 012, 013, 014, 015, 024, 025, 026, 027, 028, 029, 030, 031 the FMGR has to be replaced, at the occu-
rence of one of the errors SGR001, 002, 003, 004, 005, 008, 009, 012, 013, 014, 015, 024, 025, 026, 027, 028,
029, 030, 031 the SGR has to be replaced.
4. If errors concerning the CAN Bus occured, like FMGR 032, 033, 034 or 047, look for the description of these
errors.
5. If no additional faults are recorded, and the FMGR works properly after clearing the errors, the problem was
caused by a unique disturbance, like EMC (Electro Magnetic Compatibility) problems. No additional repair work
has to be done, but report this to the design department.

FMGR - 64 Engine false power classification up to DBD100000

Cause:
The FMGR checks the EEM at ignition ON about the right power classification.
Possible reasons:
1. FMGR was changed and was mounted in another vehicle first.
2. EEM was changed and for another power classifiction configurated.
3. new instructions if software update.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor.
1. If the FMGR was changed, remove him with a new one, or set it back by an autorized office.
2. If the EEM2 was changed, remove him with a new one with the right power classification.
3. If fault occurres after a software update, follow the instructions which was given by the update. If there are no
usefull new instructions, contact the central customer service.

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FMGR - 64 Engine false power classification from DBD100001

Cause:
The FMGR checks the engine controller with the starter switch in the "ON" position for the configured output class.
Possible causes:
1. The FMGR was exchanged and was already built into a vehicle of a different output class.
2. The EEM was exchanged and does not correspond to the engine specification.
Remedy:
The error is stored and signalled on the display by a warning triangle.
1. If the FMGR was exchanged, replace with a new device, or have it reset by an authorized office.
2. If this EC occurs in conjunction with EEM3 - 451 remedy it first.
3. If this error occurs after a software update, follow the instructions given with this update. Should the error re-ap-
pear, contact customer service.

FMGR - 69 Engine variation impossible

Cause:
In these vehicles, an electronically controlled engine is used, where the speed variation is done via CAN Bus. The
FMGR (A4) checks the availability of engine control unit by monitoring the status information of the message Engine
Hours&Status (engine power). If this message contains error information, this error is set.
Possible reasons:
1. The engine control unit (EEM) has detected a fault, and the speed adjustment is not possible.
Solution:
Failure will be stored. Look for fault codes stored in the EEM. Clear errors of FMGR.
Refer to the according EEM Troubleshooting procedure.

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FMGR - 84 Accelerator pedal potentiometer R8 - signal voltage

(Analogue 1) above permissible range
Cause:
The signal voltage (Analogue 1) of the accelerator pedal R8 (potentiometer) is more than 4.6 V.
The fault is stored.
Possible causes:
1. The signal line is shorted to a plus line or to the potentiometer supply line.
2. The potentiometer has an internal defect. (Short circuit to supply)
3. The potentiometer or the potentiometer actuator is loose.
4. The potentiometer is not adjusted correctly.
5. The FMGR has an internal defect.
Remedy:
The accelerator pedal potentiometer R8 is mounted in front of the accelerator pedal on the outside of the cabin under
a cover. Make sure that the accelerator pedal bearing, the potentiometer actuator and the potentiometer holder are
ok.
The potentiometer adjustment is made at the bearing plate.
Use the Service Tool monitor function "ACCELERATOR PEDAL POSITION"
Use the Service Tool to display the analogue voltage 1 in accordance with the accelerator pedal position as a percen-
tage. If the potentiometer and pedal stops are adjusted correctly, the following guidelines apply:
12±2 % when the accelerator pedal is released, 75±2 % when fully depressed; the adjusting range must be at least
30%. 12% corresponds to a signal voltage of 0.7±0.1 V, 75% to a signal voltage of 4.1±0.5 V.
If the values displayed are outside the guideline values, the accelerator pedal potentiometer must be adjusted using
the Service Tool.
If the value displayed stays permanently at >94%, the Analogue 1 signal line is shorted to the potentiometer supply
line or the potentiometer is defective.
(go to step 1)
Potentiometer adjustment using the Service Tool monitor function ACCELERATOR PEDAL POSITION:
NOTE: Check the accelerator pedal home position before starting the adjustment. The accelerator pedal must be
level in the released position. If necessary, correct the adjustment by turning the rubber buffer (1) on the bearing
plate.
• Turn the ignition switch to the ON position.
• Slacken the stop pin (2) securing screw on the bearing plate. Shift the stop pin in the bearing plate so that
12% are displayed on the monitor when the accelerator pedal is not operated.
• Tighten the securing screw.
• Adjust the stop screw (3) for the "Accelerator pedal fully depressed" position so that 75% are displayed on
the monitor.
• Check the values against the guideline values mentioned above.
NOTE: After successful adjustment of the accelerator pedal potentiometer or after the potentiometer supply was
shorted to the potentiometer signal it can happen that the accelerator pedal cannot set the engine speed to the final
speed of 2300 rpm. This is not caused by mechanical reasons but results from replacing or readjusting the accelera-
tor pedal potentiometer. By constant calibration, the speed governor (FMGR) is able to suppress any effects on the
road behaviour when the mechanical setting of the accelerator pedal is changed. If the accelerator pedal potentio-
meter is replaced or readjusted, the FMGR must recalibrate the accelerator pedal potentiometer. Proceed as fol-
lows:
Turn the ignition switch to the ON position - wait 2 seconds - turn the ignition switch to the OFF position - wait 2
seconds. Repeat this process 20-30 times. Start the tractor and check whether the final speed is reached again.
If the guidelines given above are not reached, continue troubleshooting as follows:
1. Detach the plug-in connection from the accelerator pedal potentiometer R8 and connect the measuring adapter
380000062 in between. Turn the ignition switch to the ON position. Check the supply voltage (5.5±1 V) between
PIN2 and PIN1 (GND). Measure the signal voltage (Analogue 1) between PIN4 and PIN1 (GND). When the pedal
is fully depressed, you should measure max. 4.6 V here.

a) If the signal voltage (Analogue 1) exceeds 4.6 V when the pedal is fully depressed, but drops again when the
pedal is released, the accelerator pedal potentiometer must be adjusted.
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b) If the signal voltage (Analogue 1) permanently stays above 4.6 V, check the signal line from R8 X4/70 PIN4 to
A4/4 PIN3 for a short circuit. If you cannot detect a short-circuit, replace potentiometer R8.
If you cannot detect a fault in step 1, replace the FMGR.

FMGR - 85 Accelerator pedal potentiometer R8 - signal faulty

Cause:
The accelerator pedal potentiometer supplies two voltage signals with opposed directions. These are checked with
respect to their respective characteristics and continual change of values.
Possible causes:
2. Line for potentiometer signal 1 swapped with potentiometer signal 2.
3. Lines for potentiometer signal 1 and 2 are connected.
4. The potentiometer has an internal defect.
5. The FMGR has an internal defect.
Remedy:
The accelerator pedal potentiometer R8 is mounted in front of the accelerator pedal on the outside of the cabin under
a cover. Make sure that the accelerator pedal bearing, the potentiometer actuator and the potentiometer holder are
ok.
The potentiometer adjustment is made at the bearing plate.
Use the Service Tool monitor function "ACCELERATOR PEDAL POSITION"
Use the Service Tool to display the analogue voltage 1 in accordance with the accelerator pedal position as a percen-
tage. If the potentiometer and pedal stops are adjusted correctly, the following guidelines apply:
12±2 % when the accelerator pedal is released, 75±2 % when fully depressed; the adjusting range must be at least
30%. 12% corresponds to a signal voltage of 0.7±0.1 V, 75% to a signal voltage of 4.1±0.5 V.
If the values displayed are outside the guideline values, the accelerator pedal potentiometer must be adjusted using
the Service Tool. (see fault description FMGR 84)
1. Detach the plug-in connection from the accelerator pedal potentiometer R8 and connect the measuring adapter
380000062 in between. Turn the ignition switch to the ON position. Check the supply voltage (5.5±1 V) between
PIN2 and PIN1 (GND).
Measure the signal voltage (Analogue 1) between PIN4 and PIN1 (GND) and the signal voltage (Analogue 2) bet-
ween PIN3 and PIN1 when the accelerator pedal is released.
Add the two signal voltages and note down the value.
e.g.: 0.77 (Analogue 1) + 4.58 (Analogue 2) = 5.35 V

Measure the signal voltages over the entire range and note down the totals. The totals of the two signal voltages
may deviate by max. ±10%.

a) If the deviation is more than 10%, check the wiring:

Signal Analogue 1 from R8 X4/70 PIN4 to A4/4 PIN3
Signal Analogue 2 from R8 X4/70 PIN3 to A4/4 PIN6

b) If the wiring is ok, replace accelerator pedal potentiometer R8.

If you cannot detect a fault in step 1, replace the FMGR.

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FMGR - 87 Accelerator pedal potentiometer R8 - signal voltage

(Analogue 1) below permissible range
Cause:
The signal voltage (Analogue 1) of the accelerator pedal potentiometer R8 (potentiometer) is less than 0.6 V.
The fault is stored.
Possible causes:
1. Short-circuit to ground in the signal line.
2. The potentiometer has an internal defect. (Short circuit to ground)
3. The potentiometer or the potentiometer actuator is loose.
4. The potentiometer is not adjusted correctly.
5. The FMGR has an internal defect.
Remedy:
The accelerator pedal potentiometer R8 is mounted in front of the accelerator pedal on the outside of the cabin under
a cover. Make sure that the accelerator pedal bearing, the potentiometer actuator and the potentiometer holder are
ok.
The potentiometer adjustment is made at the bearing plate.
Use the Service Tool monitor function "ACCELERATOR PEDAL POSITION"
Use the Service Tool to display the analogue voltage 1 in accordance with the accelerator pedal position as a percen-
tage. If the sensor and pedal stops are adjusted correctly, the following guidelines apply:
12±2 % when the accelerator pedal is released, 75±2 % when fully depressed; the adjusting range must be at least
30%. 12% corresponds to a signal voltage of 0.7±0.1 V, 75% to a signal voltage of 4.1±0.5 V.
If the values displayed are outside the guideline values, the accelerator pedal potentiometer must be adjusted using
the Service Tool.
If the value displayed stays permanently at < 2%, the Analogue 1 signal line is shorted to ground.
(go to step 1)
Potentiometer adjustment using the Service Tool monitor function ACCELERATOR PEDAL POSITION:
NOTE: Check the accelerator pedal home position before starting the adjustment. The accelerator pedal must be
level in the released position. If necessary, correct the adjustment by turning the rubber buffer (1) on the bearing
plate.
• Turn the ignition switch to the ON position.
• Slacken the stop pin (2) securing screw on the bearing plate. Shift the stop pin in the bearing plate so that
12% is displayed on the monitor when the accelerator pedal is not operated.
• Tighten the securing screw.
• Adjust the stop screw (3) for the "Accelerator pedal fully depressed" position so that 75% are displayed on
the monitor.
• Check the values against the guideline values mentioned above.
NOTE: After successful adjustment of the accelerator pedal potentiometer or after the potentiometer supply was
shorted to the potentiometer signal it can happen that the accelerator pedal cannot set the engine speed to the final
speed of 2300 rpm. This is not caused by mechanical reasons but results from replacing or readjusting the accelera-
tor pedal potentiometer. By constant calibration, the speed governor (FMGR) is able to suppress any effects on the
road behaviour when the mechanical setting of the accelerator pedal is changed. If the accelerator pedal potentio-
meter is replaced or readjusted, the FMGR must recalibrate the accelerator pedal potentiometer. Proceed as fol-
lows:
Turn the ignition switch to the ON position - wait 2 seconds - turn the ignition switch to the OFF position - wait 2
seconds. Repeat this process 20-30 times. Start the tractor and check whether the final speed is reached again.
If the guidelines given above are not reached, continue troubleshooting as follows:
1. Detach the plug-in connection from the accelerator pedal potentiometer R8 and connect the measuring adapter
380000062 in between. Turn the ignition switch to the ON position. Check the supply voltage (5.5±1 V) between
PIN2 and PIN1 (GND). Measure the signal voltage (Analogue 1) between PIN4 and PIN1 (GND).
When the pedal is released, you should measure at least 0.6 V.

a) If the signal voltage (Analogue 1) is less than 0.6 V when the pedal is released, but rises again when the pedal
is operated, the accelerator pedal potentiometer must be adjusted.

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b) If the signal voltage (Analogue 1) permanently stays below 0.6 V, check the signal line from R8 X4/70 PIN4 to
A4/4 PIN3 for a short-circuit to ground. If you cannot detect a short-circuit, replace potentiometer R8.
If you cannot detect a fault in step 1, replace the FMGR.

FMGR - 93 Hand throttle sensor - signal incorrect

Cause:
The handthrottle signal is generated by the armrest and transfered by CAN Bus. The diagnostic is done in the armrest
and the information is transferred.
Solution:
Failure will be stored.
1. Check Errors of armrest (ARU) and repair.
2. Check the value of the handthrottle with the monitorfunktion of the Service Tool.
Use service tool monitor function:
• "ARMREST ENGINE HAND THROTTLE CONTROL".

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FMGR - 100 Clutch pedal angle of rotation sensor B17 - signal

voltage above permissible range
Cause:
The signal voltage of the angle of rotation sensor is more than 4.5 V. The fault is stored.
Possible causes:
1. The signal line is shorted to a plus line or the sensor supply line.
2. The sensor is not adjusted correctly.
3. Sensor has an internal defect (short to supply).
4. The FMGR has an internal defect.
Remedy:
The angle of rotation sensor (B17) is fitted laterally to the clutch pedal and can be adjusted using the slots in the sen-
sor housing. Make sure the clutch pedal bearing, the sensor actuator and the sensor holder are ok.
Use the Service Tool monitor function: "CLUTCH PEDAL SWITCH and CLUTCH PEDAL POSITION".
Use the Service Tool to display the signal voltage in accordance with the clutch pedal position as a percentage. If the
angle of rotation sensor and the pedal stop are adjusted correctly, the following guidelines apply:
17.5±2.5 % when the pedal is released, <75±2 % when fully depressed; the adjusting range must be at least 30%.
17.5% = 1±0.2 V and 75% = 4.1 V signal voltage
If the values displayed are outside the guideline values, the angle of rotation sensor must be adjusted using the Ser-
vice Tool.
If the value displayed stays permanently at >85%, the signal line is shorted to the sensor supply line or the sensor is
defective. (go to step 1)
Sensor adjustment using the Service Tool monitor function CLUTCH PEDAL POSITION:
Turn the ignition switch to the ON position. Slacken the screws securing the angle of rotation sensor and turn the sen-
sor so that 17.5% are displayed when the clutch pedal is not operated. Tighten the securing screws. Check the values
against the guideline values mentioned above.
NOTE: When the angle of rotation sensor has been successfully adjusted or after the sensor supply was shorted to
the sensor signal, it can happen that the transmission does not switch to neutral even if the clutch pedal is fully
depressed. This is not caused by mechanical reasons but results from replacing or readjusting the angle of rotation
sensor. By constant calibration, the speed governor (FMGR) is able to suppress any effects on the road behaviour
when the mechanical setting of the clutch pedal is changed. If the angle of rotation sensor is replaced or readjusted,
the FMGR must recalibrate the angle of rotation sensor. Proceed as follows:
Turn the ignition switch to the ON position - wait 2 seconds - turn the ignition switch to the OFF position - wait 2
seconds. Repeat this process 20-30 times. Start the tractor, preselect the driving direction and check whether the
transmission switches to neutral when the clutch pedal is operated.
If the guidelines given above are not reached, continue troubleshooting as follows:
1. Detach the plug-in connection from the angle of rotation sensor B17 and connect the measuring adapter
380000070 in between. Turn the ignition switch to the ON position. Check the 5.5±1 V supply voltage between
PIN2 and PIN1 (GND). Measure the signal voltage between PIN3 and PIN1 (GND). If the signal voltage is the
same as the supply voltage, there is a short-circuit to the sensor supply or the sensor has an internal defect.
2. Disconnect the angle of rotation sensor and check the signal line and the supply line for a short-circuit.
• Sensor supply B17, PIN2 via X24/3 PIN14 to A4/4 PIN11
• Sensor signal B17, PIN3 via X24/3 PIN15 to A4/4 PIN12
If you cannot detect a short-circuit, replace the angle of rotation sensor B17.
If you cannot detect a fault in step 1 and 2, replace the FMGR.

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FMGR - 103 Clutch pedal angle of rotation sensor B17 - signal

voltage below permissible range
Cause:
The signal voltage of the angle of rotation sensor is less than 0.5V. The fault is stored.
Possible causes:
1. Short-circuit to ground in the signal line.
2. The sensor has an internal defect (short to ground).
3. The sensor or the sensor actuator is loose.
4. The FMGR has an internal defect.
Remedy:
The angle of rotation sensor (B17) is fitted laterally to the clutch pedal and can be adjusted using the slots in the sen-
sor housing. Make sure the clutch pedal bearing, the sensor actuator and the sensor holder are ok.
Use the Service Tool monitor function: "CLUTCH PEDAL SWITCH and CLUTCH PEDAL POSITION".
Use the Service Tool to display the signal voltage in accordance with the clutch pedal position as a percentage. If the
angle of rotation sensor and the pedal stop are adjusted correctly, the following guidelines apply:
17.5±2.5 % when the pedal is released, <75±2 % when fully depressed; the adjusting range must be at least 30%.
17.5% = 1±0.2 V and 75% = 4.1 V signal voltage
If the values displayed are outside the guideline values, the angle of rotation sensor must be adjusted using the Ser-
vice Tool.
If the value displayed stays permanently at <2%, the signal line is shorted to ground or the sensor is defective. (go to
step 1)
Sensor adjustment using the Service Tool monitor function CLUTCH PEDAL POSITION:
Turn the ignition switch to the ON position. Slacken the screws securing the angle of rotation sensor and turn the sen-
sor so that 17.5% is displayed when the clutch pedal is not operated. Tighten the securing screws. Check the values
against the guideline values mentioned above.
NOTE: When the angle of rotation sensor has been successfully adjusted or after the sensor supply was shorted to
the sensor signal, it can happen that the transmission does not switch to neutral even if the clutch pedal is fully
depressed. This is not caused by mechanical reasons but results from replacing or readjusting the angle of rotation
sensor. By constant calibration, the speed governor (FMGR) is able to suppress any effects on the road behaviour
when the mechanical setting of the clutch pedal is changed. If the angle of rotation sensor is replaced or readjusted,
the FMGR must recalibrate the angle of rotation sensor. Proceed as follows:
Turn the ignition switch to the ON position - wait 2 seconds - turn the ignition switch to the OFF position - wait 2
seconds. Repeat this process 20-30 times. Start the tractor, preselect the driving direction and check whether the
transmission switches to neutral when the clutch pedal is operated.
If the guidelines given above are not reached, continue troubleshooting as follows:
1. Detach the plug-in connection from the angle of rotation sensor B17 and connect the measuring adapter
380000070 in between. Turn the ignition switch to the ON position. Check the supply voltage (approx. 5.5±1 V)
between PIN2 and PIN1 (GND). Measure the signal voltage between PIN3 and PIN1 (GND). If the signal voltage
is 0 V, there is a short-circuit to ground or the sensor has an internal defect. Disconnect the angle of rotation sen-
sor and check the ground line for a short-circuit:
Sensor signal B17, PIN3 via X24/3 PIN15 to A4/4 PIN12
Sensor ground B17, PIN1 via X24/3 PIN13 to A4/4 PIN4

If you cannot detect a short-circuit, replace the angle of rotation sensor.

If you cannot detect a fault in step 1, the FMGR is defective and must be replaced.

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FMGR - 104 Signal of plus key (+) present for too long
Cause:
The signal issued by the plus key on the multi-controller is present permanently or the key was pressed for too long
(> 5 minutes). The fault is stored.
Possible causes:
1. The key has an internal defect (does not open).
2. Incorrect operation.
Remedy:
Use the Service Tool monitor function "MULTI-CONTROLLER +KEY"
1. Cancel the fault, turn the ignition switch to the OFF position (at least 10 secs) and make sure that the key is not
operated. Turn the ignition switch to the ON position.
Read off the data value of the "MULTI-CONTROLLER +KEY" monitor function. If the data value is "ON" even if
the key is not pressed, replace the keyboard.

Replacing the keyboard:

• Remove the securing screw on the rear of the multi-controller
• Take out the keyboard and detach the plugs
• Connect the plugs to the new keyboard
• Place the keyboard in the multi-controller and secure it with a securing screw.
NOTE: Pay attention to the cable harness when inserting the keyboard. Do not shut in the cable harness!

FMGR - 105 Signal of minus key (-) present for too long
Cause:
The signal issued by the minus key on the multi-controller is present permanently or the key was pressed for too long
(> 5 minutes). The fault is stored.
Possible causes:
1. The key has an internal defect. (does not open)
2. Incorrect operation.
Remedy:
Use the Service Tool monitor function "MULTI-CONTROLLER -KEY"
1. Cancel the fault, turn the ignition switch to the OFF position (at least 10 secs) and make sure that the key is not
operated. Turn the ignition switch to the ON position.
Read off the data value of the "MULTI-CONTROLLER -KEY" monitor function. If the data value permanently stays
at "ON", there is a fault in the key or in the wiring.
Take out the keyboard and disconnect the 14-pin plug (X21) (see "Replacing the keyboard). If the data value is
still "ON", there is a short-circuit in the wiring. If the data value changes to "OFF" when the plug is disconnected,
replace the keyboard.
NOTE: When plug X21 is disconnected, faults ARU 38 and ARU 40 are activated.
Replacing the keyboard:
• Remove the securing screw on the rear of the multi-controller
• Take out the keyboard and detach the plugs
• Connect the plugs to the new keyboard
• Place the keyboard in the multi-controller and secure it with a securing screw.
NOTE: Pay attention to the cable harness when inserting the keyboard. Do not shut in the cable harness!

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FMGR - 106 Signal of cruise control OFF/resume key present for

too long
Cause:
The signal issued by the cruise control OFF/resume key on the multi-controller is present permanently or the key was
pressed for too long (> 5 minutes). The fault is stored.
Possible causes:
1. The key has an internal defect (does not open).
2. Incorrect operation.
Remedy:
Use the Service Tool monitor function
"CRUISE CONTROL OFF/RESUME KEY"
1. Cancel the fault, turn the ignition switch to the OFF position (at least 10 secs) and make sure that the key is not
operated. Turn the ignition switch to the ON position.
Read off the data value of the "CRUISE CONTROL OFF/RESUME KEY" monitor function. If the data value is
"ON" even if the key is not pressed, replace the keyboard.

Replacing the keyboard:

• Remove the securing screw on the rear of the multi-controller
• Take out the keyboard and detach the plugs
• Connect the plugs to the new keyboard
• Place the keyboard in the multi-controller and secure it with a securing screw.
NOTE: Pay attention to the cable harness when inserting the keyboard. Do not shut in the cable harness!

FMGR - 109 Signal of forwards/reverse key present for too long

Cause:
The signal issued by the forwards / reverse key on the multi-controller is present permanently or the key was pressed
for too long (> 1 minute). The fault is stored.
Possible causes:
1. The key has an internal defect (does not open).
2. Incorrect operation.
Remedy:
Use the Service Tool monitor function "FORWARDS / REVERSE KEY"
1. Cancel the fault, turn the ignition switch to the OFF position (at least 10 secs) and make sure that the key is not
operated. Turn the ignition switch to the ON position.
Read off the data value of the "FORWARDS / REVERSE KEY" monitor function. If the data value is "ON" even if
the key is not pressed, replace the keyboard.

Replacing the keyboard:

• Remove the securing screw on the rear of the multi-controller
• Take out the keyboard and detach the plugs
• Connect the plugs to the new keyboard
• Place the keyboard in the multi-controller and secure it with a securing screw.
NOTE: Pay attention to the cable harness when inserting the keyboard. Do not shut in the cable harness!

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FMGR - 112 Signal of seat switch S8 is interrupted

Cause:
The signal issued by seat switch S8 does not reach the FMGR although the driver is sitting in the driver's seat so that
switch S8 ought to be closed. The fault is activated if the driver tries at least 6 times (after starting the motor) to select
the forwards or reverse driving direction in this situation.
Possible causes:
1. The switch has an internal defect. (does not close)
2. The signal line or the supply line is interrupted.
3. Incorrect operation. (The driving direction is preselected at least 6 times, and the driver is not in the driver's seat)
4. The FMGR has an internal defect.
Remedy:
Use the Service Tool monitor function "SEAT SWITCH"
1. Cancel the fault, turn the ignition switch to the OFF position (at least 10 secs) and make sure the seat is loaded.
Turn the ignition switch to the ON position and read off the data value of the "SEAT SWITCH" monitor function.

a) If the data value is ON, start the tractor and preselect a driving direction at least 6 times. If the fault is activated
again, the FMGR must be replaced.

b) If the data value is OFF, there is a fault in the switch or in the wiring.
2. Disconnect plug X4/61 and check the clocked supply voltage (GSV3) at PIN2. The voltage should be approx.
3.1 V. If no voltage is present, check the supply line up to FMGR A4/2 PIN1.
3. Check the continuity through switch S8 using an ohmmeter.
a) If there is continuity (< 1 Ohm) when the seat is loaded and an interruption when it is not, check the signal line
from X4/61 to FMGR A4/2 PIN17.

b) If there is no continuity when the seat is loaded, check the X4/61 up to switch S8. If the wiring is ok, replace
switch S8.

FMGR - 114 Seat switch S8 - signal permanently at +

Cause:
Seat switch S8 is supplied by a clocked supply (GSV 3). The fault is active if the signal from S8 is at plus permanently.
The fault is stored.
Possible causes:
1. Short-circuit to plus in the signal line.
2. The FMGR has an internal defect.
Remedy:
Fault FMGR222 is probably also active. If faults FMGR126, 150 or 162 occur at the same time, the cause can also
be in this area as these components are also supplied by the same output.
Use the Service Tool monitor function "SEAT SWITCH"
1. Cancel the fault, turn the ignition switch to the OFF position and make sure the seat is not loaded, the handbrake
is not applied and the engine back pressure brake is not operated. Start the engine. If the fault is active again,
and faults FMGR126, 150, 162 or 222 are not active, try pinpointing the fault in the signal line of the seat switch
(see step 2 b)
NOTE: The fault can also become active sporadically again when a function which is independent of the transmis-
sion is operated. Should faults FMGR 126, 150 or 162 be active, these faults must be eliminated.
2. Disconnect plug A4/2 from the FMGR and use a voltmeter to measure the voltage across PIN17 of the plug and
GND (ground connection) at (turn the ignition switch to ON).

a) If no voltage is present, the FMGR is defective and must be replaced.

b) If a voltage is present, try pinpointing the fault in the signal line of the seat switch. (short-circuit to plus)
Check the signal line from A4/2 PIN17 via X4/61 to seat switch S8.

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FMGR - 115 Seat switch S8 - incorrect phase angle of input signal

Cause:
Seat switch S8 is supplied by a clocked supply (GSV 3). The fault is active if the signal is clocked with another supply
unit (GSV1 or GSV2). The fault is stored.
Possible causes:
1. The signal line to switch S8 is shorted to another clocked supply line.
2. The FMGR has an internal defect.
Remedy:
Faults FMGR221, 213 of 217 are probably also active. If faults FMGR127, 151 or 163 occur at the same time, the
cause can also be in this area as these components are also supplied by the same output.
Use the Service Tool monitor function "SEAT SWITCH"
1. Cancel the fault, turn the ignition switch to the OFF position and make sure the seat is not loaded, the handbrake
is not applied and the engine back pressure brake is not operated. Start the engine. If the fault is active again,
and faults FMGR121, 151, 163, 213, 217 or 221 are not active, try pinpointing the fault in the seat switch signal
line.
NOTE: The fault can also become active sporadically again when another transmission function is operated. Should
faults FMGR 127, 151 or 163 be active, these faults must be eliminated.
2. Disconnect plugs A4/1 and A4/2 from the FMGR and measure the resistance across A4/2 PIN17 and A4/1 PIN18
(GSV1) as well as across to A4/2 PIN6 (GSV2) (turn the ignition switch to OFF).

a) If no continuity is present, the FMGR is defective and must be replaced.

b) If continuity is present, try pinpointing the fault in the cable route to the seat switch. There is a short circuit in
signal line S8 to clocked supply 1 or 2.
Check the signal line from A4/2 PIN17 via X4/61 to seat switch S8.

FMGR - 116 Steering brake inductive switch - signal doesn't change

Cause:
The Signal on this Input is permanently on, off or activated too long, although there should be a different input signal
due to the driving situation.
Possible causes:
1. Wire to the switch (S25) has short to correct pulsed supply.
2. Connector on the switch is loose and touches the pulsed supply.
3. Switch has an internal defect, don´t opened anytime.
4. Incorrect vehicle handling (driver acivates steering brake longer than 2 min.).
5. Failure occured by repair or rework.
Solution:
Failure will be stored. The most occurences of this error will be a defective switch or a broken wire. In some cases
the error can be caused by mishandling of the vehicle (try to activate the steeringbrake for more than 2 minutes).
1. Clear error records, Switch ignition OFF (for at min.10 sec.), switch Ignition ON again and start engine, wait for
at minimum 2 minutes. If error is active again, then the defect can be found in the way to the steeringbrake switch.
2. If the error doesn't occur again, the detection was due to a mishandling of the vehicle. Use service tool monitor
function:
- "STEERING BRAKE SWITCH".
3. Unplug connector A4/2 of FMGR and measure resistance between PIN14 and PIN6, operate steeringbrake and
release. There must be a contact, when steeringbrake is in use and released open. If this works correctly, the
FMGR has to be replaced, else the error is on the way to the steeringbrake switch.
4. Please check wiring between A4/2 PIN14 over X24/3 PIN4 to S25 and X4/14 PIN3.
5. Check wiring of GSV2 between A4/2 PIN6 over X24/3 PIN12 to S25 X4/14 PIN1.

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FMGR - 118 Steering brake inductive switch - signal permanent On

(instead PWM)
Cause:
The Signal on this Input is permanently powered, although there should be a pulsed supply.
Possible causes:
1. Wire to the switch (S25) has short to power.
2. Connector on the switch is loose and touches a power terminal.
3. Caused by another defect of a unit in the same pulsed supply circuit.
4. Switch with two supplies (e.g. illumination) has an internal defect.
5. Failure occured by repair or rework.
6. FMGR Controller failure.
Solution:
Failure will be stored. The most occurences of this error will be after repair work, or after installation of option. Check
these possibilities first. In most cases also error FMGR218 will be active.

If Errors FMGR122, 158, 170, 174, 178 or FMGR 182 are recorded, the reason can be found also in that circuits,
because these components are supplied by the same pulsed power output.
1. Clear error records, Switch ignition OFF, make sure that the steeringbrake, the clutchpedal and the shuttle lever
S4/4 (V/R/N) are not used. Switch ignition ON and start engine. If error is active again, and errors FMGR122, 158,
170, 174, 178, 182 or 218 are not activ, the defect can be found in the way to the steeringbrake switch.
NOTE: the error can also be only temporary if other vehicle fuctions are use that are not part of the transmission
control!
If error FMGR122, 158, 170, 174, 178 or 182 is activ, look for these error codes.
2. Disconnect connector A4/2 on the FMGR, check with voltage meter on PIN14 of the connector voltage to ground
(Ignition ON). Use service tool monitor function: - "STEERING BRAKE SWITCH".
Can no voltage be read out, then there is a defect of the FMGR and this unit has to be replaced.
3. If there is voltage, the error can be found in the circuit down to the steeringbrake switch.
4. Please check wiring between A4/2 PIN14 over X24/3 PIN4 to S25
X4/14 PIN3.
5. Check wiring GSV 2 between A4/2 PIN6 over X24/3 PIN12 to S25 X4/14 PIN1.

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FMGR - 119 Steering brake inductive switch - input signal with

wrong circuit
Cause:
The Signal on this Input has a different timing of the pulsed supply as it is assumed.
Possible causes:
1. Wire to the swich has short to another pulsed supplyline.
2. Connector on the switch is loose and touches another pulsed supplyline.
3. Caused by another defect of a unit in the same pulsed supply circuit.
4. Failure occured by repair or rework.
5. FMGR Controller failure.
Solution:
Failure will be stored. The most occurences of this error will be after repair work, or after installation of option. Check
these possibilities first. In most cases also errors FMGR217 and 213 or 221 will be active. If errors FMGR123, 159,
171, 175, 179 or 183 are recorded, the reason can be found also in that circuit, because this components are supplied
by the same pulsed power output.
1. Clear error records, Switch ignition OFF, make sure that the the steeringbrake, the clutchpedal and the shuttle
lever S4/4 (V/R/N) are not used. Switch ignition ON and start engine. If error is active again, and errors FMGR123,
159, 171, 175, 179, 183 or 217 are not activ, the defect can be found in the way to the steeringbrake switch.
NOTE: the error can also be only temporary if other transmission fuctions are activated!
If errors FMGR123, 159, 171, 175, 179, 183 oder 217 are activ, look for these errors code.
2. Disconnect connector A4/1 and A4/2 on the FMGR, check with ohmmeter on A4/2 PIN14 of the connector the
resistance to A4/1 PIN18 (GSV 1) and A4/2 PIN1 (GSV 3) (Ignition OFF). Use service tool monitor function: -
"STEERING BRAKE SWITCH".
Can no connection be read out, then there is a defect of the FMGR and this unit has to be replaced.
3. If there is a connection, the error can be found in the circuit down to the steeringbrake switch.
4. Please check wiring between A4/2 PIN14 over X24/3 PIN4 to S25
X4/14 PIN1.
5. Check wiring GSV2 between A4/2 PIN6 over X24/3 PIN12 to S25 X4/14 PIN1.

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FMGR - 120 Stop light switch - signal doen't change

Cause:
The Signal on this Input is permanently on, off or activated too long, although there should be a different input signal
due to the driving situation.
Possible causes:
1. Wire to the switch (S5) has short to correct pulsed supply
2. Connector on the switch is loose and touches the supply line or is free.
3. Switch has an internal defect, don´t open anytime
4. Incorrect vehicle handling (use brake longer than 5min.).
5. Failure occured by repair or rework.
6. FMGR Controller failure.
Solution:
Failure will be stored. The most occurences of this error will be a defective switch or a broken wire. In some cases
the error can be caused by mishandling of the vehicle (try to activate the servicebrake for more than 5 minutes).
1. Clear error records, Switch ignition OFF (for at min.10 sec.), switch Ignition ON again and start engine, wait for
at minimum 2 minutes. If error is active again, then the defect can be found in the way to the stoplight switch.
2. If the error does't occur again, the detection was due to a mishandling of the vehicle. Use service tool monitor
function:
• "STOP LAMP SWITCH".
3. Unplug connector A4/2 of FMGR and measure resistance between PIN13 and PIN6, apply servicebrake and re-
lease. There must be a contact, when servicebrake is in use and released open. If this works correctly, the FMGR
has to be replaced, else the error is on the way to the stoplight switch.
4. For this check wire from A4/2 PIN13 over X24/3 PIN5 to S5
X4/14 PIN2.
5. Check wiring GSV 2 between A4/2 PIN6 over X24/3 PIN12 to S25 X4/14 PIN1.

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FMGR - 122 Stop switch - signal permanent On instead of press

ratio (PWM)
Cause:
The Signal on this Input is permanently powered, although there should be a pulsed supply.
Possible causes:
1. Wire to the switch (S5) has short to power.
2. Connector on the switch is loose and touches a power terminal.
3. Caused by another defect of a unit in the same pulsed supply circuit.
4. Switch with two supplies (e.g. illumination) has an internal defect.
5. Failure occured by repair or rework.
6. FMGR Controller failure.
Solution:
Failure will be stored. The most occurences of this error will be after repair work, or after installation of option. Check
these possibilities first. In most cases also error FMGR218 will be active. If Errors FMGR118, 158, 170, 174, 178 or
FMGR182 are recorded, the reason can be found also in that circuits, because these components are supplied by
the same pulsed power output.
1. Clear error records, Switch ignition OFF, make sure that the brake, the clutchpedal and the shuttle lever S4/4 (V/
R/N) are not used. Switch ignition ON and start engine. If error is active again, and errors FMGR118, 158, 170,
174, 178, 182 or 218 are not activ, the defect can be found in the way to the steeringbrake switch.
NOTE: the error can also be only temporary if other vehicle fuctions are use that are not part of the transmission
control! If error FMGR118, 158, 170, 174, 178 or 182 is activ, look for these error codes.
Use service tool monitor function:
• "STOP LAMP SWITCH".
2. Disconnect connector A4/2 on the FMGR, check with voltage meter on PIN13 of the connector voltage to ground
(Ignition ON). Can no voltage be read out, then there is a defect of the FMGR and this unit has to be replaced.
3. If there is voltage, the error can be found in the circuit down to the stop light switch.
4. For this check wire from A4/2 PIN13 over X24/3 PIN5 to S5
X4/14 PIN2.
5. Check wiring GSV 2 between A4/2 PIN6 over X24/3 PIN12 to S25 X4/14 PIN1.

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FMGR - 123 Stop switch - input signal On with wrong circuit

Cause:
The Signal on this Input has a different timing of the pulsed supply as it is assumed.
Possible causes are:
1. Wire to the switch (S5) has short to another pulsed supplyline.
2. Connector on the switch is loose and touches another pulsed supplyline.
3. Caused by another defect of a unit in the same pulsed supply circuit.
4. Failure occured by repair or rework.
5. FMGR Controller failure.
Solution:
Failure will be stored. The most occurences of this error will be after repair work, or after installation of option. Check
these possibilities first. In most cases also errors FMGR217 and 213 or 221 will be active.

If errors FMGR119, 159, 171, 175, 179 or 183 are recorded, the reason can be found also in that circuit, because this
components are supplied by the same pulsed power output.
1. Clear error records, Switch ignition OFF, make sure that the the brake, the clutchpedal and the shuttle lever
S4/4 (V/R/N) are not used. Switch ignition ON and start engine. If error is active again, and errors FMGR119, 159,
171, 175, 179, 183 or 217 are not active, the defect can be found in the way to the stoplight switch.
NOTE: the error can also be only temporary if other transmission fuctions are activated! If errors FMGR119, 159,
171, 175, 179, 183 oder 217 are active, look for these error codes.
Use service tool monitor function:
• "STOP LAMP SWITCH".
2. Disconnect connector A4/1 and A4/2 on the FMGR, check with ohmmeter on A4/2 PIN13 of the connector the
resistance to A4/1 PIN18 and A4/2 PIN1 (Ignition OFF). Can no connection be read out, then there is a defect of
the FMGR and this unit has to be replaced.
3. If there is a connection, the error can be found in the circuit down to the stoplightswitch.
4. For this check wire from A4/2 PIN13 over X24/3 PIN5 to S5
X4/14 PIN2.
5. Check wiring GSV 2 between A4/2 PIN6 over X24/3 PIN12 to S25 X4/14 PIN1.

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FMGR - 124 Parking brake switch S21 - signal permanently present

Cause:
The signal from switch S21 is permanently present. The fault is activated after driving off more than 10 times. The
fault can also be activated by incorrect operation (driving off more than 10 times with the parking brake applied). The
fault is stored.
Possible causes:
1. Signal line from switch S21 has a short-circuit to correctly clocked supply.
2. Switch S21 has an internal defect. (does not open)
3. Incorrect operation.
4. The FMGR has an internal defect.
Remedy:
Use the Service Tool monitor function "PARKING BRAKE SWITCH"
1. Cancel the fault and turn the ignition switch to the OFF position for at least 10 secs. Start the engine and drive off
briefly at least 10 times with the parking brake released.

a) If the fault is activated again, then check switch S21, the signal line or the FMGR. (see step 2)

b) If the fault does not reoccur, then it was caused by incorrect operation.
2. Disconnect plug A4/2 on the FMGR and measure the resistance between PIN16 and PIN1 on the plug; apply and
release the parking brake.

a) If there is continuity with the parking brake applied and an interruption when released, then the FMGR must
be replaced.

b) If there is permanent continuity, then the fault is in the signal line or in switch S21.
3. Check the cabling between A4/2 PIN16 via X4/25 PIN1 to switch S21 and repair, if necessary. If the cabling is ok,
then switch S21 must be replaced.

FMGR - 126 Parking brake switch S21 - signal permanently at +

Cause:
The parking brake switch S21 is supplied by a clocked supply (GSV 3). The fault is active if the signal issued by S21
is at plus permanently. The fault is stored.
Possible causes:
1. Short-circuit to plus in the signal line of switch S21.
2. The FMGR has an internal defect.
Remedy:
Fault FMGR222 is probably also active. If faults FMGR114, 150 or 162 occur at the same time, the cause can also
be in this area as these components are also supplied by the same output.
Use the Service Tool monitor function "PARKING BRAKE SWITCH"
1. Cancel the fault, turn the ignition switch to the OFF position and make sure the seat is not loaded, the parking
brake is not applied and the engine back pressure brake is not operated. Start the engine. If the fault is active
again, and faults FMGR114, 150, 162 or 222 are not active, try pinpointing the fault in the signal line to S21 (see
step 2 b)
NOTE: The fault can also become active sporadically again when a function which is independent of the transmis-
sion is operated. Should faults FMGR 114, 150 or 162 be active, these faults must be eliminated.
2. Disconnect plug A4/2 from the FMGR and use a voltmeter to measure the voltage across PIN16 of the plug and
GND (ground connection) at (turn the ignition switch to ON).

a) If no voltage is present, the FMGR is defective and must be replaced.

b) If a voltage is present, try pinpointing the fault in the signal line of S21. (short-circuit to plus)
Check the signal line from A4/2 PIN16 via X4/25 to switch S21.

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FMGR - 127 Parking brake switch S21 - incorrect phase angle of

input signal
Cause:
The parking brake switch S21 is supplied by a clocked supply (GSV 3). The fault is active if the signal is clocked with
another supply unit (GSV1 or GSV2). The fault is stored.
Possible causes:
1. The signal line to switch (S21) is shorted to another clocked supply line.
2. The FMGR has an internal defect.
Remedy:
Faults FMGR221, 213 or 217 are probably also active. If faults FMGR115, 151 or 163 occur at the same time, the
cause can also be in this area as these components are also supplied by the same output.
1. Cancel the fault, turn the ignition switch to the OFF position and make sure the seat is not loaded, the parking
brake is not applied and the engine back pressure brake is not operated. Start the engine. If the fault is active
again, and faults FMGR115, 151, 163, 213, 217 or 221 are not active, try pinpointing the fault in the signal line of
switch S21.
NOTE: The fault can also become active sporadically again when another transmission function is operated. Should
faults FMGR 115, 151 or 163 be active, these faults must be eliminated.
2. Disconnect plugs A4/1 and A4/2 from the FMGR and measure the resistance across A4/2 PIN16 and A4/1 PIN18
(GSV 1) as well as A4/2 PIN6 (GSV 2) (turn the ignition switch to OFF).

a) If no continuity is present, the FMGR is defective and must be replaced.

b) If continuity is present, try pinpointing the fault in the cable route to switch S21. There is a short circuit in signal
line S21 to the GSV 1 or 2.
Check the signal line from A4/2 PIN16 via X4/25 to switch S21.

FMGR - 130 Manual mode switch - signal permanently at +

Cause:
The signal at this input is permanently plus, even though it should be clocked.
The fault is stored.
Possible causes:
1. Short-circuit to plus in the signal line.
2. The FMGR has an internal defect.
Remedy:
Fault FMGR214 is probably also active. If faults FMGR134, 138, 142, 186, or 190 occur at the same time, the cause
can also be in this area as these components are also clocked by the same control unit output.
Use the Service Tool monitor function "MANUAL MODE"
1. Cancel the fault, turn the ignition switch to the OFF position and make sure the Manual mode and 4-wheel drive
switches are in position 0 and the Speed range switch in position 3. Start the engine. If the fault is activated again,
and faults FMGR138, 142, 186, 190, or 214 are not active, try pinpointing the fault in the signal line to Manual
mode switch S2/58/2.
NOTE: The fault can also become active sporadically again when a function which is independent of the transmis-
sion is operated. Should faults FMGR134, 138, 142, 186, or 190 be active, then these faults must be eliminated.
2. Disconnect plug A4/1 from the FMGR and use a voltmeter to measure the voltage to GND (ground connection)
at PIN5 of the plug (turn the ignition switch to ON).

a) If no voltage is present, the FMGR is defective and must be replaced.

b) If a voltage is present, try pinpointing the fault in the signal line from switch S2/58/2. (Short-circuit to plus)
Check the signal line from A4/1 PIN5 via X24/5 PIN8 to S2/58/2 PIN1.

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FMGR - 131 Manual mode switch - incorrect phase angle of

input signal
Cause:
The signal at this input is clocked differently than planned.
The fault is stored.
Possible causes:
1. The switch cable has a short-circuit to another clocked supply line.
2. The FMGR has an internal defect.
Remedy:
Faults FMGR213, 217 or 221 are probably also active. If faults FMGR139, 143, 187 or 191 occur at the same time,
the cause can also be in this area as these components are also clocked by the same control unit output.
Use the Service Tool monitor function "MANUAL MODE"
1. Cancel the fault, turn the ignition switch to the OFF position and make sure the Manual mode and 4-wheel drive
switches are in position 0 and the Speed range switch in position 3. Start the engine. If the fault is activated again,
and FMGR139, 143, 187, 191 or 213 are not active, try pinpointing the fault in the signal line to Manual mode
switch S2/58/2.
NOTE: The fault can also become active sporadically again when a function which is independent of the transmis-
sion is operated. Should faults FMGR139, 143, 187, 191 or 213 be active, then these faults must be eliminated.
2. Disconnect plugs A4/1 and A4/2 from the FMGR and measure the resistance from A4/1 PIN5 to A4/2 PIN1
(GSV 3) and PIN6 (GSV 2) (ignition switch in OFF position).

a) If there is no continuity, the FMGR is defective and must be replaced.

b) If there is continuity, then check for a fault in the cable to switch S2/58/2. There is a short circuit in the signal
line to GSV 3 or 2.
Check the signal line from A4/1 PIN5 via X24/5 PIN8 to S2/58/2 PIN1.

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FMGR - 138 Switch MFD Management - Signal permanent On

(instead PWM)
Cause:
The Signal on this Input is permanently powered, although there should be a pulsed supply.
Possible causes are:
1. Wire to the switch (S2/59) has short to power.
2. Connector on the switch is loose and touches a power terminal.
3. Caused by another defect of a unit in the same pulsed supply circuit.
4. Switch with two supplies (e.g. illumination) has an internal defect.
5. Failure occured by repair or rework.
6. FMGR Controller failure.
Solution:
Failure will be stored. The most occurences of this error will be after repair work, or after installation of option. Check
these possibilities first. In most cases also error FMGR214 will be active. If Errors FMGR130, 134, 142, 186 or
FMGR190 are recorded, the reason can be found also in that circuits, because these components are supplied by
the same pulsed power output.
1. Clear error records, switch ignition OFF, make sure that there is manual mode switch S2/58/2, speed range 1
switch S2/58/1 and the MFD switch S2/59 are not ON. Switch ignition ON and start engine. If error is active again,
and errors FMGR130, 134, 142, 186, 190 or 214 are not activ, the defect can be found in the way to the MFD
switch.
NOTE: the error can also be only temporary if other vehicle fuctions are use that are not part of the transmission
control! If error FMGR130, 134, 142, 186 or 190 is activ, look for these error codes.
Use service tool monitor function:
• "MFD SWITCH MANAGEMENT"
• "MFD SWITCH ON"
• "FMGR-SGR AWD OFF"
• "FMGR AWD ENGAGED"
• "FMGR AWD MODE".
2. Disconnect connector A4/1 on the FMGR, check with voltage meter on PIN1 of the connector voltage to ground
(Ignition ON). Can no voltage be read out, then there is a defect of the FMGR and this unit has to be replaced.
3. If there is voltage, the error can be found in the circuit down to the MFD switch (Connection Management).
• Check wiring from A4/1 PIN1 over X24/5 PIN3 to S2/59 PIN5.
• Check wiring GSV 1 from S2/59 PIN3 over X10/4 PIN1 and X14/4 PIN8 to A4/1 PIN18.

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FMGR - 139 Switch MFD Management - Input Siganl with

wrong circuit
Cause:
The Signal on this Input has a different timing of the pulsed supply as it is assumed.
Possible causes are:
1. Wire to the switch (S2/59) has short to another pulsed supplyline.
2. Connector on the switch is loose and toughes another pulsed supplyline.
3. Caused by another defect of a unit in the same pulsed supply circuit.
4. Failure occured by repair or rework.
5. FMGR Controller failure.
Solution:
Failure will be stored. The most occurences of this error will be after repair work, or after installation of option. Check
these possibilities first. In most cases also errors FMGR213 and FMGR217 or FMGR221 will be active.

If errors FMGR131, 135, 143, 187 or 191 are recorded, the reason can be found also in that circuit, because this com-
ponents are supplied by the same pulsed power output.
1. Clear error records, switch ignition OFF, make sure that there is manual mode switch S2/58/2, speed range 1
switch S2/58/1 and the MFD switch S2/59 are not ON. Switch ignition ON and start engine. If error is active again,
and errors FMGR131, 135, 143, 187, 191 or 213 are not activ, the defect can be found in the way to the MFD
switch.
NOTE: the error can also be only temporary if other transmission fuctions are activated! If errors FMGR131, 135,
143, 187, 191 or 213 are activ, look for these errors code.
Use service tool monitor function:
• "MFD SWITCH MANAGEMENT"
• "MFD SWITCH ON"
• "FMGR-SGR AWD OFF"
• "FMGR AWD ENGAGED"
• "FMGR AWD MODE".
2. Disconnect connector A4/1 and A4/2 on the FMGR, check with ohmmeter on A4/1 PIN1 of the connector the re-
sistance to and A4/2 PIN1 and PIN6 (Ignition OFF). Can no connection be read out, then there is a defect of the
FMGR and this unit has to be replaced.
3. If there is a connection, the error can be found in the circuit down to the MFD switch (range Management).
• Check wiring from A4/1 PIN1 over X24/5 PIN3 to S2/59 PIN5.
• Check wiring GSV 1 from S2/59 PIN3 over X10/4 PIN1 and X14/4 PIN8 to A4/1 PIN18.

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FMGR - 142 Switch MFD ON - signal permanent On (instead PWM)

Cause:
The Signal on this Input is permanently powered, although there should be a pulsed supply.
Possible causes are:
1. Wire to the switch (S2/59) has short to power.
2. Connector on the switch is loose and touches a power terminal.
3. Caused by another defect of a unit in the same pulsed supply circuit.
4. Switch with two supplies (e.g. illumination) has an internal defect.
5. Failure occured by repair or rework.
6. FMGR Controller failure.
Solution:
Failure will be stored. The most occurences of this error will be after repair work, or after installation of option. Check
these possibilities first. In most cases also error FMGR214 will be active.

If Errors FMGR130, 134, 138, 186 or FMGR190 are recorded, the reason can be found also in that circuits, because
these components are supplied by the same pulsed power output.
1. Clear error records, switch ignition OFF, make sure that there is manual mode switch S2/58/2, speed range 1
switch S2/58/1 and the MFD switch S2/59 are not ON. Switch ignition ON and start engine. If error is active again,
and errors FMGR130, 134, 138, 186, 190 or 214 are not activ, the defect can be found in the way to the MFD
switch.
NOTE: the error can also be only temporary if other vehicle fuctions are use that are not part of the transmission
control! If error FMGR130, 134, 138, 186 or 190 is activ, look for these error codes.
Use service tool monitor function:
- "MFD SWITCH MANAGEMENT"
- "MFD SWITCH ON"
- "FMGR-SGR AWD OFF"
- "FMGR AWD ENGAGED"
- "FMGR AWD MODE".
2. Disconnect connector A4/1 on the FMGR, check with voltmeter on PIN2 of the connector voltage to ground (Igni-
tion ON). Can no voltage be read out, then there is a defect of the FMGR and this unit has to be replaced.
3. If there is voltage, the error can be found in the circuit down to the MFD switch (Connection ON).
- Check wiring from A4/1 PIN2 over X24/5 PIN4 to S2/59 PIN1.
- Check wiring GSV 1 from S2/59 PIN3 over X10/4 PIN1 and X14/4 PIN8 to A4/1 PIN18.

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FMGR - 143 Switch MFD ON - input signal with wrong circuit

Cause:
The Signal on this Input has a different timing of the pulsed supply as it is assumed.
Possible causes are:
1. Wire to the switch (2/59) has short to another pulsed supply line.
2. Connector on the switch is loose and touches another pulsed supply line.
3. Caused by another defect of a unit in the same pulsed supply circuit.
4. Failure occured by repair or rework.
5. FMGR Controller failure.
Solution:
Failure will be stored. The most occurences of this error will be after repair work, or after installation of option. Check
these possibilities first. In most cases also errors FMGR213 and FMGR217 or FMGR221 will be active.

If errors FMGR131, 135, 139, 187 or 191 are recorded, the reason can be found also in that circuit, because this com-
ponents are supplied by the same pulsed power output.
1. Clear error records, Switch ignition OFF, make sure that there is manual mode switch S2/58/2, speed range 1
switch S2/58/1 and the MFD switch S2/59 are not ON. Switch ignition ON and start engine. If error is active again,
and errors FMGR131, 135, 139, 187, 191 or 213 are not activ, the defect can be found in the way to the MFD
switch.
NOTE: the error can also be only temporary if other transmission fuctions are activated! If errors FMGR131, 135,
139, 187, 191 or 213 are activ, look for these errors code.
Use service tool monitor function:
• "MFD SWITCH MANAGEMENT"
• "MFD SWITCH ON"
• "FMGR-SGR AWD OFF"
• "FMGR AWD ENGAGED"
• "FMGR AWD MODE".
2. Disconnect connector A4/1 and A4/2 on the FMGR, check with ohmmeter on A4/1 PIN2 of the connector the re-
sistance to A4/1 PIN18 and A4/2 PIN1 (Ignition OFF). Can no connection be read out, then there is a defect of
the FMGR and this unit has to be replaced.
3. If there is a connection, the error can be found in the circuit down to the MFD switch (range ON).
• Check wiring from A4/1 PIN2 over X24/5 PIN4 to S2/59 PIN1.
• Check wiring GSV 1 from S2/59 PIN3 over X10/4 PIN1 and X14/4 PIN8 to A4/1 PIN18.

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FMGR - 150 Reversible seat switch S8/2 (with reversing facility) -

signal permanently at +
Cause:
Reversible seat switch S8/2 (for version with reversing facility) is supplied by a clocked supply (GSV 3). The fault is
activated if the signal from S8/2 is permanently at plus. The fault is stored.
Possible causes:
1. Short-circuit to plus in the signal line.
2. The FMGR has an internal defect.
Remedy:
Fault FMGR222 is probably also active. If faults FMGR114, 126 or 162 occur at the same time, the cause can also
be in this area as these components are also supplied by the same output.
1. Cancel the fault, turn the ignition switch to the OFF position and make sure the seat is not loaded (the seat is
positioned in the forward driving direction if the vehicle is fitted with a reversing facility), the handbrake is not ap-
plied and the engine back pressure brake is not operated. Start the engine. If the fault is activated again, and
faults FMGR114, 126, 162 or 222 are not active, try pinpointing the fault in the signal line to switch S8/2.
(see step 2b)
NOTE: The fault can also become active sporadically again when a function which is independent of the transmis-
sion is operated. Should faults FMGR 114, 126 or 162 be active, these faults must be eliminated.
2. Disconnect plug A4/1 from the FMGR and use a voltmeter to measure the voltage to GND (ground connection)
at PIN4 of the plug (turn the ignition switch to ON).

a) If no voltage is present, the FMGR is defective and must be replaced.

b) If a voltage is present, try pinpointing the fault in the seat switch signal line. (Short-circuit to plus)
Check the signal line from A4/1 PIN4 via X6/58 and X6/27 to seat switch S8/2.

FMGR - 151 Reversible seat switch S8/2 (with reversing facility) -

incorrect phase angle of input signal
Cause:
Reversible seat switch S8/2 is supplied by a clocked supply (GSV 3). The fault is active if the signal is clocked with
another supply unit (GSV1 or GSV2). The fault is stored.
Possible causes:
1. The signal line to switch S8/2 is shorted to another clocked supply line.
2. The FMGR has an internal defect.
Remedy:
Faults FMGR221, 213 of 217 are probably also active. If faults FMGR115, 127 or 163 occur at the same time, the
cause can also be in this area as these components are also supplied by the same output.
1. Cancel the fault, turn the ignition switch to the OFF position and make sure the seat is not loaded (the seat is
positioned in the forward driving direction if the vehicle is fitted with a reversing facility), the handbrake is not ap-
plied and the engine back pressure brake is not operated. Start the engine. If the fault is activated again, and
faults FMGR115, 163, 213, 217 or 221 are not active, try pinpointing the fault in the signal line to switch S8/2.
NOTE: The fault can also become active sporadically again when another transmission function is operated. Should
faults FMGR 115, 127 or 163 be active, these faults must be eliminated.
2. Disconnect plugs A4/1 and A4/2 from the FMGR and measure the resistance from A4/1 PIN4 to A4/1 PIN18
(GSV 1) as well as to A4/2 PIN6 (GSV 2) (turn the ignition switch to OFF).

a) If no continuity is present, the FMGR is defective and must be replaced.

b) If continuity is present, try pinpointing the fault in the cable route to switch S8/2. There is a short-circuit in signal
line S8/2 to GSV 1 or 2.
Check the signal line from A4/1 PIN4 via X6/58 and X6/27 to seat switch S8/2.

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FMGR - 156 Clutch switch 80% signal doesn't change

Cause:
Signal on this input is permanently on, off or activated too long, although there should be a different input signal due
to the driving situation
Possible reasons:
1. Wire to switch (S46) has short to correct pulsed supply, or is interrupted.
2. Connector on switch is loose and touches the pulsedsupply line, or is free.
3. Switch has an internal defect, don´t open, or close anytime.
4. Incorrect vehicle handling.
5. Failure occured by repair or rework.
6. FMGR controller failure.
Solution:
Failure will be stored after 5 minutes. The most occurences of this error will be a defective switch, or a broken wire.
In some cases the error can be caused by mishandling of the vehicle (try to activate the clutch for more than
5 minutes).
1. Clear error records, switch ignition OFF (for at min.10 sec.), switch Ignition ON again and start engine, wait for at
minimum 1 minute. If error is active again, then the defect can be found in the way to the clutch switch 75%.
2. If the error doesn't occur again, the detection was due to a misshandling of the vehicle.
Use service tool monitor function:
• "CLUTCH PEDAL SWITCH (80% TRAVEL)",
• "CLUTCH PEDAL POSITION".
3. Unplug connector A4/1 and A4/2 of FMGR and measure resistance between A4/1 PIN15 and A4/2 PIN6, press
clutchpedal fully and release. There must be a contact, when clutchpedal is pressed and released open. If this
works correctly, the FMGR has to be replaced, else the error is on the way to the clutch switch 80%.
• Check wiring between A4/1 PIN15 over X24/3 PIN24 to S46 PIN2.
• Check wiring GSV 2 form S46 PIN1 to X24/3 PIN12 and A4/2 PIN6.

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FMGR - 157 Clutch switch 80% plausibility with clutch sensor not
provided
Cause:
The input switchover signal is not in the tolerant range (compared with the clutch sensor) or does not happen.
Possible causes:
1. The switch cable has a short-circuit to the correctly clocked supply or is interrupted.
2. The plug is loose, touches the clocked supply or is free.
3. The switch (S46) is defective or never closes / opens.
4. The switch is not operated mechanically.
5. Incorrectly adjusted during conversion or not / incorrectly calibrated.
6. Clutch sensor or FMGR defective.
Remedy:
The most frequent occurrence of this fault will be a faulty switch or an interrupted line. In some cases, the switch or
clutch sensor B17 may also be incorrectly adjusted or the clutch sensor may be defective. When a fault occurs, the
cruise control is deactivated and the fault is stored and indicated by a warning triangle on the display.
1. Cancel the fault and turn the ignition switch to the OFF position for at least 10 secs. Turn the ignition switch to the
ON position again and press the clutch pedal right down. (at least at least 10 secs.)
Then turn the ignition switch to the OFF position and wait 2 secs.
2. If the fault does not reoccur, then it may be a vibration problem that only occurs when driving. If the clutch pedal
functions perfectly when driving, keep an eye on it until it is certain that the malfunction was a one-off occurrence.
Use the Service Tool monitor function:
• "CLUTCH PEDAL SWITCH"
• "CLUTCH PEDAL POSITION"
3. Repeat calibration. Refer to calibration instructions in the Configuration menu item.
4. If the fault continues to occur, disconnect plugs A4/1 and A4/2 on the FMGR and measure the resistance between
A4/1 PIN15 and A4/2 PIN6; fully engage and then release the clutch. There must be continuity when the clutch
is operated and an interruption when it is not. The changeover must be effected at approx. 80% of the pedal travel.
If this functions properly, the clutch sensor must be checked. See sensor setting - fault FMGR100. If there is no
fault here either, then the FMGR must be replaced, otherwise the fault lies in the cable to the clutch switch (80%).
5. Check the cabling:
• Check the signal cabling between A4/1 PIN15 via X24/3 PIN24 to S46 PIN2.
• Check the GSV 2 cabling from S46 PIN1 to X24/3 PIN12 to A4/2 PIN6.

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FMGR - 158 Clutch switch 75% signal permanent on (instead PWM)

Cause:
The Signal on this Input is permanently powered, although there should be a pulsed supply.
Possible reasons:
1. Wire to the switch has short to power.
2. Connector on the switch (S46) is loose and touches a power terminal.
3. Caused by another defect of a unit in the same pulsed supply circuit.
4. Switch with two supplies (e.g. illumination) has an internal defect.
5. Failure occured by repair or rework.
6. FMGR Controller failure.
Solution:
Failure will be stored. The most occurences of this error will be after repair work, or after installation of option. Check
these possibilities first. In most cases also error FMGR218 will be active.
If Errors FMGR118, 122, 162, 170, 174, 178 or FMGR182 are recorded, the reason can be found also in that circuits,
because these components are supplied by the same pulsed power output.
1. Clear error records, Switch ignition OFF, make sure that the brake, the clutchpedal, the exhaust brake and the
shuttle lever S4/4 (V/R/N) are not used. Switch ignition ON and start engine. If error is active again, and errors
FMGR118, 122, 162, 170, 174, 178, 182 or 218 are not activ, the defect can be found in the way to the clutch
switch 75%.
NOTE: the error can also be only temporary if other vehicle fuctions are use that are not part of the transmission
control! If error FMGR118, 122, 162, 170, 174, 178 or 182 is activ, look for these error codes.
2. Disconnect connector A4/1 on the FMGR, check with voltmeter on PIN15 of the connector voltage to ground (Igni-
tion ON). Can no voltage be read out, then there is a defect of the FMGR and this unit has to be replaced. Use
service tool monitor function:
• "CLUTCH PEDAL SWITCH (75% TRAVEL)"
• "CLUTCH PEDAL POSITION".
3. If there is voltage, the error can be found in the circuit down to the clutch switch 75%.
4. Check wiring:
• Check the signal cabling between A4/1 PIN15 via X24/3 PIN24 to S46 PIN2.
• Check wiring GSV 2 from S46 PIN1 to X24/3 PIN12 and A4/2 PIN6.

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FMGR - 159 Clutch switch 75% input signal with wrong circuit
Cause:
The Signal on this Input has a different timing of the pulsed supply as it is assumed.
Possible reasons:
1. Wire to the switch has short to another pulsed supply line.
2. Connector on the switch is loose and touches another pulsed supply line.
3. Caused by another defect of a unit in the same pulsed supply circuit.
4. Failure occured by repair or rework.
5. FMGR Controller failure.
Solution:
Failure will be stored. The most occurences of this error will be after repair work, or after installation of option. Check
these possibilities first. In most cases also errors FMGR217 and 213 or 221 will be active.
If errors FMGR119, 123, 163, 171, 175, 179 or 183 are recorded, the reason can be found also in that circuit, because
this components are supplied by the same pulsed power output.
1. Clear error records, Switch ignition OFF, make sure that the the brake, the clutchpedal, the exhaust brake and
the shuttle lever S4/4 (V/R/N) are not used. Switch ignition ON and start engine. If error is active again, and errors
FMGR119, 123, 163, 171, 175, 179, 183 or 217 are not activ, the defect can be found in the way to the clutch
switch 75%.
NOTE: the error can also be only temporary if other transmission fuctions are activated!
If errors FMGR119, 123, 163, 171, 175, 179, 183 oder 217 are activ, look for these error codes.
2. Disconnect connector A4/1 and A4/2 on the FMGR, check with ohmmeter on A4/1 PIN15 of the connector the
resistance to A4/1 PIN18 and A4/2 PIN1. (Ignition OFF). Can no connection be read out, then there is a defect of
the FMGR and this unit has to be replaced. Use service tool monitor function:
• "CLUTCH PEDAL SWITCH (75% TRAVEL)"
• "CLUTCH PEDAL POSITION".
3. Check wiring:
• Check the signal cabling between A4/1 PIN15 via X24/3 PIN24 to S46 PIN2.
• Check wiring GSV 2 from S46 PIN1 to X24/3 PIN12 and A4/2 PIN6.

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FMGR - 160 Engine back pressure brake switch S20 - signal

permanently present
Cause:
The signal from switch S20 is permanently present. The fault is also activated if the engine back pressure brake is
operated for longer than 5 mins. The fault is stored.
Possible causes:
1. Signal line from switch S20 has a short-circuit to correctly clocked supply. (GSV3)
2. Switch S20 has an internal defect. (does not open)
3. Incorrect operation.
4. The FMGR has an internal defect.
Remedy:
Use the Service Tool monitor function "ENGINE BACK PRESSURE BRAKE SWITCH"
1. Cancel the fault and turn the ignition switch to the OFF position for at least 10 secs. Start the engine and wait for
at least 5 minutes.
a) If the fault is activated again, then check switch S20, the signal line or the FMGR. (see step 2)

b) If the fault does not reoccur, then it was caused by incorrect operation.
2. Disconnect plugs A4/1 and A4/2 on the FMGR and measure the resistance between A4/1 PIN3 and A4/2 PIN1
on the plug; fully apply and release the engine back pressure brake.
a) If there is continuity when the engine back pressure brake is applied and an interruption when released, then
the FMGR must be replaced.

b) If there is permanent continuity, then the fault is in the signal line or in switch S20.
3. Check the cabling from A4/1 PIN3 to S20 and repair it, if necessary.

FMGR - 162 Engine back pressure brake switch S20 - signal

permanently at +
Cause:
The engine back pressure brake switch S20 is supplied by a clocked supply (GSV 3). The fault is active if the signal
issued by switch S20 is at plus permanently.
The fault is stored.
Possible causes:
1. Short-circuit to plus in the signal line.
2. The FMGR has an internal defect.
Remedy:
Fault FMGR 222 is probably also active. If faults FMGR114, 126 or 150 occur at the same time, the cause can also
be in this area as these components are also supplied by the same output.
Use the Service Tool monitor function "ENGINE BACK PRESSURE BRAKE SWITCH"
1. Cancel the fault, turn the ignition switch to the OFF position and make sure the seat is not loaded, the handbrake
is not applied and the engine back pressure brake is not operated. Start the engine. If the fault is active again,
and faults FMGR114, 126, 150 or 222 are not active, try pinpointing the fault in the signal line of the engine back
pressure brake S20 (see step 2 b)
NOTE: The fault can also become active sporadically again when a function which is independent of the transmis-
sion is operated. Should faults FMGR 114, 126 or 150 be active, these faults must be eliminated.
2. Disconnect plug A4/1 from the FMGR and use a voltmeter to measure the voltage against GND (ground connec-
tion) at PIN3 of the plug (turn the ignition switch to ON).

a) If no voltage is present, the FMGR is defective and must be replaced.

b) If a voltage is present, try pinpointing the fault in the signal line of the engine back pressure brake switch. (short-
circuit to plus)
Check the signal line from A4/1 PIN3 to the engine back pressure switch S20.

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FMGR - 163 Engine back pressure brake switch S20 - incorrect

phase angle of input signal
Cause:
The engine back pressure brake switch S20 is supplied by a clocked supply (GSV 3). The fault is active if the signal
is clocked with another supply unit (GSV1 or GSV2). The fault is stored.
Possible causes:
1. The signal line of switch S20 is shorted to another clocked supply line.
2. The FMGR has an internal defect.
Remedy:
Faults FMGR 217 and FMGR 213 or FMGR 221 are probably also active. If faults FMGR115, 127 or 151 occur at the
same time, the cause can also be in this area as these components are also supplied by the same output.
1. Cancel the fault, turn the ignition switch to the OFF position and make sure the seat is not loaded, the handbrake
is not applied and the engine back pressure brake is not operated. Start the engine. If the fault is active again,
and faults FMGR115, 127, 151 or 221 are not active, try pinpointing the fault in the signal line of the engine back
pressure brake switch S20.
NOTE: The fault can also become active sporadically again when another transmission function is operated. Should
faults FMGR 115, 127, 151 or 221 be active, these faults must be eliminated.
2. Disconnect plugs A4/1 and A4/2 from the FMGR and measure the resistance of A4/1 PIN3 against A4/1 PIN18
(GSV 1) as well as A4/2 PIN6 (GSV 2) (turn the ignition switch to OFF).
a) If no continuity is present, the FMGR is defective and must be replaced.

b) If continuity is present, try pinpointing the fault in the cable route to the engine back pressure brake switch.
There is a short circuit in the signal line S20 to the GSV 1 or 2.
Check the signal line from A4/1 PIN3 to the engine back pressure switch S20.

FMGR - 164 Parklock ON - signal On too long

Cause:
The Signal on this Input is permanently on or off or activated too long, although there should be a different input signal
due to the driving situation.
Possible reasons:
1. Wire to the switch has short to correct pulsed supply or is interrupted.
2. Connector on the switch S2/61 is loose and touches the pulsed supply line or is free.
3. Switch has an internal defect, don´t open or close anytime.
4. Incorrect vehicle handling.
5. False connected by rework.
6. FMGR Controller failure
Solution:
Failure will be stored. The most occurences of this error will be a defective switch or a broken wire. In some cases
the error can be caused by misshandling of the vehicle (activate parking lock mor than 10 sec.).
1. Clear error records, switch ignition OFF (for at min.10 sec.), switch Ignition ON again and start engine, wait for at
minimum 10 sec. If error is active again, then the defect can be found in the way to the parking lock switch. Use
service tool monitor function:
• "FMGR-SGR PARKING LOCK ".
2. If the error doesn't occur again, the detection was due to a misshandling of the vehicle.
3. Unplug connector A4/1 and A4/2 of FMGR and measure resistance between A4/1 PIN13 and A4/2 PIN6, activate
parking lock switch S2/61 and release . There must be a contact, when parking lock is avtivated and released
open. If this works correctly, the FMGR has to be replaced, else the error is on the way to the parking lock switch.
• Check wiring from A4/1 PIN13 to X24/3 PIN18 and switch S2/61 PIN3.
• Check wiring pulsed supply 2 switch S2/61 PIN1 to X24/3 PIN15 and A4/2 PIN6.

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FMGR - 166 Parklock ON - signal permanent On (instead PWM)

Cause:
The Signal on this Input is permanently powered, although there should be a pulsed supply.
Possible reasons:
1. Wire to the switch has short to power.
2. Connector on the switch S2/61 is loose and touches a power terminal.
3. Caused by another defect of a unit in the same pulsed supply circuit.
4. Switch with two supplies (e.g. illumination) has an internal defect.
5. False connected by rework.
6. FMGR Controller failure.
Solution:
Failure will be stored. The most occurences of this error will be after repair work, or after installation of option. Check
these possibilities first. In most cases also error FMGR218 will be active. If Errors FMGR118, 122, 158, 170, 174 or
FMGR178 are recorded, the reason can be found also in that circuits, because these components are supplied by
the same pulsed power output.
1. Clear error records, switch ignition OFF, make sure that the brake, the clutchpedal and the shuttle lever S4/4
(V/R/N) are not used. Switch ignition ON and start engine. If error is active again, and errors FMGR118, 122, 158,
170, 174, 178 or 218 are not activ, the defect can be found in the way to the parking lock switch S2/61.
NOTE: the error can also be only temporary if other vehicle functions are use which are not part of the transmission
control!
If error FMGR118, 122, 158, 170, 174 or 178 is activ, look for these error codes. Use service tool monitor function:
• "FMGR-SGR PARKING LOCK ".
2. Disconnect connector A4/1 on the FMGR, check with voltmeter on PIN13 of the connector voltage to ground (Igni-
tion ON). Can no voltage be read out, then there is a defect of the FMGR and this unit has to be replaced.
3. If there is voltage, the error can be found in the circuit down to the parking lock switch.
• Check wiring from A4/1 PIN13 to X24/3 PIN18 and switch S2/61 PIN3.
• Check wiring GSV 2 switch S2/61 PIN1 to X24/3 PIN12 and A4/2 PIN6.

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FMGR - 167 Parklock ON - input signal with wrong circuit

Cause:
The Signal on this Input has a different timing of the pulsed supply as it is assumed.
Possible reasons:
1. Wire to the switch has short to another pulsed supply line.
2. Connector on the switch (S2/61) is loose and touches another pulsed supply line.
3. Caused by another defect of a unit in the same pulsed supply circuit.
4. False connected by rework.
5. FMGR Controller failure.
Solution:
Failure will be stored. The most occurences of this error will be after repair work, or after installation of option. Check
these possibilities first. In most cases also errors FMGR217 and 213 or 221 will be active.
If errors FMGR119, 123, 159, 171, 175 or 179 are recorded, the reason can be found also in that circuit, because this
components are supplied by the same pulsed power output.
1. Clear error records, switch ignition OFF, make sure that the the brake, the clutchpedal and the shuttle lever S4/4
(V/R/N) are not used. Switch ignition ON and start engine. If error is active again, and errors FMGR119, 123, 159,
171, 175, 179 or 217 are not activ, the defect can be found in the way to the parking lock switch S2/61.
NOTE: the error can also be only temporary if other transmission functions are activated!
If errors FMGR119, 123, 159, 171, 175, 179 or 217 are activ, look for these error codes. Use service tool monitor
function:
• "FMGR-SGR PARKING LOCK ".
2. Disconnect connector A4/1 and A4/2 on the FMGR, check with ohmmeter on A4/1 PIN13 of the connector the
resistance to A4/1 PIN18 and A4/2 PIN1 (Ignition OFF). Can no connection be read out, then there is a defect of
the FMGR and this unit has to be replaced.
3. If there is a connection, the error can be found in the circuit down to the parking lock switch.
• Check wiring from A4/1 PIN13 to X24/3 PIN18 and switch S2/61 PIN3.
• Check wiring GSV 2 switch S2/61 PIN1 to X24/3 PIN12 and A4/2 PIN6.

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FMGR - 168 Signal of "Forward driving direction" shuttle lever

present for too long
Cause:
The signal issued by the shuttle lever S4/4 in the forward position is present permanently or the lever was operated
for too long (> 1 minute). The fault is stored.
Possible causes:
1. The signal line is shorted to the clocked supply 2 (GSV2).
2. The switch has an internal defect. (does not open)
3. Incorrect operation.
4. The FMGR has an internal defect.
Remedy:
Use the Service Tool monitor function "SHUTTLE LEVER FORWARDS"
1. Cancel the fault, turn the ignition switch to the OFF position (at least 10 secs) and make sure that the shuttle lever
S4/4 is not operated. Turn the ignition switch to the ON position and read off the data value of the " SHUTTLE
LEVER FORWARDS" monitor function.

a) If the shuttle lever is not operated, the data value must be "OFF" and must be "ON" when the lever is shifted
to forwards. If this is the case, the fault was probably caused by incorrect operation. (The shuttle lever was ope-
rated > 1 minute)

b) If the data value is permanently "ON", the signal line is shorted to the power supply (GSV2), or the switch has
an internal defect (does not open). Go to step 2.
2. Detach plug X6/3 from the steering column switch and read off the data value of the "SHUTTLE LEVER
FORWARDS" monitor function.

a) If the data value stays "ON", the signal line is shorted to the power supply (GSV2).
Check whether the signal line is shorted to GSV2.
From X6/3, PIN5 via the Limp Home plug connection X4/59/a, PIN1 to X24/3, PIN7 to A4/2, PIN11

If you do not detect a short-circuit, replace the FMGR.

b) If the data value changes to "OFF" when you disconnect plug X6/3, the fault is caused by the shuttle lever
S4/4 or the wiring between X6/3 and S4/4.
If the wiring is ok, the shuttle lever S4/4 must be replaced.

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FMGR - 170 Switch forward - signal permanent On (instead PWM)

Cause:
The Signal on this Input is permanently powered, although there should be a pulsed supply.
Possible reasons:
1. Wire to the switch has short to power.
2. Connector on the switch S4/4 is loose and touches a power terminal.
3. Caused by another defect of a unit in the same pulsed supply circuit.
4. Switch with two supplies (e.g. illumination) has an internal defect.
5. False connected by rework.
6. FMGR has internal failure.
Solution:
Failure will be stored. The most occurences of this error will be after repair work, or after installation of option. Check
these possibilities first. In most cases also error FMGR218 will be active. If Errors FMGR118, 122, 158, 174, 178 or
FMGR182 are recorded, the reason can be found also in that circuits, because these components are supplied by
the same pulsed power output.
1. Clear error records, Switch ignition OFF, make sure that the brake, the clutchpedal and the shuttle lever (V/R/N)
are not used. Switch ignition ON and start engine. If error is active again, and errors FMGR118, 122, 158, 174,
178, 182 or 218 are not activ, the defect can be found in the way to the shuttle lever S4/4.
NOTE: the error can also be only temporary if other vehicle fuctions are use that are not part of the transmission
control!
If error FMGR118, 122, 158, 174, 178 or 182 is activ, look for these error codes. Use service tool monitor function:
• "FMGR-SGR REVERSE COMMAND "
• "FMGR FORWARD SELECTED"
• "FMGR FORWARD ACTUAL"
• "FMGR REVERSE SELECTED"
• "FMGR REVERSE ACTUEL"
• "DEAD MAN SWITCH - STEERING COLUMN"
• "FORWARD SWITCH - STEERING COLUMN"
• "REVERSE SWITCH - STEERING COLUMN"
• "NEUTRAL SWITCH - STEERING COLUMN"
2. Disconnect connector A4/2 on the FMGR, check with voltmeter on PIN11 of the connector voltage to ground (Igni-
tion ON). Can no voltage be read out, then there is a defect of the FMGR and this unit has to be replaced.
3. If there is voltage, the error can be found in the circuit down to the shuttle lever (forward).
4. Check wiring:
• Check wiring between A4/2 PIN10 over X24/3 PIN7 to Limp Home connection X4/59/a, PIN1 and foward
to X6/3 PIN5.
• Check wiring GSV 2 from X6/3 PIN1 to Limp Home connection X4/59/a PIN2 to X24/3 PIN12 and A4/2
PIN6.

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FMGR - 171 Switch forward - input signal with wrong circuit

Cause:
The Signal on this Input has a different timing of the pulsed supply as it is assumed.
Possible reasons:
1. Wire to the switch has short to another pulsed supplyline.
2. Connector on the switch S4/4 is loose and touches another pulsed supplyline.
3. Caused by another defect of a unit in the same pulsed supply circuit.
4. False connected by rework.
5. FMGR Controller failure.
Solution:
Failure will be stored. The most occurences of this error will be after repair work, or after installation of option. Check
these possibilities first. In most cases also errors FMGR217 and 213 or 221 will be active. If errors FMGR119, 123,
159, 175, 179 or 183 are recorded, the reason can be found also in that circuit, because this components are supplied
by the same pulsed power output.
1. Clear error records, Switch ignition OFF, make sure that the the brake, the clutchpedal and the shuttle Lever (V/
R/N) are not used. Switch ignition ON and start engine. If error is active again, and errors FMGR119, 123, 159,
175, 179, 183 or 217 are not activ, the defect can be found in the way to the shuttle lever S4/4.
NOTE: the error can also be only temporary if other transmission fuctions are activated!
If errors FMGR119, 123, 159, 175, 179, 183 oder 217 are activ, look for these errors code. Use service tool mo-
nitor function:
• "FMGR-SGR REVERSE COMMAND "
• "FMGR FORWARD SELECTED"
• "FMGR FORWARD ACTUAL"
• "FMGR REVERSE SELECTED"
• "FMGR REVERSE ACTUEL"
• "DEAD MAN SWITCH - STEERING COLUMN"
• "FORWARD SWITCH - STEERING COLUMN"
• "REVERSE SWITCH - STEERING COLUMN"
• "NEUTRAL SWITCH - STEERING COLUMN"
2. Disconnect connector A4/1 and A4/2 on the FMGR, check with ohmmeter on A4/2 PIN11 of the connector the
resistance to A4/1 PIN18 and A4/2 PIN1 (Ignition OFF). Can no connection be read out, then there is a defect of
the FMGR and this unit has to be replaced.
3. If there is a connection, the error can be found in the circuit down to the shuttle lever (forward).
4. Check wiring:
• Check wiring between A4/2 PIN10 over X24/3 PIN7 to Limp Home connection X4/59/a, PIN1 and X6/3
PIN5.
• Check wiring GSV 2 from X6/3 PIN1 to Limp Home connection X4/59/a PIN2 to X24/3 PIN12 and A4/2
PIN6.

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FMGR - 172 Signal of "Reverse driving direction" shuttle

lever present for too long
Cause:
The signal issued by the shuttle lever S4/4 in the reverse position is present permanently or the lever was operated
for too long (> 1 minute). The fault is stored.
Possible causes:
1. The signal line is shorted to the clocked supply 2 (GSV2).
2. The switch has an internal defect. (does not open)
3. Incorrect operation.
4. The FMGR has an internal defect.
Remedy:
Use the Service Tool monitor function "SHUTTLE LEVER REVERSE"
1. Cancel the fault, turn the ignition switch to the OFF position (at least 10 secs) and make sure that the shuttle lever
is not operated. Turn the ignition switch to the ON position and read off the data value of the " SHUTTLE LEVER
REVERSE" monitor function.

a) If the shuttle lever is not operated, the data value must be "OFF" and must be "ON" when the lever is shifted
to reverse. If this is the case, the fault was probably caused by incorrect operation. (The shuttle lever was opera-
ted > 1 minute)

b) If the data value is permanently "ON", the signal line is shorted to the power supply (GSV2), or the switch has
an internal defect (does not open). Go to step 2.
2. Detach plug X6/3 from the steering column switch and read off the data value of the "SHUTTLE LEVER RE-
VERSE" monitor function.

a) If the data value stays "ON", the signal line is shorted to the power supply (GSV2).
Check whether the signal line is shorted to GSV2.
From X6/3, PIN6 via the Limp Home plug connection X4/59/a, PIN3 to X24/3, PIN8 to A4/2, PIN10

If you do not detect a short-circuit, replace the FMGR.

b) If the data value changes to "OFF" when you disconnect plug X6/3, the fault is caused by the shuttle lever
S4/4 or the wiring between X6/3 and S4/4.
If the wiring is ok, the shuttle lever S4/4 must be replaced.

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FMGR - 174 Switch reverse - signal permanent On (instead PWM)

Cause:
The Signal on this Input is permanently powered, although there should be a pulsed supply.
Possible causes are:
1. Wire to the switch has short to power.
2. Connector on the switch S4/4 is loose and touches a power terminal.
3. Caused by another defect of a unit in the same pulsed supply circuit.
4. False connected by rework.
5. FMGR has internal failure.
Solution:
Failure will be stored. The most occurences of this error will be after repair work, or after installation of option. Check
these possibilities first. In most cases also error FMGR218 will be active. If Errors FMGR118, 122, 158, 170, 178 or
FMGR182 are recorded, the reason can be found also in that circuits, because these components are supplied by
the same pulsed power output.
1. Clear error records, Switch ignition OFF, make sure that the brake, the clutchpedal and the shuttle lever (V/R/N)
are not used. Switch ignition ON and start engine. If error is active again, and errors FMGR118, 122, 158, 170,
178, 182 or 218 are not activ, the defect can be found in the way to the shuttle lever S4/4.
NOTE: the error can also be only temporary if other vehicle fuctions are use that are not part of the transmission
control!
If error FMGR118, 122, 158, 170, 178 or 182 is activ, look for these error codes.
Use service tool monitor function:
• "FMGR-SGR REVERSE COMMAND "
• "FMGR FORWARD SELECTED"
• "FMGR FORWARD ACTUAL"
• "FMGR REVERSE SELECTED"
• "FMGR REVERSE ACTUEL"
• "DEAD MAN SWITCH - STEERING COLUMN"
• "FORWARD SWITCH - STEERING COLUMN"
• "REVERSE SWITCH - STEERING COLUMN"
• "NEUTRAL SWITCH - STEERING COLUMN"
2. Disconnect connector A4/2 on the FMGR, check with voltage meter on PIN10 of the connector voltage to ground
(Ignition ON). Can no voltage be read out, then there is a defect of the FMGR and this unit has to be replaced.
3. If there is voltage, the error can be found in the circuit down to the shuttle lever (backward).
4. Check wiring:
• Check wiring between A4/2 PIN10 over X24/3 PIN7 to Limp Home connection X4/59/a, PIN3 and forward
to X6/3 PIN6.
• Check wiring GSV 2 from X6/3 PIN1 to Limp Home connection X4/59/a PIN2 to X24/3 PIN12 and A4/2
PIN6.

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FMGR - 175 Switch reverse - input signal with wrong circuit

Cause:
The Signal on this Input has a different timing of the pulsed supply as it is assumed.
Possible reasons:
1. Wire to the switch has short to another pulsed supplyline.
2. Connector on the switch S4/4 is loose and touches another pulsed supplyline.
3. Caused by another defect of a unit in the same pulsed supply circuit.
4. False connected by rework.
5. FMGR Controller failure.
Solution:
Failure will be stored. The most occurences of this error will be after repair work, or after installation of option. Check
these possibilities first. In most cases also errors FMGR217 and 213 or 221 will be active. If errors FMGR119, 123,
159, 171, 179 or 183 are recorded, the reason can be found also in that circuit, because this componenta are supplied
by the same pulsed power output.
1. Clear error records,switch ignition OFF, make sure that the the brake, the clutchpedal and the shuttle lever (V/R/
N)are not used. Switch ignition ON and start engine. If error is active again, and errors FMGR119, 123, 159, 171,
179, 183 or 217 are not activ, the defect can be found in the way to the shuttle lever S4/4.
NOTE: the error can also be only temporary if other transmission fuctions are activated!
If errors FMGR119, 123, 159, 171, 179, 183 oder 217 are activ, look for these errors code.
Use service tool monitor function:
• "FMGR-SGR REVERSE COMMAND "
• "FMGR FORWARD SELECTED"
• "FMGR FORWARD ACTUAL"
• "FMGR REVERSE SELECTED"
• "FMGR REVERSE ACTUEL"
• "DEAD MAN SWITCH - STEERING COLUMN"
• "FORWARD SWITCH - STEERING COLUMN"
• "REVERSE SWITCH - STEERING COLUMN"
• "NEUTRAL SWITCH - STEERING COLUMN"
2. Disconnect connector A4/1 and A4/2 on the FMGR, check with ohmmeter on A4/2 PIN10 of the connector the
resistance to A4/1 PIN18 and A4/2 PIN1 (Ignition OFF). Can no connection be read out, then there is a defect of
the FMGR and this unit has to be replaced.
3. If there is a connection, the error can be found in the circuit down to the shuttle lever (reverse).
4. Check wiring:
• Check wiring between A4/2 PIN10 over X24/3 PIN8 to Limp Home connection X4/59/a, PIN3 and forward
to X6/3 PIN6.
• Check wiring GSV 2 from X6/3 PIN1 to Limp Home connection X4/59/a PIN2 to X24/3 PIN12 and A4/2
PIN6.

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FMGR - 176 Signal of "neutral button" on the shuttle lever present

for too long
Cause:
The signal issued by the shuttle lever S4/4 in the "neutral" position is present permanently or the button was operated
for too long (> 1 minute). The fault is stored.
Possible causes:
1. The signal line is shorted to the clocked supply 2 (GSV2).
2. The button has an internal defect. (does not open)
3. Incorrect operation.
4. The FMGR has an internal defect.
Remedy:
Use the Service Tool monitor function "NEUTRAL BUTTON ON SHUTTLE LEVER"
1. Cancel the fault, turn the ignition switch to the OFF position (at least 10 secs) and make sure that the neutral
button on the shuttle lever is not operated. Turn the ignition switch to the ON position and read off the data value
of the "NEUTRAL BUTTON ON THE SHUTTLE LEVER" monitor function.

a) If the button is not operated, the data value must be "OFF" and must be "ON" when the lever is shifted to re-
verse. If this is the case, the fault was probably caused by incorrect operation. (The button lever was operated >
1 minute)

b) If the data value is permanently "ON", there is a short-circuit between the signal line and the power supply
(GSV2), or the button has an internal defect (does not open). Go to step 2.
2. Detach plug X6/3 from the shuttle lever and read off the data value of the "NEUTRAL BUTTON ON THE SHUTT-
LE LEVER" monitor function.

a) If the data value stays "ON", the signal line is shorted to the power supply (GSV2). Check whether the signal
line is shorted to GSV2:
From X6/3, PIN3 via X24/3 PIN10 to A4/2, PIN8

If you do not detect a short-circuit, replace the FMGR.

b) If the data value changes to "OFF" when you disconnect plug X6/3, the fault is caused by the shuttle lever
S4/4 or the wiring between X6/3 and S4/4.
If the wiring is ok, the shuttle lever S4/4 must be replaced.

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FMGR - 178 Switch neutral - signal permanent On (instead PWM)

Cause:
The Signal on this Input is permanently powered, although there should be a pulsed supply.
Possible causes are:
1. Wire to the switch has short to power.
2. Connector on the switch S4/4 is loose and touches a power terminal.
3. Caused by another defect of a unit in the same pulsed supply circuit
4. False connected by rework.
5. FMGR Controller failure.
Solution:
Failure will be stored. The most occurences of this error will be after repair work, or after installation of option. Check
these possibilities first. In most cases also error FMGR218 will be active. If Errors FMGR118, 122, 158, 170, 174 or
FMGR182 are recorded, the reason can be found also in that circuits, because these components are supplied by
the same pulsed power output.
1. Clear error records, switch ignition OFF, make sure that the brake, the clutchpedal and the shuttle lever (V/R/N)
are not used. Switch ignition ON and start engine. If error is active again, and errors FMGR118, 122, 158, 170,
174, 182 or 218 are not activ, the defect can be found in the way to the shuttle lever S4/4.
NOTE: the error can also be only temporary if other vehicle fuctions are use that are not part of the transmission
control!
If error FMGR118, 122, 158, 170, 174 or 182 is activ, look for these error codes.
Use service tool monitor function:
• "FMGR-SGR REVERSE COMMAND "
• "FMGR FORWARD SELECTED"
• "FMGR FORWARD ACTUAL"
• "FMGR REVERSE SELECTED"
• "FMGR REVERSE ACTUEL"
• "DEAD MAN SWITCH - STEERING COLUMN"
• "FORWARD SWITCH - STEERING COLUMN"
• "REVERSE SWITCH - STEERING COLUMN"
• "NEUTRAL SWITCH - STEERING COLUMN"
2. Disconnect connector A4/2 on the FMGR, check with voltage meter on PIN8 of the connector voltage to ground
(Ignition ON). Can no voltage be read out, then there is a defect of the FMGR and this unit has to be replaced.
3. If there is voltage, the error can be found in the circuit down to the shuttle lever (neutral).
4. Check wiring.
• Check wiring between A4/2 PIN8 over X24/3 PIN10 to X6/3 PIN3.
• Check wiring pulsed supplyGSV 2 from X6/3 PIN4 to X24/3 PIN12 and A4/2 PIN6.

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FMGR - 179 Switch neutral - input signal with wrong circuit

Cause:
The Signal on this Input has a different timing of the pulsed supply as it is assumed.
Possible reasons:
1. Wire to the switch has short to another pulsed supplyline.
2. Connector on the switch S4/4 is loose and touches another pulsed supplyline.
3. Caused by another defect of a unit in the same pulsed supply circuit.
4. False connected by rework.
5. FMGR Controller failure.
Solution:
Failure will be stored. The most occurences of this error will be after repair work, or after installation of option. Check
these possibilities first. In most cases also errors FMGR217 and 213 or 221 will be active. If errors FMGR119, 123,
159, 171, 175 or 183 are recorded, the reason can be found also in
1. Clear error records, switch ignition OFF, make sure that the the brake, the clutchpedal and the shuttle lever
(V/R/N) are not used. Switch ignition ON and start engine. If error is active again, and errors FMGR119, 123, 159,
171, 175, 183 or 217 are not activ, the defect can be found in the way to the shuttle lever S4/4.
NOTE: the error can also be only temporary if other transmission fuctions are activated!
If errors FMGR119, 123, 159, 171, 175, 183 oder 217 are activ, look for these errors code.
Use service tool monitor function:
• "FMGR-SGR REVERSE COMMAND "
• "FMGR FORWARD SELECTED"
• "FMGR FORWARD ACTUAL"
• "FMGR REVERSE SELECTED"
• "FMGR REVERSE ACTUEL"
• "DEAD MAN SWITCH - STEERING COLUMN"
• "FORWARD SWITCH - STEERING COLUMN"
• "REVERSE SWITCH - STEERING COLUMN"
• "NEUTRAL SWITCH - STEERING COLUMN"
2. Disconnect connector A4/1 and A4/2 on the FMGR, check with ohmmeter on A4/2 PIN8 of the connector the re-
sistance to A4/1 PIN18 and A4/2 PIN1 (Ignition OFF). Can no connection be read out, then there is a defect of
the FMGR and this unit has to be replaced.
3. If there is a connection, the error can be found in the circuit down to the shuttle lever (neutral).
4. Check wiring.
• Check wiring between A4/2 PIN8 over X24/3 PIN10 to X6/3 PIN3.
• Check wiring GSV 2 from X6/3 PIN4 to X24/3 PIN12 and A4/2 PIN6.

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FMGR - 180 Signal of "Shuttle lever raised" present for too long
Cause:
The signal issued by the shuttle lever S4/4 in the raised position (dead man function) is present permanently or the
lever was operated for too long (> 1 minute). The fault is stored.
Possible causes:
1. The signal line is shorted to the clocked supply 2 (GSV2).
2. The switch has an internal defect. (does not open)
3. Incorrect operation.
4. The FMGR has an internal defect.
Remedy:
Use the Service Tool monitor function "SHUTTLE LEVER RAISED"
1. Cancel the fault, turn the ignition switch to the OFF position (at least 10 secs) and make sure that the shuttle lever
is not operated. Turn the ignition switch to the ON position and read off the data value of the " SHUTTLE LEVER
RAISED" monitor function.

a) If the shuttle lever is not operated, the data value must be "OFF" and must be "ON" when the lever is raised.
If this is the case, the fault was probably caused by incorrect operation. (The shuttle lever was raised > 1 minute)

b) If the data value is permanently "ON", the signal line is shorted to the power supply (GSV2), or the switch has
an internal defect (does not open). Go to step 2.
2. Detach plug X6/3 from the shuttle lever and read off the data value of the "SHUTTLE LEVER RAISED" monitor
function.

a) If the data value stays "ON", the signal line is shorted to the power supply (GSV2). Check whether the signal
line is shorted to GSV2:
From X6/3 PIN2 via X24/3 PIN11 to A4/2, PIN7

If you do not detect a short-circuit, replace the FMGR.

b) If the data value changes to "OFF" when you disconnect plug X6/3, the fault is caused by the shuttle lever
S4/4 or the wiring between X6/3 and S4/4.
If the wiring is ok, the shuttle lever S4/4 must be replaced.

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FMGR - 182 Switch deadman - signal permanent On (instead PWM)

Cause:
The Signal on this Input is permanently powered, although there should be a pulsed supply.
Possible reasons:
1. Wire to the switch has short to power.
2. Connector on the switch S4/4 is loose and touches a power terminal.
3. Caused by another defect of a unit in the same pulsed supply circuit.
4. False connected by rework.
5. FMGR Controller failure.
Solution:
Failure will be stored. The most occurences of this error will be after repair work, or after installation of option. Check
these possibilities first. In most cases also error FMGR218 will be active. If Errors FMGR118, 122, 158, 170, 174 or
FMGR178 are recorded, the reason can be found also in that circuits, because these components are supplied by
the same pulsed power output.
1. Clear error records, switch ignition OFF, make sure that the brake, the clutchpedal and the shuttle lever are not
used. Switch ignition ON and start engine. If error is active again, and errors FMGR118, 122, 158, 170, 174, 178
or 218 are not activ, the defect can be found in the way to the shuttle lever S4/4.
NOTE: the error can also be only temporary if other vehicle fuctions are use that are not part of the transmission
control!
If error FMGR118, 122, 158, 170, 174 or 178 is activ, look for these error codes.
Use service tool monitor function:
• "FMGR-SGR REVERSE COMMAND "
• "FMGR FORWARD SELECTED"
• "FMGR FORWARD ACTUAL"
• "FMGR REVERSE SELECTED"
• "FMGR REVERSE ACTUEL"
• "DEAD MAN SWITCH - STEERING COLUMN"
• "FORWARD SWITCH - STEERING COLUMN"
• "REVERSE SWITCH - STEERING COLUMN"
• "NEUTRAL SWITCH - STEERING COLUMN"
2. Disconnect connector A4/2 on the FMGR, check with voltage meter on PIN7 of the connector voltage to ground
(Ignition ON). Can no voltage be read out, then there is a defect of the FMGR and this unit has to be replaced.
3. If there is voltage, the error can be found in the circuit down to the shuttle lever (deadman).
4. Check wiring.
• Check wiring from A4/2 PIN7 over X24/3 PIN11 to X6/3 PIN2.
• Check wiring GSV 2 from X6/3 PIN4 to X24/3 PIN12 and A4/2 PIN6.

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FMGR - 183 Switch deadman - input signal with wrong circuit

Cause:
The Signal on this Input has a different timing of the pulsed supply as it is assumed.
Possible reasons:
1. Wire to the switch has short to another pulsed supplyline.
2. Connector on the switch S4/4 is loose and touches another pulsed supplyline.
3. Caused by another defect of a unit in the same pulsed supply circuit.
4. False connected by rework.
5. FMGR Controller failure.
Solution:
Failure will be stored. The most occurences of this error will be after repair work, or after installation of option. Check
these possibilities first. In most cases also errors FMGR217 and 213 or 221 will be active. If errors FMGR119, 123,
159, 171, 175 or 179 are recorded, the reason can be found also in that circuit, because this components are supplied
by the same pulsed power output.
1. Clear error records, switch ignition OFF, make sure that the the brake, the clutchpedal and the shuttle lever are
not used. Switch ignition ON and start engine. If error is active again, and errors FMGR119, 123, 159, 171, 175,
179 or 217 are not activ, the defect can be found in the way to the shuttle lever S4/4.
NOTE: the error can also be only temporary if other transmission fuctions are activated!
If errors FMGR119, 123, 159, 171, 175, 179 or 217 are activ, look for these errors code.
Use service tool monitor function:
• "FMGR-SGR REVERSE COMMAND "
• "FMGR FORWARD SELECTED"
• "FMGR FORWARD ACTUAL"
• "FMGR REVERSE SELECTED"
• "FMGR REVERSE ACTUEL"
• "DEAD MAN SWITCH - STEERING COLUMN"
• "FORWARD SWITCH - STEERING COLUMN"
• "REVERSE SWITCH - STEERING COLUMN"
• "NEUTRAL SWITCH - STEERING COLUMN"
2. Disconnect connector A4/1 and A4/2 on the FMGR, check with ohmmeter on A4/2 PIN7 of the connector the re-
sistance to A4/1 PIN18 and A4/2 PIN1 (Ignition OFF). Can no connection be read out, then there is a defect of
the FMGR and this unit has to be replaced.
3. If there is a connection, the error can be found in the circuit down to the shuttle lever (deadman).
4. Check wiring.
• Check wiring from A4/2 PIN7 over X24/3 PIN11 to X6/3 PIN2.
• Check wiring GSV 2 from X6/3 PIN4 to X24/3 PIN12 and A4/2 PIN6.

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FMGR - 186 Speed range switch - signal permanently at plus in

position I
Cause:
The signal at this input is permanently plus, even though it should be clocked.
The fault is stored.
Possible causes:
1. Short-circuit to plus in the signal line.
2. The FMGR has an internal defect.
Remedy:
Fault FMGR214 is probably also active. If faults FMGR130, 138, 142 or 190 occur at the same time, the cause can
also be in this area as these components are also clocked by the same control unit output.
Use the Service Tool monitor function "SPEED RANGE 1 / 2 / 3"
1. Cancel the fault, turn the ignition switch to the OFF position and make sure the Manual mode and 4-wheel drive
switches are in position 0 and the Speed range switch in position 3. Start the engine. If the fault is activated again,
and faults FMGR130, 138, 142, 190 or 214 are not active, try pinpointing the fault in the signal line to Speed range
switch S2/58/1.
NOTE: The fault can also become active sporadically again when a function which is independent of the transmis-
sion is operated. Should faults FMGR130, 138, 142 or 190 be active, then these faults must be eliminated.
2. Disconnect plug A4/1 from the FMGR and use a voltmeter to measure the voltage to GND (ground connection)
at PIN17 of the plug (turn the ignition switch to ON).

a) If no voltage is present, the FMGR is defective and must be replaced.

b) If a voltage is present, try pinpointing the fault in the signal line from switch S2/58/1.
Check signal from A4/1 PIN17 via X24/5 PIN5 to S2/58/1 PIN1.

FMGR - 187 Speed range switch - incorrect phase angle of input

signal in position I
Cause:
The signal at this input is clocked differently than planned.
The fault is stored.
Possible causes:
1. The signal line has a short-circuit to another clocked supply line.
2. The FMGR has an internal defect.
Remedy:
Faults FMGR213 and 217 or 221 are probably also active. If faults FMGR131, 139, 143 or 191 occur at the same
time, the cause can also be in this area as these components are also supplied (clocked) by the same control unit
output.
Use the Service Tool monitor function "SPEED RANGE 1 / 2 / 3"
1. Cancel the fault, turn the ignition switch to the OFF position and make sure the Manual mode and 4-wheel drive
switches are in position 0 and the Speed range switch in position 3. Start the engine. If the fault is activated again,
and faults FMGR131, 139, 143, 191 or 213 are not active, try pinpointing the fault in the signal line to switch
S2/58/1.
NOTE: The fault can also become active sporadically again when another transmission function is operated. Should
faults FMGR131, 139, 143, 191 or 213 be active, then these faults must be eliminated.
2. Disconnect plugs A4/1 and A4/2 from the FMGR and measure the resistance from A4/1 PIN17 to A4/2 PIN1 and
PIN6 (turn the ignition switch to OFF).

a) If there is no continuity, the FMGR is defective and must be replaced.

b) If there is continuity, try pinpointing the fault in the cable to switch S2/58/1.
Check signal line via A4/1 PIN17 via X24/5 PIN5 to S2/58/1 PIN1.

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FMGR - 190 Speed range switch - signal permanently at plus in

position II
Cause:
The signal at this input is permanently plus, even though it should be clocked.
The fault is stored.
Possible causes:
1. Short-circuit to plus in the signal line.
2. The FMGR has an internal defect.
Remedy:
Fault FMGR214 is probably also active. If faults FMGR130, 138, 142 or 186 occur at the same time, the cause can
also be in this area as these components are also clocked by the same control unit output.
Use the Service Tool monitor function "SPEED RANGE 1 / 2 / 3"
1. Cancel the fault, turn the ignition switch to the OFF position and make sure the Manual mode and 4-wheel drive
switches are in position 0 and the Speed range switch in position 3. Start the engine. If the fault is activated again,
and faults FMGR130, 138, 142, 186 or 214 are not active, try pinpointing the fault in the signal line to Speed range
switch S2/58/1.
NOTE: The fault can also become active sporadically again when a function which is independent of the transmis-
sion is operated. Should faults FMGR130, 138, 142 or 186 be active, then these faults must be eliminated.
2. Disconnect plug A4/1 from the FMGR and use a voltmeter to measure the voltage to GND (ground connection)
at PIN16 of the plug (turn the ignition switch to ON).

a) If no voltage is present, the FMGR is defective and must be replaced.

b) If a voltage is present, try pinpointing the fault in the signal line from switch S2/58/1.
Check signal from A4/1 PIN16 via X24/5 PIN23 to S2/58/1 PIN7.

FMGR - 191 Speed range switch - incorrect phase angle of input

signal in position II
Cause:
The signal at this input is clocked differently than planned.
The fault is stored.
Possible causes:
1. The signal line has a short-circuit to another clocked supply line.
2. The FMGR has an internal defect.
Remedy:
Faults FMGR213 and 217 or 221 are probably also active. If faults FMGR131, 139, 143 or 187 occur at the same
time, the cause can also be in this area as these components are also supplied (clocked) by the same control unit
output.
Use the Service Tool monitor function "SPEED RANGE 1 / 2 / 3"
1. Cancel the fault, turn the ignition switch to the OFF position and make sure the Manual mode and 4-wheel drive
switches are in position 0 and the Speed range switch in position 3. Start the engine. If the fault is activated again,
and faults FMGR131, 139, 143, 187 or 213 are not active, try pinpointing the fault in the signal line to switch
S2/58/1.
NOTE: The fault can also become active sporadically again when another transmission function is operated. Should
faults FMGR131, 139, 143, 187 or 213 be active, then these faults must be eliminated.
2. Disconnect plugs A4/1 and A4/2 from the FMGR and measure the resistance from A4/1 PIN16 to A4/2 PIN1 and
PIN6 (turn the ignition switch to OFF).

a) If there is no continuity, the FMGR is defective and must be replaced.

b) If there is continuity, try pinpointing the fault in the cable to switch S2/58/1.
Check signal line via A4/1 PIN16 via X24/5 PIN23 to S2/58/1 PIN7.

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FMGR - 200 Accelerator pedal potentiometer R8 - supply voltage

too low (<4.5V)
Cause:
The supply voltage is less than 4.5 V, although it should be 5.5±1 V.
The fault is stored.
Possible causes:
1. Potentiometer R8 has an internal defect (resistance too low).
2. The FMGR has an internal defect.
Remedy:
1. Check the supply voltage at the accelerator pedal potentiometer R8:
Detach the plug from the accelerator pedal potentiometer and connect it to the measuring adapter 380000062
(do not connect the measuring adapter to the potentiometer). Turn the ignition switch to the ON position. Measure
the supply voltage between PIN2 and PIN1 (GND). If the voltage is 5.5±1 V, replace the accelerator pedal poten-
tiometer. If the voltage is less than 4.5 V, the fault is caused by the wiring or by the FMGR.
NOTE: If you replace the accelerator pedal potentiometer, remember to readjust it. (see fault description FMGR 84)
2. Check the wiring from X4/70 PIN2 (supply) to A4/4 PIN10.
If you do not detect a fault in step 1 and 2, replace the FMGR.

FMGR - 201 Accelerator pedal potentiometer R8 - supply voltage

too high (>6.5V)
Cause:
The supply voltage is higher than 6.5 V, although it should be 5.5±1 V.
The fault is stored.
Possible causes:
1. The supply line is shorted to a plus line via a resistor.
2. The FMGR has an internal defect.
Remedy:
1. Check the supply voltage at the accelerator pedal potentiometer R8:
Detach the plug from the accelerator pedal potentiometer and connect the measuring adapter 380000062 in bet-
ween. Turn the ignition switch to the ON position. Measure the supply voltage between PIN2 and PIN1 (GND). If
the voltage is more than 6.5 V, the fault is caused by the wiring or by the FMGR.
2. Check the wiring from X4/70 PIN2 (supply) to A4/4 PIN10.
If you do not detect a fault in step 1 and 2, replace the FMGR.

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FMGR - 202 Accelerator pedal potentiometer R8 - supply voltage

shorted to +
Cause:
This output is connected to a battery voltage, although the voltage should be 5.5±1 V.
The fault is stored.
Possible causes:
1. Short-circuit to plus in the supply line. (12 V)
2. The FMGR has an internal defect.
Remedy:
1. Check the supply voltage at the accelerator pedal potentiometer R8:
Detach the plug from the accelerator pedal potentiometer and connect the measuring adapter 380000062 in bet-
ween. Turn the ignition switch to the ON position. Measure the supply voltage between PIN2 and PIN1 (GND). If
the voltage is approx. 12 V, the line is shorted to +.
2. Check the wiring from X4/70 PIN2 to A4/4 PIN10.
If the wiring is ok, the FMGR is defective and must be replaced.

FMGR - 203 Accelerator pedal potentiometer R8 - supply voltage

shorted to ground
Cause:
The supply voltage is permanently grounded, although the voltage should be 5.5±1 V.
Possible causes:
1. Short-circuit to ground in the supply line.
2. The potentiometer has an internal defect (short to ground).
3. The FMGR has an internal defect.
Remedy:
1. Check the supply voltage at the accelerator pedal potentiometer R8:
Detach plug X4/70 from the accelerator pedal potentiometer R8 and connect it to the measuring adapter
380000062 (do not connect the potentiometer to the measuring adapter). Turn the ignition switch to the ON po-
sition. Measure the supply voltage between PIN2 and PIN1 (GND). If the voltage is 5.5±1 V, replace the accele-
rator pedal potentiometer. If the voltage is approx. 0 V, the fault is caused by the wiring or the FMGR.
NOTE: If you replace the accelerator pedal potentiometer, remember to readjust it. (see fault description FMGR 84)
2. Check the wiring from X4/70 PIN2 to A4/4 PIN10.

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FMGR - 204 Full-load potentiometer - supply voltage too low (<4.5V)

Cause:
The supply voltage to the full-load potentiometer R23 is less than 4.5 V, although it should be 5.5±1 V. This fault is
most frequently caused by a defective FMGR. The fault is stored.
Possible causes:
1. The full-load potentiometer has an internal defect (resistance too low).
2. The FMGR has an internal defect.
Remedy:
1. Detach plug A4/4 from the FMGR and connect an ohmmeter to measure the resistance between PIN14 and PIN5
(turn ignition switch to OFF). The resistance should be 4.7 kOhm (+/- 10%).

a) If the resistance obtained is lower, the fault is caused by a short-circuit in the wiring or a defective potentiome-
ter. (see step 2)

b) If the value you have measured is ok, cancel the fault. Should the fault occur again when you turn the ignition
switch to "ON", the FMGR is defective and must be replaced.
2. Check the wiring up to the full-load potentiometer R23:
Check A4/4 PIN14 (supply) via plug X24/5 PIN11 to plug X3/23 PIN1.

If you cannot detect a short-circuit, replace the potentiometer.

FMGR - 205 Full-load potentiometer - supply voltage too

high (>6.5V)
Cause:
The supply voltage to the full-load potentiometer R23 is more than 6.5 V, although it should be 5.5±1 V. This fault is
most frequently caused by a defective FMGR. The fault is stored.
Possible causes:
1. The supply line is shorted to plus via a resistor.
2. The FMGR has an internal defect.
Remedy:
1. Detach plug A4/4 from the FMGR and connect a voltmeter to measure the voltage across PIN14 and GND
(ground connection). (turn the ignition switch to ON)

a) If no voltage is present, the FMGR is defective and must be replaced.

b) If a voltage is present, the line is shorted to a plus line. Check the wiring up to the full-load potentiometer R23:
Check A4/4 PIN14 (supply) via plug X24/5 PIN11 to plug X3/23 PIN1.

FMGR - 206 Full-load potentiometer - supply voltage shorted to +

Cause:
The supply voltage is connected to a battery voltage, although the voltage should be 5.5±1 V.
Possible causes:
1. The supply line is shorted to plus.
2. The FMGR has an internal defect.
Remedy:
1. Detach plug A4/4 from the FMGR and connect a voltmeter to measure the voltage across PIN14 and GND
(ground connection). (Turn the ignition switch to ON)

a) If no voltage is present, the FMGR is defective and must be replaced.

b) If a voltage is present, the line is shorted to a plus line. Check the wiring up to the full-load potentiometer R23:
Check A4/4 PIN14 (supply) via plug X24/5 PIN11 to plug X3/23 PIN1.

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FMGR - 207 Full-load potentiometer - supply voltage shorted to

ground
Cause:
The supply voltage is permanently at ground potential, although it should be 5.5±1 V.
The fault is stored.
Possible causes:
1. The supply line to the full-load potentiometer R23 is shorted to ground.
2. The full-load potentiometer has an internal defect (short to ground).
3. The FMGR has an internal defect.
Remedy:
1. Detach plug A4/4 from the FMGR and measure the resistance between PIN14 and GND (ground connection). If
you cannot detect a short-circuit, the fault is caused by the full-load potentiometer, the wiring (short to ground line)
or the FMGR.
2. Measure the resistance between PIN14 and PIN5. You should measure 4.7 kOhm (+/- 10%) here.
a) If you obtain the 4.7 kOhm (+/- 10%), the FMGR is defective and must be replaced.

b) If the value you obtain is lower, there is a short between the supply and the ground line or the full-load poten-
tiometer is defective. (see step 3)
3. Check the wiring up to the full-load potentiometer R23:
Check A4/4 PIN14 (supply) via plug X24/5 PIN11 to plug X3/23 PIN1.
Check A4/4 PIN5 (ground) via plug X24/5 PIN13 to plug X3/23 PIN2.

If the wiring is ok, check the resistance between full-load potentiometer PINA and PINC (4,7 kOhm +/- 10%).
If the resistance is ok, replace the FMGR.

FMGR - 208 Clutch pedal angle of rotation sensor B17 - supply

voltage too low (<4.5V)
Cause:
The supply voltage is less than 4.5 V, although it should be 5.5±1 V.
The fault is stored.
Possible causes:
1. Sensor B17 has an internal defect (resistance too low).
2. Supply line to B17 interrupted.
3. The FMGR has an internal defect.
Remedy:
1. Check the supply voltage at the angle of rotation sensor B17:
Detach the plug from the angle of rotation sensor B17 and connect it to the measuring adapter 380000070 (do
not connect the measuring adapter to the sensor). Turn the ignition switch to the ON position. Measure the supply
voltage between PIN2 and PIN1 (GND). If the voltage is 5.5±1 V, replace the angle of rotation sensor. If the voltage
is less than 4.5 V, the fault is caused by the wiring or by the FMGR.
NOTE: If you replace the angle of rotation sensor, remember to readjust it. (see fault description FMGR 100)
2. Check the wiring from B17 PIN2 (supply) via X24/3 PIN14 to A4/4 PIN11.
If the wiring is ok, detach the plug A4/4, turn the ignition switch to ON and cancel the fault. Should the fault occur again
when you turn the ignition switch OFF / ON, the FMGR is defective and must be replaced.

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FMGR - 209 Clutch pedal angle of rotation sensor B17 - supply

voltage too high (>6.5V)
Cause:
The supply voltage is higher than 6.5 V, although it should be 5.5±1 V.
The fault is stored.
Possible causes:
1. The supply line is shorted to a plus line via a resistor.
2. The FMGR has an internal defect.
Remedy:
1. Check the supply voltage at the angle of rotation sensor B17:
Detach the plug from the angle of rotation sensor B17 and connect the measuring adapter 380000070 in between.
Turn the ignition switch to the ON position. Measure the supply voltage between PIN2 and PIN1 (GND). If the
voltage is more than 6.5 V, the fault is caused by the wiring or by the FMGR.
2. Check the wiring from B17 PIN2 (supply) via X24/3 PIN14 to A4/4 PIN11.
If the wiring is ok, the FMGR is defective and must be replaced.

FMGR - 210 Clutch pedal angle of rotation sensor B17 - supply

voltage shorted to +
Cause:
This output is connected to a battery voltage, although the voltage should be 5.5±1 V. The fault is stored.
Possible causes:
1. The supply line is shorted to plus (12V).
2. The FMGR has an internal defect.
Remedy:
1. Check the supply voltage at the angle of rotation sensor B17:
Detach the plug from the angle of rotation sensor B17 and connect the measuring adapter 380000070 in between.
Turn the ignition switch to the ON position. Measure the supply voltage between PIN2 and PIN1 (GND). If the
voltage is approx. 12 V, the line is shorted to +.
2. Check the wiring from B17 PIN2 (supply) via X24/3 PIN14 to A4/4 PIN11.
If the wiring is ok, the FMGR is defective and must be replaced.

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FMGR - 211 Clutch pedal angle of rotation sensor B17 - supply

voltage shorted to ground
Cause:
This output is permanently at ground potential, although the voltage should be 5.5±1 V.
The fault is stored.
Possible causes:
1. Short-circuit to ground in the supply line.
2. The sensor has an internal defect (short-circuit to ground).
3. The FMGR has an internal defect.
Remedy:
1. Check the supply voltage at the angle of rotation sensor B17:
Detach the plug from the angle of rotation sensor B17 and connect it to the measuring adapter 380000070 (do
not connect the sensor to the measuring adapter). Turn the ignition switch to the ON position. Measure the supply
voltage between PIN2 and PIN1 (GND). If the voltage is 5.5±1 V, replace the angle of rotation sensor. If the voltage
is approx. 0 V, the fault is caused by the wiring or the FMGR.
NOTE: If you replace the angle of rotation sensor, remember to readjust it. (see fault description FMGR 100)
2. Check the wiring from B17 PIN2 (supply) via X24/3 PIN14 to A4/4 PIN11.
If the wiring is ok, detach the plug A4/4, turn the ignition switch to ON and cancel the fault. Should the fault occur again
when you turn the ignition switch OFF / ON, the FMGR is defective and must be replaced.

FMGR - 213 Supply switches pulsed GSV 1 - short-circuit to other

circuit
Cause:
The Voltage on this output has a connection to another pulsed supply line (GSV2 or GSV3).
Possible reasons:
1. Wire to switches has short-circuit to another pulsed supply line.
2. Connector on the switch is loose and touches another pulsed supply line.
3. Caused by another defect of a unit in the same pulsed supply circuit.
4. False connected by rework.
5. FMGR Controller failure.
Solution:
Failure will be stored. The most occurences of this error will be after repair work, or after installation of option. Check
these possibilities first. In most cases also errors FMGR 221 or FMGR 217 will be active. In these cases, the reason
can be found also in that circuit, because this components are then connected together.
1. Clear error records, switch ignition OFF, make sure that there is no switch activated, no pedal pressed, the par-
king brake not applied and no load on the seat. Switch ignition ON and start engine. If error is active again, and
only errors FMGR 217 or 221 are activ, the defect can be found in the apply line to the switches, speed range
(S2/58/1), MFD (S2/59), manual mode (S2/58/2) or in the line of the second monitored error (see FMGR 217 or
221).
2. Disconnect connector A4/1 and A4/2 on the FMGR, check harness with ohmmeter on A4/1 PIN18 of the connec-
tor the resistance to A4/2 PIN1 and A4/2 PIN6. (Ignition OFF). Can no connection be read out, then there is a
defect of the FMGR and it has to be replaced.
3. If there is a connection, the error can be found in the supply line of the above mentioned switches. Check from
FMGR A4/1 PIN18 cable to EDC Print (A16) X14/4 PIN8 to X10/4 PIN1.
4. If the error is not active switch all functions on, one after the other, until the error occurs again. At that time also
other error codes must be monitored. Look at these errorcodes.

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FMGR - 214 Supply switches pulsed GSV1 - short-circuit to power

Cause:
The Output is permanently powered, although there should be a pulsed supply.
Possible reasons:
1. Wire to the switches has short-circuit to power.
2. Connector on a switch is loose and touches a power terminal.
3. Caused by another defect of a unit in the same pulsed supply circuit.
4. Switch with two supplies ( e.g. illumination ) has an internal defect.
5. False connected by rework.
6. FMGR Controller failure.
Solution:
Failure will be stored. The most occurences of this error will be after repair work, or after installation of option. Check
these possibilities first. In most cases also errors FMGR 130 or 134 or 138 or 142 or 186 or 190 will be active. If error
one of these errors is recorded, the reason could be found also in that circuit, because this components are supplied
by the same power output.
1. Clear error records, Switch ignition OFF, make sure that there is no switch activated, no pedal pressed, the par-
kingbrake not applied and no load on the seat. Switch ignition ON and start engine. If error is active again, and
error FMGR 130 or 134 or 138 or 142 or 186 or 190 are not activ, the defect can be found in the supply line to the
switches, speed range (S2/58/1), manual mode (S2/58/2) or MFD (S2/59).
2. Disconnect connectorA4/1 on the FMGR, check with voltage meter on PIN18 of FMGR to ground. (Ignition ON).
Can no voltage be read out, then there is a defect of the FMGR and this unit has to be replaced.
3. If there is voltage, the error can be found in the circuit down to an above mentioned switch.
• A4/1 PIN18 to X14/4 PIN8, X10/4 PIN1 over S2/58/1 to X24/5 PIN5 and A4/1 PIN17.
• A4/1 PIN18 to X14/4 PIN8 over X10/4 PIN1 and S2/59 to X24/5 PIN3 and A4/1 PIN1.
• A4/1 PIN18 to X14/4 PIN8, X10/4 PIN1 over S2/59 and X24/5 PIN4 to A4/1 PIN2.
• X10/4 PIN1 over S2/58/2 to X24/5 PIN8 and A4/1 PIN5.
4. If the error is not active switch all functions on, one after the other, until the error occurs again. At that time also
other errorcodes must be monitored. Look at these errorcodes.

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FMGR - 215 Supply switches pulsed GSV1 - short circuit, or short-

circuit to ground
Cause:
The Output is permanently ground, although there should be a pulsed supply.
Possible reasons:
1. Wire to the switches has short-circuit to ground.
2. Connector on a switch is loose and touches ground.
3. Caused by another defect of a unit in the same pulsed supply circuit.
4. Switch with ground (e.g. illumination) has an internal defect.
5. False connected by rework.
6. FMGR Controller failure.
Solution:
Failure will be stored. The most occurences of this error will be a shortcut to ground of a terminal on a switch.
1. Clear error records, Switch ignition OFF, make sure that there is no switch activated, no pedal pressed, the par-
kingbrake not applied and no load on the seat. Switch ignition ON and start engine. If error is active again, the
defect can be found in the supply line to the switches, speed range (S2/58/1), manual mode (S2/58/2) or MFD
(S2/59).
2. Disconnect connector A4/1 on the FMGR, check with ohmmeter on PIN18 of harness the connector resistance
to ground. (Ignition ON). Can no connection can be read out, then there is a defect of the FMGR and this unit has
to be replaced.
3. If there is voltage, the error can be found in the circuit down to an above mentioned switch.
• A4/1 PIN18 to X14/4 PIN8, X10/4 PIN1 over S2/58/1 to X24/5 PIN5 and A4/1 PIN17.
• A4/1 PIN18 to X14/4 PIN8 over X10/4 PIN1 and S2/59 to X24/5 PIN3 and A4/1 PIN1.
• A4/1 PIN18 to X14/4 PIN8, X10/4 PIN1 over S2/59 and X24/5 PIN4 to A4/1 PIN2.
• X10/4 PIN1 over S2/58/2 to X24/5 PIN8 and A4/1 PIN5.
4. If the error is not active switch all functions on, one after the other, until the error occurs again.

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FMGR - 217 Supply Switches pulsed GSV2 - short-circuit to other

circuit
Cause:
The Voltage on this output has a connection to another pulsed supply line (GSV1 or GSV3).
Possible reasons:
1. Wire to switches has Short-circuit to another pulsed supply line.
2. Connector on the switch is loose and touches another pulsed supply line.
3. Caused by another defect of a unit in the same pulsed supply circuit.
4. False connected by rework.
5. FMGR Controller failure.
Solution:
Failure will be stored. The most occurences of this error will be after repair work, or after installation of option. Check
these possibilities first. In most cases also errors FMGR 213 or FMGR 221 will be active. In these cases, the reason
can be found also in that circuit, because this components are then connected together.
1. Clear error records, switch ignition OFF, make sure that there is no switch activated, no pedal pressed, the par-
king brake not applied and no load on the seat. Switch ignition ON and start engine. If error is active again, and
only errors FMGR213 or 221 are activ, the defect can be found in the apply line to the switches,V/R/N (S4/4) at
steering column, stoplight (S5), steeringbrake (S25), clutch switch 75% (S46) or park lock switch (S2/61) or in the
line of the second monitored error (see FMGR213 or 221).
2. If so, disconnect connector A4/1 and A4/2 on the FMGR, check the harness with ohmmeter on A4/2 PIN6 of the
connector the resistance to A4/1 PIN18 and A4/2 PIN1 (Ignition OFF). Can no connection be read out, then there
is a defect of the FMGR has to be replaced.
3. If there is a connection, the error can be found in the supply line of the above mentioned switches. From FMGR
A4/2 PIN6 to X24/3 PIN12, the switches S25, S5, S46, S2/61 and S4/4.
4. If the error is not active switch all functions on, one after the other, until the error occurs again. At that time also
other error codes must be monitored. Look at these error codes.

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FMGR - 218 Supply switches pulsed GSV2 - short-circuit to power

Cause:
The Output is permanently powered, although there should be a pulsed supply.
Possible reasons:
1. Wire to the switches has short-circuit to power.
2. Connector on a switch is loose and touches a power terminal.
3. Caused by another defect of a unit in the same pulsed supply circuit.
4. Switch with two supplies ( e.g. illumination ) has an internal defect.
5. False connected by rework.
6. FMGR Controller failure.
Solution:
Failure will be stored. The most occurences of this error will be after repair work, or after installation of option. Check
these possibilities first. In most cases also errors FMGR118, 122, 158, 162, 170, 174, 178 or 182 will be active.
If error one of these errors is recorded, the reason could be found also in that circuit, because this components are
supplied by the same pulsed power output.
1. Clear error records, switch ignition OFF, make sure that there is no switch activated, no pedal pressed, the par-
king brake not applied and no load on the seat. Switch ignition ON and start engine. If error is active again, and
error FMGR118 or 122 or 158 or 162 or 170 or 174 or 178 or 182 are not activ, the defect can be found in the
supply line to the switches, V/R/N (S4/4) at steering column, stoplight (S5), steering brake (S25), clutch switch
75 % (S46) of park lock (S2/61).
2. Disconnect connector A4/1 on the FMGR, check with voltmeter on PIN6 of FMGR to ground (Ignition ON). Can
no voltage be read out, then there is a defect of the FMGR and this unit has to be replaced.
3. If there is voltage, the error can be found in the circuit down to an above mentioned switch.
From FMGR A4/2 PIN6 to X24/3 PIN12, the switches S25, S5, S46, S2/61 and S4/4.
4. If the error is not active switch all functions on, one after the other, until the error occurs again. At that time also
other error codes must be monitored. Look at these error codes.

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FMGR - 219 Supply switches pulsed GSV2 - short circuit, or short

to ground
Cause:
The Output is permanently ground, although there should be a pulsed supply.
Possible reasons:
1. Wire to the switches has short to ground.
2. Connector on a switch is loose and touches ground.
3. Caused by another defect of a unit in the same pulsed supply circuit.
4. Switch with ground ( e.g. illumination ) has an internal defect.
5. False connected by rework.
6. FMGR Controller failure.
Solution:
Failure will be stored. The most occurences of this error will be a shortcut to ground of a terminal on a switch.
1. Clear error records, switch ignition OFF, make sure that there is no switch activated, no pedal pressed, the par-
king brake not applied and no load on the seat. Switch ignition ON and start engine. If error is active again, the
defect can be found in the supply line to the switches,V/R/N (S4/4) at steering column, stoplight (S5), steering
brake (S25), clutch switch 75% (S46) and park lock (S2/61).
2. Disconnect connector A4/2 on the FMGR, check harness with ohmmeter on PIN6 of the connector resistance to
ground (Ignition ON). Can no connection can be read out, then there is a defect of the FMGR and this unit has to
be replaced.
3. If there is voltage, the error can be found in the circuit down to an above mentioned switch.
From FMGR A4/2 PIN6 to X24/3 PIN12, the switches S25, S5, S46, S2/61 and S4/4.
4. If the error is not active switch all functions on, one after the other, until the error occurs again. Depending on the
occurence of the error the defect can be found in on of the signal lines of steering brake, stoplight, clutch 75%,
exhaustbrake, forward, backward, neutral or deadman.

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FMGR - 221 Clocked switch supply (GSV3) - short-circuit to other

phase
Cause:
The clocked power supply GSV3 is connected with another clocked power supply (GSV1 or GSV2). Either fault
FMGR 213 or 217 is also active. The fault is stored.
Possible causes:
1. The supply line to the individual consumers has short-circuit on another clocked supply line.
2. The FMGR has an internal defect.
Remedy:
1. Cancel the fault, turn the ignition switch to the OFF position and make sure the seat is not loaded (the seat is
positioned in the forward driving direction if the vehicle is fitted with a reversing facility), the handbrake is not ap-
plied and the engine back pressure brake is not operated (all switches are open). Start the engine and check whe-
ther the fault is activated again.
If no, go to step 2.
If yes, go to step 3.
2. Operate (close) all the switches described in step 1 and check whether one of the faults 115, 127, 151, 163 is
activated together with fault 221. If yes, the fault is caused by the area which corresponds to the fault code.
(go to 3b)
(Use the corresponding Service Tool monitor functions)
3. Disconnect plugs A4/1 and A4/2 from the FMGR and measure the resistance across A4/2 PIN1 and A4/1 PIN18
(GSV 1) as well as A4/2 PIN6 (GSV 2) (turn the ignition switch to OFF).

a) If no continuity is present, the FMGR is defective and must be replaced.

NOTE: Before replacing the FMGR, check whether faults caused by other transmission functions are active. If this
is the case, eliminate these faults first and repeat steps 1 - 2.
b) If continuity is present, the fault is caused by the supply line to the parking brake switch S21, seat switch S8,
reversible seat switch S8/2 (if vehicle is equipped with a reversing facility) and engine back pressure brake S20.
Check the wiring using the diagrams listed below and repair if required.

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FMGR - 222 Clocked switch supply (GSV3) - short-circuit to +

Cause:
The clocked power supply GSV3 is shorted to plus. The fault is stored.
Possible causes:
1. The supply line to the individual consumers is shorted to plus.
2. The FMGR has an internal defect.
Remedy:
One of the faults FMGR114, 126, 151 or 162 is probably also active. If one of these faults occurs at the same time,
the cause can also be in this area as these components are also supplied by the same output.
1. Cancel the fault, turn the ignition switch to the OFF position and make sure the seat is not loaded (the seat is
positioned in the forward driving direction if the vehicle is fitted with a reversing facility), the handbrake is not ap-
plied and the engine back pressure brake is not operated. Start the engine.
If the fault is active again, and faults FMGR114, 126, 151 or 162 are not active, try pinpointing the fault in the
supply lines to the parking brake switch S21, seat switch S8, reversible seat switch S8/2 or engine back pressure
brake switch S20.
NOTE: If one of the faults FMGR114, 126, 151 or 162 is active, this must be eliminated first. Repeat step 1.
2. Disconnect plug A4/2 from the FMGR and use a voltmeter to measure the voltage between PIN16 and GND
(ground connection) (turn the ignition switch to ON).
a) If no voltage is present, the FMGR is defective and must be replaced.

b) If a voltage is present, try pinpointing the fault in the supply lines to the parking brake switch S21, seat switch
S8, reversible seat switch S8/2 (if the vehicle is equipped with a reversing facility) or engine back pressure brake
switch S20.
Check the wiring using the diagrams listed below and repair if required.

FMGR - 223 Clocked switch supply (GSV 3) - short to ground

Cause:
The clocked power supply GSV3 is permanently at ground potential. The fault is stored.
Possible causes:
1. The supply line GSV3 is shorted to ground.
2. The FMGR has an internal defect.
Remedy:
1. Cancel the fault, turn the ignition switch to the OFF position and make sure the seat is not loaded (the seat is
positioned in the forward driving direction if the vehicle is fitted with a reversing facility), the handbrake is not ap-
plied and the engine back pressure brake is not operated. Start the engine.

a) If the fault is active again, try pinpointing the fault in the supply lines to the parking brake switch S21, seat switch
S8, reversible seat switch S8/2 or engine back pressure brake switch S20. (go to step 2)

b) If the fault is not active, operate (close) all of the switches listed under "a" one after the other and check whether
the fault is activated. If the fault is activated, it can be attributed to the relevant function. (see 2b)
2. Disconnect plug A4/2 from the FMGR and use an ohmmeter to measure the resistance between PIN1 and GND
(ground connection) (turn the ignition switch to OFF).

a) If no continuity is present, the FMGR is defective and must be replaced.

b) If continuity is present, check the supply lines to the parking brake switch S21, seat switch S8, reversible seat
switch S8/2 or engine back pressure brake switch S20 using the diagrams listed below and repair them if requi-
red.

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FMGR - 232 Solenoid valve 2, brake oil cooling - control

interruption up to DBD100000
Cause:
The connection between the FMGR and the solenoid valve was diagnosed as interrupted.
Possible causes:
1. Solenoid valve defective.
2. Line interrupted.
3. Plug on FMGR defective.
4. Plug on solenoid valve defective.
5. FMGR defective.
Remedy:
The fault is stored and signalled on screen by a warning triangle. The most frequent occurrence of this fault will be a
faulty solenoid valve or it was not connected again after a repair.
1. Disconnect the solenoid valve and check the plug for bent, corroded or retracted contacts. If the plug turns out to
be defective, remedy the defect.
2. Check the solenoid valve's resistance by means of a multimeter. It should be approx. 8 ohms. If the solenoid valve
is interrupted, then it must be replaced. If the solenoid valve is ok, continue with step 3.
3. Refit the solenoid valve. Disconnect plug A4/3 at the FMGR (A4) and check the plug for bent, corroded or retrac-
ted contacts. If the plug turns out to be defective, remedy the defect.
4. Measure the resistance between PIN8 and 13 on the plug. If an interruption is discerned here, then the line must
be replaced or repaired (if the damage is visible).
5. If the line and the solenoid valve are ok, then the FMGR must be replaced.

FMGR - 232 Solenoid valve 1, brake oil cooling -

control interruption from DBD100001
Cause:
The connection between the FMGR and the solenoid valve was diagnosed as interrupted.
Possible causes:
1. Solenoid valve defective.
2. Line interrupted.
3. Plug on FMGR defective.
4. Plug on solenoid valve defective.
5. FMGR defective.
Remedy:
The fault is stored and signalled on screen by a warning triangle. The most frequent occurrence of this fault will be a
faulty solenoid valve or it was not connected again after a repair.
1. Disconnect the solenoid valve and check the plug for bent, corroded or retracted contacts. If the plug turns out to
be defective, remedy the defect.
2. Check the solenoid valve's resistance by means of a multimeter. It should be approx. 8 ohms. If the solenoid valve
is interrupted, then it must be replaced. If the solenoid valve is ok, continue with step 3.
3. Refit the solenoid valve. Disconnect plug A4/3 at the FMGR (A4) and check the plug for bent, corroded or retrac-
ted contacts. If the plug turns out to be defective, remedy the defect.
4. Measure the resistance between PIN5 and 13 on the plug. If an interruption is discerned here, then the line must
be replaced or repaired (if the damage is visible).
5. If the line and the solenoid valve are ok, then the FMGR must be replaced.

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FMGR - 234 Solenoid valve 2, brake oil cooling - short-circuit to +

up to DBD100000
Cause:
The FMGR tries to switch off a solenoid valve but the valve is still supplied with power.
Possible causes:
1. FMGR defective.
2. Insulation of the line to the solenoid valve is chafed and touches another solenoid valve line.
Remedy:
The fault is stored and signalled on screen by a warning triangle. This fault is most frequently caused by a defective
solenoid valve.
1. Disconnect plug A4/3 and check the plug for bent, corroded or retracted contacts. If the plug turns out to be de-
fective, remedy the defect.
2. Switch on the ignition and cancel the fault. If the fault is still active, then the FMGR must be replaced. The other
points should still be checked just to make sure that everything is ok.
3. Switch off the ignition. Disconnect plug A4/3 and measure the resistance between PIN8 and 13. It should be ap-
prox. 8 ohms. Measure the resistance between PIN8 and the other assigned PINs on plug A4/3. If a connection
is discerned here, then the line must be replaced or repaired (if the damage is visible).

FMGR - 234 Solenoid valve 1, brake oil cooling - short-circuit to +

from DBD100001
Cause:
The FMGR tries to switch off a solenoid valve but the valve is still supplied with power.
Possible causes:
1. FMGR defective.
2. Insulation of the line to the solenoid valve is chafed and touches another solenoid valve line.
Remedy:
The fault is stored and signalled on screen by a warning triangle. This fault is most frequently caused by a defective
solenoid valve.
1. Disconnect plug A4/3 and check the plug for bent, corroded or retracted contacts. If the plug turns out to be de-
fective, remedy the defect.
2. Switch on the ignition and cancel the fault. If the fault is still active, then the FMGR must be replaced. The other
points should still be checked just to make sure that everything is ok.
3. Switch off the ignition. Disconnect plug A4/3 and measure the resistance between PIN5 and 13. It should be
approx. 8 ohms. Measure the resistance between PIN5 and the other assigned pins on plug A4/3. If a connection
is discerned here, then the line must be replaced or repaired (if the damage is visible).

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FMGR - 235 Solenoid valve 2, brake oil cooling - short-circuit to

ground up to DBD100000
Cause:
The FMGR diagnoses a short to ground at the output on solenoid valve 1.
Possible causes:
1. Solenoid valve has got a short-circuit.
2. Insulation of the line to solenoid valve is chafed and touches a ground line.
3. FMGR defective.
Remedy:
The fault is stored and signalled on screen by a warning triangle. This fault is most frequently caused by a defective
solenoid valve.
1. Disconnect the solenoid valve and check the plug for bent, corroded or retracted contacts. If the plug turns out to
be defective, remedy the defect.
2. Check the solenoid valve's resistance by means of a multimeter. It should be approx. 8 ohms. If the solenoid valve
has a short-circuit, then it must be replaced. If the solenoid valve is ok, continue with step 3.
3. Disconnect plug A4/3 and measure the resistance between PIN8 and 13 as well as between PIN8 and and the
ground connection. (Solenoid valve disconnected)
If a short-circuit is discerned here, then the line must be replaced or repaired (if the damage is visible).
If a short-circuit is not discernible, then the FMGR must be replaced.

FMGR - 235 Solenoid valve 1, brake oil cooling - short-circuit

to ground from DBD100001
Cause:
The FMGR diagnoses a short to ground at the output on solenoid valve 1.
Possible causes:
1. Solenoid valve has got a short-circuit.
2. Insulation of the line to solenoid valve is chafed and touches a ground line.
3. FMGR defective.
Remedy:
The fault is stored and signalled on screen by a warning triangle. This fault is most frequently caused by a defective
solenoid valve.
1. Disconnect the solenoid valve and check the plug for bent, corroded or retracted contacts. If the plug turns out to
be defective, remedy the defect.
2. Check the solenoid valve's resistance by means of a multimeter. It should be approx. 8 ohms. If the solenoid valve
has a short-circuit, then it must be replaced. If the solenoid valve is ok, continue with step 3.
3. Disconnect plug A4/3 and measure the resistance between PIN5 and 13 as well as between PIN5 and and the
ground connection. (Solenoid valve disconnected)
If a short-circuit is discerned here, then the line must be replaced or repaired (if the damage is visible).
If a short-circuit is not discernible, then the FMGR must be replaced.

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FMGR - 236 Solenoid valve 1, brake oil cooling - control

interruption up to DBD100000
Cause:
The connection between the FMGR and the solenoid valve was diagnosed as interrupted.
Possible causes:
1. Solenoid valve defective.
2. Line interrupted.
3. Plug on FMGR defective.
4. Plug on solenoid valve defective.
5. FMGR defective.
Remedy:
The fault is stored and signalled on screen by a warning triangle. The most frequent occurrence of this fault will be a
faulty solenoid valve or it was not connected again after a repair.
1. Disconnect the solenoid valve and check the plug for bent, corroded or retracted contacts. If the plug turns out to
be defective, remedy the defect.
2. Check the solenoid valve's resistance by means of a multimeter. It should be approx. 8 ohms. If the solenoid valve
is interrupted, then it must be replaced. If the solenoid valve is ok, continue with step 3.
3. Refit the solenoid valve. Disconnect plug A4/3 at the FMGR (A4) and check the plug for bent, corroded or retrac-
ted contacts. If the plug turns out to be defective, remedy the defect.
4. Measure the resistance between PIN5 and 13 on the plug. If an interruption is discerned here, then the line must
be replaced or repaired (if the damage is visible).
5. If the line and the solenoid valve are ok, then the FMGR must be replaced.

FMGR - 236 Solenoid valve 2, brake oil cooling -

control interruption from DBD100001
Cause:
The connection between the FMGR and the solenoid valve was diagnosed as interrupted.
Possible causes:
1. Solenoid valve defective.
2. Line interrupted.
3. Plug on FMGR defective.
4. Plug on solenoid valve defective.
5. FMGR defective.
Remedy:
The fault is stored and signalled on screen by a warning triangle. The most frequent occurrence of this fault will be a
faulty solenoid valve or it was not connected again after a repair.
1. Disconnect the solenoid valve and check the plug for bent, corroded or retracted contacts. If the plug turns out to
be defective, remedy the defect.
2. Check the solenoid valve's resistance by means of a multimeter. It should be approx. 8 ohms. If the solenoid valve
is interrupted, then it must be replaced. If the solenoid valve is ok, continue with step 3.
3. Refit the solenoid valve. Disconnect plug A4/3 at the FMGR (A4) and check the plug for bent, corroded or retrac-
ted contacts. If the plug turns out to be defective, remedy the defect.
4. Measure the resistance between PIN8 and 13 on the plug. If an interruption is discerned here, then the line must
be replaced or repaired (if the damage is visible).
5. If the line and the solenoid valve are ok, then the FMGR must be replaced.

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FMGR - 238 Solenoid valve 1, brake oil cooling - short-circuit to +

up to DBD100000
Cause:
The FMGR tries to switch off a solenoid valve but the valve is still supplied with power.
Possible causes:
1. FMGR defective.
2. Insulation of the line to the solenoid valve is chafed and touches another solenoid valve line.
Remedy:
The fault is stored and signalled on screen by a warning triangle. This fault is most frequently caused by a defective-
solenoid valve.
1. Disconnect plug A4/3 and check the plug for bent, corroded or retracted contacts. If the plug turns out to be de-
fective, remedy the defect.
2. Switch on the ignition and cancel the fault. If the fault is still active, then the FMGR must be replaced. The other
points should still be checked just to make sure that everything is ok.
3. Switch off the ignition. Disconnect plug A4/3 and measure the resistance between PIN5 and 13. It should be ap-
prox. 8 ohms. Measure the resistance between PIN5 and the other assigned PINs on plug A4/3. If a connection
is discerned here, then the line must be replaced or repaired (if the damage is visible).

FMGR - 238 Solenoid valve 2, brake oil cooling - short-circuit to +

from DBD100001
Cause:
The FMGR tries to switch off a solenoid valve but the valve is still supplied with power.
Possible causes:
1. FMGR defective.
2. Insulation of the line to the solenoid valve is chafed and touches another solenoid valve line.
Remedy:
The fault is stored and signalled on screen by a warning triangle. This fault is most frequently caused by a defective
solenoid valve.
1. Disconnect plug A4/3 and check the plug for bent, corroded or retracted contacts. If the plug turns out to be de-
fective, remedy the defect.
2. Switch on the ignition and cancel the fault. If the fault is still active, then the FMGR must be replaced. The other
points should still be checked just to make sure that everything is ok.
3. Switch off the ignition. Disconnect plug A4/3 and measure the resistance between PIN8 and 13. It should be ap-
prox. 8 ohms. Measure the resistance between PIN8 and the other assigned pins on plug A4/3. If a connection
is discerned here, then the line must be replaced or repaired (if the damage is visible).

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FMGR - 239 Solenoid valve 1, brake oil cooling - short-circuit to

ground up to DBD100000
Cause:
The FMGR diagnoses a short to ground at the output on solenoid valve .
Possible causes:
1. Solenoid valve has got a short-circuit.
2. Insulation of the line to solenoid valve is chafed and touches a ground line.
3. FMGR defective.
Remedy:
The fault is stored and signalled on screen by a warning triangle. This fault is most frequently caused by a defective
solenoid valve.
1. Disconnect the solenoid valve and check the plug for bent, corroded or retracted contacts. If the plug turns out to
be defective, remedy the defect.
2. Check the solenoid valve's resistance by means of a multimeter. It should be approx. 8 ohms. If the solenoid valve
has a short-circuit, then it must be replaced. If the solenoid valve is ok, continue with step 3.
3. Disconnect plug A4/3 and measure the resistance between PIN5 and 13 as well as between PIN5 and and the
ground connection. (Solenoid valve disconnected)
If a short-circuit is discerned here, then the line must be replaced or repaired (if the damage is visible).
If a short-circuit is not discernible, then the FMGR must be replaced.

FMGR - 239 Solenoid valve 2, brake oil cooling - short-circuit

to ground from DBD100001
Cause:
The FMGR diagnoses a short to ground at the output on solenoid valve .
Possible causes:
1. Solenoid valve has got a short-circuit.
2. Insulation of the line to solenoid valve is chafed and touches a ground line.
3. FMGR defective.
Remedy:
The fault is stored and signalled on screen by a warning triangle. This fault is most frequently caused by a defective
solenoid valve.
1. Disconnect the solenoid valve and check the plug for bent, corroded or retracted contacts. If the plug turns out to
be defective, remedy the defect.
2. Check the solenoid valve's resistance by means of a multimeter. It should be approx. 8 ohms. If the solenoid valve
has a short-circuit, then it must be replaced. If the solenoid valve is ok, continue with step 3.
3. Disconnect plug A4/3 and measure the resistance between PIN8 and 13 as well as between PIN8 and and the
ground connection. (Solenoid valve disconnected)
If a short-circuit is discerned here, then the line must be replaced or repaired (if the damage is visible).
If a short-circuit is not discernible, then the FMGR must be replaced.

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FMGR - 240 Reception of motor (EHS) CAN bus signal on vehicle

side in register 0 is faulty up to DBD100000
Cause:
The control unit detects that a time limit for a periodic data transmission between FMGR and EEM has been excee-
ded. The fault is stored and signalled on screen by a warning triangle.
Possible causes:
1. Temporary malfunction of CAN communications between FMGR and EEM.
2. Short circuit on the CAN bus.
3. Bus termination incorrect or missing.
4. Contacts of the CAN bus plugs bent, broken or corroded.
5. Control unit hardware fault of the FMGR or EEM.
Remedy:
1. A temporary malfunction can be caused by a temporary bus overload. Ensure that the power supply to the FMGR
and the EEM is correct and that both control modules are ONLINE on the bus. Use the "Control module status"
function of the Service Tool to check this. If one of the control units is OFFLINE, go to step 2. If both control units
are ONLINE, this is a temporary fault. Store the fault using the Service Tool and then delete it. Make a test drive
to check the function. If the fault code does not occur again, no further action is required.
2. Check the power supply to the module which is OFFLINE.
a) Check supply to EEM2:
I. Check ground at X70 PIN69 and PIN 46 to weld point X0/4/1 and to grounding point 11, engine component
carrier.
II. Check ground from enclosure of EEM control unit via weld point X0/4/1 to ground 11.
III. 12V (potential 15/2) at X70 PIN21 to engine print (A14) X20/1 (Würth), X24/12 (Berifors) PIN7 via F97 to
K5/3 PIN87 to PIN 30 on screw down point X1/12 on F200.
b) Check supply to FMGR:
I. Ground at A4/3 PIN13 runs via weld point X0/7/5 from grounding point 16 starter.
II. 12V (potential 15/1) at A4/3 PIN10. Runs from fuse F51 (10A) on A12 central print via connector X24/2 PIN1
to FMGR A4/3 PIN10.
III. 12V (potential 30) at A4/3 PIN14. Runs from fuse F14 (7.5A) on A12 central print via X24/2 PIN6 to FMGR
A4/3 PIN14.
3. If the power supply to the two control modules is correct, check the entire CAN bus for short-circuits. On the CAN
bus, disconnect one control module after the other and reconnect it again, checking the status of the control units
("Control module status" function of the Service Tool). If the control unit status is ONLINE, the disconnected unit
is causing the problem.
4. If the power supply to the two control modules is correct, check the entire CAN bus for interruptions or defective
terminating resistors. If the CAN bus is interrupted, only those control modules are OFFLINE which are connected
to the CAN bus after the interruption.

a) Check vehicle bus:

Diagnostics interface S31(CANH PIN8, CANL PIN7),
Armrest X18/4 (CANH PIN17, CANL PIN18),
AUX1 X4/90 (CANH PIN3, CANL PIN2),
AUX2 X4/91 (CANH PIN3, CANL PIN2),
AUX3 X4/92 (CANH PIN3, CANL PIN2),
AUX4 X4/93 (CANH PIN3, CANL PIN2),
AUX5 X4/94 (CANH PIN3, CANL PIN2),
ECCU2 CN1a (CANH PIN15, CANL PIN16),
EDC X55 (CANH PIN50, CANL PIN52),
EEM2 X70 (CANH PIN18, CANL PIN42).
ICU P8/1 (CANH PIN3, CANL PIN4) via P8/2 (CANH PIN3, CANL PIN4) to ADIC CN3 (CANH PIN26, CANL
PIN25),
KEYPAD X4/63 (CANH PIN3, CANL PIN2),
Also check whether the jumper on X70 of the EEM between PIN 66 and PIN 67 is present.
Terminating resistor X3/10 (CANH PINA, CANL PINB).

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b) Check transmission bus:
Diagnostics interface S31(CANH PIN2, CANL PIN1),
FMGR A4/3 (CANH PIN3, CANL PIN2),
SGR X16/21 (CANH PIN1, CANL PIN2),

c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN 42 and PIN18 of EEM plug X70. Also check the terminating resistor in EEM box A2
between PIN42 and PIN18 with the EEM box disconnected (setpoint 120 ohms +/- 10%).

5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.

FMGR - 240 Reception of motor (EHS) CAN bus signal on vehicle

side in register 0 is faulty from DBD100001
Cause:
The control unit detects that a time limit for a periodic data transmission between FMGR and EEM has been excee-
ded. The fault is stored and signalled on screen by a warning triangle.
Possible causes:
1. Temporary malfunction of CAN communications between FMGR and EEM.
2. Short circuit on the CAN bus.
3. Bus termination incorrect or missing.
4. Contacts of the CAN bus plugs bent, broken or corroded.
5. Control unit hardware fault of the FMGR or EEM.
Remedy:
1. A temporary malfunction can be caused by a temporary bus overload. Ensure that the power supply to the FMGR
and the EEM is correct and that both control modules are ONLINE on the bus. Use the "Control module status"
function of the Service Tool to check this. If one of the control units is OFFLINE, go to step 2. If both control units
are ONLINE, this is a temporary fault. Store the fault using the Service Tool and then delete it. Make a test drive
to check the function. If the fault code does not occur again, no further action is required.
2. Check the power supply to the module which is OFFLINE.
a) Check supply to EEM3:
I. Check ground at X89/1 PIN5, PIN6, PIN10 and PIN11 via weld point X0/42/1 to grounding point 11.
II. Check ground from enclosure of EEM control unit via weld point X0/42/1 to grounding point 11.
III. 12V (potential 15) at X89/1 PIN40 to engine print (A14) X12/1 PIN2 on fuse F207.
b) Check supply to FMGR:
I. Ground at A4/3 PIN13 via weld point X0/7/5 to grounding point 11.
II. 12V (potential 15/1) at A4/3 PIN10 to central print (A12) X24/2 PIN1 on fuse F51.
III. 12V (potential 30) at A4/3 PIN14 to central print (A12) X24/2 PIN2 on fuse F14.
3. If the power supply to the two control modules is correct, check the entire CAN bus for short-circuits. On the CAN
bus, disconnect one control module after the other and reconnect it again, checking the status of the control units
("Control module status" function of the Service Tool). If the control unit status is ONLINE, the disconnected unit
is causing the problem.
4. If the power supply to the two control modules is correct, check the entire CAN bus for interruptions or defective
terminating resistors. If the CAN bus is interrupted, only those control modules are OFFLINE which are connected
to the CAN bus after the interruption.

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a) Check vehicle bus:
Diagnostics interface X9/17 (CANH PINC, CANL PIND),
Armrest X18/4 (CANH PIN17, CANL PIN18),
AUX1 X4/90 (CANH PIN3, CANL PIN2),
AUX2 X4/91 (CANH PIN3, CANL PIN2),
AUX3 X4/92 (CANH PIN3, CANL PIN2),
AUX4 X4/93 (CANH PIN3, CANL PIN2),
AUX5 X4/94 (CANH PIN3, CANL PIN2),
ECCU2 CN1a (CANH PIN15, CANL PIN16),
EDC X55 (CANH PIN50, CANL PIN52),
EEM3 X89/1 (CANH PIN35, CANL PIN34).
ICU P8/1 (CANH PIN3, CANL PIN4) via P8/2 (CANH PIN3, CANL PIN4) to ADIC CN3 (CANH PIN26, CANL
PIN25),
KEYPAD X4/63 (CANH PIN3, CANL PIN2),
Terminating resistor X3/10 (CANH PINA, CANL PINB).

b) Check transmission bus:

Diagnostics interface X9/17 (CANH PINF, CANL PING),
FMGR A4/3 (CANH PIN3, CANL PIN2),
SGR X16/21 (CANH PIN1, CANL PIN2),

c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN34 and PIN35 of EEM plug X89/1. Also check the terminating resistor in EEM box bet-
ween PIN34 and PIN35 with the EEM box disconnected (setpoint 120 ohms +/- 10%).

5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.

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FMGR - 241 Reception of vehicle side CAN bus signal EEC2 in

register 1 is faulty up to DBD100000
Cause:
The control unit detects that a time limit for a periodic data transmission between FMGR and EEM has been excee-
ded. The fault is stored and signalled on screen by a warning triangle.
Possible causes:
1. Temporary malfunction of CAN communications between FMGR and EEM.
2. Short circuit on the CAN bus.
3. Bus termination incorrect or missing.
4. Contacts of the CAN bus plugs bent, broken or corroded.
5. Control unit hardware fault of the FMGR or EEM.
Remedy:
1. A temporary malfunction can be caused by a temporary bus overload. Ensure that the power supply to the FMGR
and the EEM is correct and that both control modules are ONLINE on the bus. Use the "Control module status"
function of the Service Tool to check this. If one of the control units is OFFLINE, go to step 2. If both control units
are ONLINE, this is a temporary fault. Store the fault using the Service Tool and then delete it. Make a test drive
to check the function. If the fault code does not occur again, no further action is required.
2. Check the power supply to the module which is OFFLINE.
a) Check supply to EEM2:
I. Check ground at X70 PIN69 and PIN 46 to weld point X0/4/1 and to grounding point 11, engine component
carrier.
II. Check ground from enclosure of EEM control unit via weld point X0/4/1 to grounding point 11.
III. 12V (potential 15/2) at X70 PIN21 to engine print (A14) X20/1 (Würth), X24/12 (Berifors) PIN7 via F97 to
K5/3 PIN87 to PIN 30 on screw down point X1/12 on F200.
b) Check supply to FMGR:
I. Ground at A4/3 PIN13 runs via weld point X0/7/5 from grounding point 16 starter.
II. 12V (potential 15/1) at A4/3 PIN10. Runs from fuse F51 (10A) on A12 central print via connector X24/2 PIN1
to FMGR A4/3 PIN10.
III. 12V (potential 30) at A4/3 PIN14. Runs from fuse F14 (7.5A) on A12 central print via X24/2 PIN6 to FMGR
A4/3 PIN14.
3. If the power supply to the two control modules is correct, check the entire CAN bus for short-circuits. On the CAN
bus, disconnect one control module after the other and reconnect it again, checking the status of the control units
("Control module status" function of the Service Tool). If the control unit status is ONLINE, the disconnected unit
is causing the problem.
4. If the power supply to the two control modules is correct, check the entire CAN bus for interruptions or defective
terminating resistors. If the CAN bus is interrupted, only those control modules are OFFLINE which are connected
to the CAN bus after the interruption.

a) Check vehicle bus:

Diagnostics interface S31(CANH PIN8, CANL PIN7),
Armrest X18/4 (CANH PIN17, CANL PIN18),
AUX1 X4/90 (CANH PIN3, CANL PIN2),
AUX2 X4/91 (CANH PIN3, CANL PIN2),
AUX3 X4/92 (CANH PIN3, CANL PIN2),
AUX4 X4/93 (CANH PIN3, CANL PIN2),
AUX5 X4/94 (CANH PIN3, CANL PIN2),
ECCU2 CN1a (CANH PIN15, CANL PIN16),
EDC X55 (CANH PIN50, CANL PIN52),
EEM2 X70 (CANH PIN18, CANL PIN42).
ICU P8/1 (CANH PIN3, CANL PIN4) via P8/2 (CANH PIN3, CANL PIN4) to ADIC CN3 (CANH PIN26, CANL
PIN25),
KEYPAD X4/63 (CANH PIN3, CANL PIN2),
Also check whether the jumper on X70 of the EEM between PIN 66 and PIN 67 is present.
Terminating resistor X3/10 (CANH PINA, CANL PINB).

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b) Check transmission bus:
Diagnostics interface S31(CANH PIN2, CANL PIN1),
FMGR A4/3 (CANH PIN3, CANL PIN2),
SGR X16/21 (CANH PIN1, CANL PIN2),

c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 ohms +/- 10%)
by measuring between PIN 42 and PIN18 of EEM plug X70. Also check the terminating resistor in EEM box A2
between PIN42 and PIN18 with the EEM box disconnected (setpoint 120 ohms +/- 10%).

5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.

FMGR - 241 Reception of vehicle side CAN bus signal EEC2

in register 1 is faulty from DBD100001
Cause:
The control unit detects that a time limit for a periodic data transmission between FMGR and EEM has been excee-
ded. The fault is stored and signalled on screen by a warning triangle.
Possible causes:
1. Temporary malfunction of CAN communications between FMGR and EEM.
2. Short circuit on the CAN bus.
3. Bus termination incorrect or missing.
4. Contacts of the CAN bus plugs bent, broken or corroded.
5. Control unit hardware fault of the FMGR or EEM.
Remedy:
1. A temporary malfunction can be caused by a temporary bus overload. Ensure that the power supply to the FMGR
and the EEM is correct and that both control modules are ONLINE on the bus. Use the "Control module status"
function of the Service Tool to check this. If one of the control units is OFFLINE, go to step 2. If both control units
are ONLINE, this is a temporary fault. Store the fault using the Service Tool and then delete it. Make a test drive
to check the function. If the fault code does not occur again, no further action is required.
2. Check the power supply to the module which is OFFLINE.
a) Check supply to EEM3:
I. Check ground at X89/1 PIN5, PIN6, PIN10 and PIN11 via weld point X0/42/1 to grounding point 11.
II. Check ground from enclosure of EEM control unit via weld point X0/42/1 to grounding point 11.
III. 12V (potential 15) at X89/1 PIN40 to engine print (A14) X12/1 PIN2 on fuse F207.
b) Check supply to FMGR:
I. Ground at A4/3 PIN13 via weld point X0/7/5 to grounding point 11.
II. 12V (potential 15/1) at A4/3 PIN10 to central print (A12) X24/2 PIN1 on fuse F51.
III. 12V (potential 30) at A4/3 PIN14 to central print (A12) X24/2 PIN2 on fuse F14.
3. If the power supply to the two control modules is correct, check the entire CAN bus for short-circuits. On the CAN
bus, disconnect one control module after the other and reconnect it again, checking the status of the control units
("Control module status" function of the Service Tool). If the control unit status is ONLINE, the disconnected unit
is causing the problem.
4. If the power supply to the two control modules is correct, check the entire CAN bus for interruptions or defective
terminating resistors. If the CAN bus is interrupted, only those control modules are OFFLINE which are connected
to the CAN bus after the interruption.

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a) Check vehicle bus:
Diagnostics interface X9/17 (CANH PINC, CANL PIND),
Armrest X18/4 (CANH PIN17, CANL PIN18),
AUX1 X4/90 (CANH PIN3, CANL PIN2),
AUX2 X4/91 (CANH PIN3, CANL PIN2),
AUX3 X4/92 (CANH PIN3, CANL PIN2),
AUX4 X4/93 (CANH PIN3, CANL PIN2),
AUX5 X4/94 (CANH PIN3, CANL PIN2),
ECCU2 CN1a (CANH PIN15, CANL PIN16),
EDC X55 (CANH PIN50, CANL PIN52),
EEM3 X89/1 (CANH PIN35, CANL PIN34).
ICU P8/1 (CANH PIN3, CANL PIN4) via P8/2 (CANH PIN3, CANL PIN4) to ADIC CN3 (CANH PIN26, CANL
PIN25),
KEYPAD X4/63 (CANH PIN3, CANL PIN2),
Terminating resistor X3/10 (CANH PINA, CANL PINB).

b) Check transmission bus:

Diagnostics interface X9/17 (CANH PINF, CANL PING),
FMGR A4/3 (CANH PIN3, CANL PIN2),
SGR X16/21 (CANH PIN1, CANL PIN2),

c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN34 and PIN35 of EEM plug X89/1. Also check the terminating resistor in EEM box bet-
ween PIN34 and PIN35 with the EEM box disconnected (setpoint 120 ohms +/- 10%).

5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.

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FMGR - 242 Reception of vehicle side CAN bus signal EEC1 in

register 2 is faulty up to DBD100000
Cause:
The control unit detects that a time limit for a periodic data transmission between FMGR and EEM has been excee-
ded. The fault is stored and signalled on screen by a warning triangle.
Possible causes:
1. Temporary malfunction of CAN communications between FMGR and EEM.
2. Short circuit on the CAN bus.
3. Bus termination incorrect or missing.
4. Contacts of the CAN bus plugs bent, broken or corroded.
5. Control unit hardware fault of the FMGR or EEM.
Remedy:
1. A temporary malfunction can be caused by a temporary bus overload. Ensure that the power supply to the FMGR
and the EEM is correct and that both control modules are ONLINE on the bus. Use the "Control module status"
function of the Service Tool to check this. If one of the control units is OFFLINE, go to step 2. If both control units
are ONLINE, this is a temporary fault. Store the fault using the Service Tool and then delete it. Make a test drive
to check the function. If the fault code does not occur again, no further action is required.
2. Check the power supply to the module which is OFFLINE.
a) Check supply to EEM2:
I. Check ground at X70 PIN69 and PIN 46 to weld point X0/4/1 and to grounding point 11, engine component
carrier.
II. Check ground from enclosure of EEM control unit via weld point X0/4/1 to ground 11.
III. 12V (potential 15/2) at X70 PIN21 to engine print (A14) X20/1 (Würth), X24/12 (Berifors) PIN7 via F97 to
K5/3 PIN87 to PIN 30 on screw down point X1/12 on F200.
b) Check supply to FMGR:
I. Ground at A4/3 PIN13 runs via weld point X0/7/5 from grounding point 16 starter.
II. 12V (potential 15/1) at A4/3 PIN10. Runs from fuse F51 (10A) on A12 central print via connector X24/2 PIN1
to FMGR A4/3 PIN10.
III. 12V (potential 30) at A4/3 PIN14. Runs from fuse F14 (7.5A) on A12 central print via X24/2 PIN6 to FMGR
A4/3 PIN14.
3. If the power supply to the two control modules is correct, check the entire CAN bus for short-circuits. On the CAN
bus, disconnect one control module after the other and reconnect it again, checking the status of the control units
("Control module status" function of the Service Tool). If the control unit status is ONLINE, the disconnected unit
is causing the problem.
4. If the power supply to the two control modules is correct, check the entire CAN bus for interruptions or defective
terminating resistors. If the CAN bus is interrupted, only those control modules are OFFLINE which are connected
to the CAN bus after the interruption.

a) Check vehicle bus:

Diagnostics interface S31(CANH PIN8, CANL PIN7),
Armrest X18/4 (CANH PIN17, CANL PIN18),
AUX1 X4/90 (CANH PIN3, CANL PIN2),
AUX2 X4/91 (CANH PIN3, CANL PIN2),
AUX3 X4/92 (CANH PIN3, CANL PIN2),
AUX4 X4/93 (CANH PIN3, CANL PIN2),
AUX5 X4/94 (CANH PIN3, CANL PIN2),
ECCU2 CN1a (CANH PIN15, CANL PIN16),
EDC X55 (CANH PIN50, CANL PIN52),
EEM2 X70 (CANH PIN18, CANL PIN42).
ICU P8/1 (CANH PIN3, CANL PIN4) via P8/2 (CANH PIN3, CANL PIN4) to ADIC CN3 (CANH PIN26, CANL
PIN25),
KEYPAD X4/63 (CANH PIN3, CANL PIN2),
Also check whether the jumper on X70 of the EEM between PIN 66 and PIN 67 is present.
Terminating resistor X3/10 (CANH PINA, CANL PINB).

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b) Check transmission bus:
Diagnostics interface S31(CANH PIN2, CANL PIN1),
FMGR A4/3 (CANH PIN3, CANL PIN2),
SGR X16/21 (CANH PIN1, CANL PIN2),

c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN 42 and PIN18 of EEM plug X70. Also check the terminating resistor in EEM box A2
between PIN42 and PIN18 with the EEM box disconnected (setpoint 120 ohms +/- 10%).

5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.

FMGR - 242 Reception of vehicle side CAN bus signal EEC1

in register 2 is faulty from DBD100001
Cause:
The control unit detects that a time limit for a periodic data transmission between FMGR and EEM has been excee-
ded. The fault is stored and signalled on screen by a warning triangle.
Possible causes:
1. Temporary malfunction of CAN communications between FMGR and EEM.
2. Short circuit on the CAN bus.
3. Bus termination incorrect or missing.
4. Contacts of the CAN bus plugs bent, broken or corroded.
5. Control unit hardware fault of the FMGR or EEM.
Remedy:
1. A temporary malfunction can be caused by a temporary bus overload. Ensure that the power supply to the FMGR
and the EEM is correct and that both control modules are ONLINE on the bus. Use the "Control module status"
function of the Service Tool to check this. If one of the control units is OFFLINE, go to step 2. If both control units
are ONLINE, this is a temporary fault. Store the fault using the Service Tool and then delete it. Make a test drive
to check the function. If the fault code does not occur again, no further action is required.
2. Check the power supply to the module which is OFFLINE.
a) Check supply to EEM3:
I. Check ground at X89/1 PIN5, PIN6, PIN10 and PIN11 via weld point X0/42/1 to grounding point 11.
II. Check ground from enclosure of EEM control unit via weld point X0/42/1 to grounding point 11.
III. 12V (potential 15) at X89/1 PIN40 to engine print (A14) X12/1 PIN2 on fuse F207.
b) Check supply to FMGR:
I. Ground at A4/3 PIN13 via weld point X0/7/5 to grounding point 11.
II. 12V (potential 15/1) at A4/3 PIN10 to central print (A12) X24/2 PIN1 on fuse F51.
III. 12V (potential 30) at A4/3 PIN14 to central print (A12) X24/2 PIN2 on fuse F14.
3. If the power supply to the two control modules is correct, check the entire CAN bus for short-circuits. On the CAN
bus, disconnect one control module after the other and reconnect it again, checking the status of the control units
("Control module status" function of the Service Tool). If the control unit status is ONLINE, the disconnected unit
is causing the problem.
4. If the power supply to the two control modules is correct, check the entire CAN bus for interruptions or defective
terminating resistors. If the CAN bus is interrupted, only those control modules are OFFLINE which are connected
to the CAN bus after the interruption.

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a) Check vehicle bus:
Diagnostics interface X9/17 (CANH PINC, CANL PIND),
Armrest X18/4 (CANH PIN17, CANL PIN18),
AUX1 X4/90 (CANH PIN3, CANL PIN2),
AUX2 X4/91 (CANH PIN3, CANL PIN2),
AUX3 X4/92 (CANH PIN3, CANL PIN2),
AUX4 X4/93 (CANH PIN3, CANL PIN2),
AUX5 X4/94 (CANH PIN3, CANL PIN2),
ECCU2 CN1a (CANH PIN15, CANL PIN16),
EDC X55 (CANH PIN50, CANL PIN52),
EEM3 X89/1 (CANH PIN35, CANL PIN34).
ICU P8/1 (CANH PIN3, CANL PIN4) via P8/2 (CANH PIN3, CANL PIN4) to ADIC CN3 (CANH PIN26, CANL
PIN25),
KEYPAD X4/63 (CANH PIN3, CANL PIN2),
Terminating resistor X3/10 (CANH PINA, CANL PINB).

b) Check transmission bus:

Diagnostics interface X9/17 (CANH PINF, CANL PING),
FMGR A4/3 (CANH PIN3, CANL PIN2),
SGR X16/21 (CANH PIN1, CANL PIN2),

c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN34 and PIN35 of EEM plug X89/1. Also check the terminating resistor in EEM box bet-
ween PIN34 and PIN35 with the EEM box disconnected (setpoint 120 ohms +/- 10%).

5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.

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FMGR - 243 Reception of vehicle side CAN bus signal DRVST in

register 3 is faulty up to DBD100000
Cause:
The control unit detects that a time limit for a periodic data transmission between FMGR and ARU has been excee-
ded. The fault is stored and signalled on screen by a warning triangle.
Possible causes:
1. Temporary malfunction of CAN communications between FMGR and ARU.
2. Short circuit on the CAN bus.
3. Bus termination incorrect or missing.
4. Contacts of the CAN bus plugs bent, broken or corroded.
5. Control unit hardware fault of FMGR or ARU.
Remedy:
1. A temporary malfunction can be caused by a temporary bus overload. Ensure that the power supply to the FMGR
and the ARU is correct and that both control modules are ONLINE on the bus. Use the "Control module status"
function of the Service Tool to check this. If one of the control units is OFFLINE, go to step 2. If both control units
are ONLINE, this is a temporary fault. Store the fault using the Service Tool and then delete it. Make a test drive
to check the function. If the fault code does not occur again, no further action is required.
2. Check the power supply to the module which is OFFLINE.
a) Check supply to ARU:
I. Ground at X18/4 PIN10 to weld point X0/7/17
II. 12V (potential 15/1) at X18/4 PIN9, 13 to central print (A12) X24/2 PIN17, 18 to F19, F20
b) Check supply to FMGR:
I. Ground at A4/3 PIN13 runs via weld point X0/7/5 from grounding point 16 starter.
II. 12V (potential 15/1) at A4/3 PIN10. Runs from fuse F51 (10A) on A12 central print via connector X24/2 PIN1
to FMGR A4/3 PIN10.
III. 12V (potential 30) at A4/3 PIN14. Runs from fuse F14 (7.5A) on A12 central print via X24/2 PIN6 to FMGR
A4/3 PIN14.
3. If the power supply to the two control modules is correct, check the entire CAN bus for short-circuits. On the CAN
bus, disconnect one control module after the other and reconnect it again, checking the status of the control units
("Control module status" function of the Service Tool). If the control unit status is ONLINE, the disconnected unit
is causing the problem.
4. If the power supply to the two control modules is correct, check the entire CAN bus for interruptions or defective
terminating resistors. If the CAN bus is interrupted, only those control modules are OFFLINE which are connected
to the CAN bus after the interruption.

a) Check vehicle bus:

Diagnostics interface S31(CANH PIN8, CANL PIN7),
Armrest X18/4 (CANH PIN17, CANL PIN18),
AUX1 X4/90 (CANH PIN3, CANL PIN2),
AUX2 X4/91 (CANH PIN3, CANL PIN2),
AUX3 X4/92 (CANH PIN3, CANL PIN2),
AUX4 X4/93 (CANH PIN3, CANL PIN2),
AUX5 X4/94 (CANH PIN3, CANL PIN2),
ECCU2 CN1a (CANH PIN15, CANL PIN16),
EDC X55 (CANH PIN50, CANL PIN52),
EEM2 X70 (CANH PIN18, CANL PIN42).
ICU P8/1 (CANH PIN3, CANL PIN4) via P8/2 (CANH PIN3, CANL PIN4) to ADIC CN3 (CANH PIN26, CANL
PIN25),
KEYPAD X4/63 (CANH PIN3, CANL PIN2),
Also check whether the jumper on X70 of the EEM between PIN 66 and PIN 67 is present.
Terminating resistor X3/10 (CANH PINA, CANL PINB).

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b) Check transmission bus:
Diagnostics interface S31(CANH PIN2, CANL PIN1),
FMGR A4/3 (CANH PIN3, CANL PIN2),
SGR X16/21 (CANH PIN1, CANL PIN2),

c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm 10%) by
measuring between PIN 42 and PIN18 of EEM plug X70. Also check the terminating resistor in EEM box A2 bet-
ween PIN42 and PIN18 with the EEM box disconnected (setpoint 120 ohms 10%).

5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.

FMGR - 243 Reception of vehicle side CAN bus signal DRVST in

register 3 is faulty from DBD100001
Cause:
The control unit detects that a time limit for a periodic data transmission between FMGR and ARU has been excee-
ded. The fault is stored and signalled on screen by a warning triangle.
Possible causes:
1. Temporary malfunction of CAN communications between FMGR and ARU.
2. Short circuit on the CAN bus.
3. Bus termination incorrect or missing.
4. Contacts of the CAN bus plugs bent, broken or corroded.
5. Control unit hardware fault of FMGR or ARU.
Remedy:
1. A temporary malfunction can be caused by a temporary bus overload. Ensure that the power supply to the FMGR
and the ARU is correct and that both control modules are ONLINE on the bus. Use the "Control module status"
function of the Service Tool to check this. If one of the control units is OFFLINE, go to step 2. If both control units
are ONLINE, this is a temporary fault. Store the fault using the Service Tool and then delete it. Make a test drive
to check the function. If the fault code does not occur again, no further action is required.
2. Check the power supply to the module which is OFFLINE.
a) Check supply to ARU:
I. Ground at X18/4 PIN10 via weld point X0/7/17 and weld point X0/7/5 to grounding point 11.
II. 12V (potential 15/1) at X18/4 PIN9, 13 to central print (A12) X24/2 PIN17, 18 to fuse F19, F20
b) Check supply to FMGR:
I. Ground at A4/3 PIN13 via weld point X0/7/5 to grounding point 11.
II. 12V (potential 15/1) at A4/3 PIN10 to central print (A12) X24/2 PIN1 on fuse F51.
III. 12V (potential 30) at A4/3 PIN14 to central print (A12) X24/2 PIN2 on fuse F14.
3. If the power supply to the two control modules is correct, check the entire CAN bus for short-circuits. On the CAN
bus, disconnect one control module after the other and reconnect it again, checking the status of the control units
("Control module status" function of the Service Tool). If the control unit status is ONLINE, the disconnected unit
is causing the problem.
4. If the power supply to the two control modules is correct, check the entire CAN bus for interruptions or defective
terminating resistors. If the CAN bus is interrupted, only those control modules are OFFLINE which are connected
to the CAN bus after the interruption.

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a) Check vehicle bus:
Diagnostics interface X9/17 (CANH PINC, CANL PIND),
Armrest X18/4 (CANH PIN17, CANL PIN18),
AUX1 X4/90 (CANH PIN3, CANL PIN2),
AUX2 X4/91 (CANH PIN3, CANL PIN2),
AUX3 X4/92 (CANH PIN3, CANL PIN2),
AUX4 X4/93 (CANH PIN3, CANL PIN2),
AUX5 X4/94 (CANH PIN3, CANL PIN2),
ECCU2 CN1a (CANH PIN15, CANL PIN16),
EDC X55 (CANH PIN50, CANL PIN52),
EEM3 X89/1 (CANH PIN35, CANL PIN34).
ICU P8/1 (CANH PIN3, CANL PIN4) via P8/2 (CANH PIN3, CANL PIN4) to ADIC CN3 (CANH PIN26, CANL
PIN25),
KEYPAD X4/63 (CANH PIN3, CANL PIN2),
Terminating resistor X3/10 (CANH PINA, CANL PINB).

b) Check transmission bus:

Diagnostics interface X9/17 (CANH PINF, CANL PING),
FMGR A4/3 (CANH PIN3, CANL PIN2),
SGR X16/21 (CANH PIN1, CANL PIN2),

c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN34 and PIN35 of EEM plug X89/1. Also check the terminating resistor in EEM box bet-
ween PIN34 and PIN35 with the EEM box disconnected (setpoint 120 ohms +/- 10%). s

5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.

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FMGR - 245 Reception of vehicle side CAN bus signal AUX1 in

register 5 is faulty up to DBD100000
Cause:
The control unit detects that a time limit for a periodic data transmission between FMGR and AUX 1 has been excee-
ded.
Possible causes:
1. Temporary malfunction of CAN communications between FMGR and AUX1.
2. Short circuit on the CAN bus.
3. Bus termination incorrect or missing.
4. Contacts of the CAN bus plugs bent, broken or corroded.
5. Control unit hardware fault of FMGR or AUX1.
Remedy:
1. A temporary malfunction can be caused by a temporary bus overload. Ensure that the power supply to FMGR
and AUX1 is correct and that both control modules are ONLINE on the bus. Use the "Control module status"
function of the Service Tool to check this. If one of the control units is OFFLINE, go to step 2. If both control units
are ONLINE, this is a temporary fault. Store the fault using the Service Tool and then delete it. Make a test drive
to check the function. If the fault code does not occur again, no further action is required.
2. Check the power supply to the module which is OFFLINE.
a) Check supply to AUX1:
I. Ground at X4/90 PIN4 to weld point X0/9/11 via X4/83 PIN2 to plug connection X5/1 on central print A12.
II. 12V (potential 15/1) at X4/90 PIN1 to weld point X0/9/10 via X4/83 PIN1 to plug X24/2 PIN24 on fuse F47.
b) Check supply to FMGR:
I. Ground at A4/3 PIN13 runs via weld point X0/7/5 from grounding point 16 starter.
II. 12V (potential 15/1) at A4/3 PIN10. Runs from fuse F51 (10A) on A12 central print via connector X24/2 PIN1
to FMGR A4/3 PIN10.
III. 12V (potential 30) at A4/3 PIN14. Runs from fuse F14 (7.5A) on A12 central print via X24/2 PIN6 to FMGR
A4/3 PIN14.
3. If the power supply to the two control modules is correct, check the entire CAN bus for short-circuits. On the CAN
bus, disconnect one control module after the other and reconnect it again, checking the status of the control units
("Control module status" function of the Service Tool). If the control unit status is ONLINE, the disconnected unit
is causing the problem.
4. If the power supply to the two control modules is correct, check the entire CAN bus for interruptions or defective
terminating resistors. If the CAN bus is interrupted, only those control modules are OFFLINE which are connected
to the CAN bus after the interruption.

a) Check vehicle bus:

Diagnostics interface S31(CANH PIN8, CANL PIN7),
Armrest X18/4 (CANH PIN17, CANL PIN18),
AUX1 X4/90 (CANH PIN3, CANL PIN2),
AUX2 X4/91 (CANH PIN3, CANL PIN2),
AUX3 X4/92 (CANH PIN3, CANL PIN2),
AUX4 X4/93 (CANH PIN3, CANL PIN2),
AUX5 X4/94 (CANH PIN3, CANL PIN2),
ECCU2 CN1a (CANH PIN15, CANL PIN16),
EDC X55 (CANH PIN50, CANL PIN52),
EEM2 X70 (CANH PIN18, CANL PIN42).
ICU P8/1 (CANH PIN3, CANL PIN4) via P8/2 (CANH PIN3, CANL PIN4) to ADIC CN3 (CANH PIN26, CANL
PIN25),
KEYPAD X4/63 (CANH PIN3, CANL PIN2),
Also check whether the jumper on X70 of the EEM between PIN 66 and PIN 67 is present.
Terminating resistor X3/10 (CANH PINA, CANL PINB).

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b) Check transmission bus:
Diagnostics interface S31(CANH PIN2, CANL PIN1),
FMGR A4/3 (CANH PIN3, CANL PIN2),
SGR X16/21 (CANH PIN1, CANL PIN2),

c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN 42 and PIN18 of EEM plug X70. Also check the terminating resistor in EEM box A2
between PIN42 and PIN18 with the EEM box disconnected (setpoint 120 ohms +/- 10%).

5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.

FMGR - 245 Reception of vehicle side CAN bus signal AUX1

in register 5 is faulty from DBD100001
Cause:
The control unit detects that a time limit for a periodic data transmission between FMGR and AUX 1 has been excee-
ded.
Possible causes:
1. Temporary malfunction of CAN communications between FMGR and AUX1.
2. Short circuit on the CAN bus.
3. Bus termination incorrect or missing.
4. Contacts of the CAN bus plugs bent, broken or corroded.
5. Control unit hardware fault of FMGR or AUX1.
Remedy:
1. A temporary malfunction can be caused by a temporary bus overload. Ensure that the power supply to FMGR
and AUX1 is correct and that both control modules are ONLINE on the bus. Use the "Control module status"
function of the Service Tool to check this. If one of the control units is OFFLINE, go to step 2. If both control units
are ONLINE, this is a temporary fault. Store the fault using the Service Tool and then delete it. Make a test drive
to check the function. If the fault code does not occur again, no further action is required.
2. Check the power supply to the module which is OFFLINE.
a) Check supply to AUX1:
I. Ground at X4/90 PIN4 to weld point X0/9/11 via X4/83 PIN2 to weld point X0/7/5 on grounding point 11.
II. 12V (potential 15/1) at X4/90 PIN1 to weld point X0/9/10 via plug X4/83 PIN1 to plug X24/2 PIN24 on fuse
F47.
b) Check supply to FMGR:
I. Ground at A4/3 PIN13 via weld point X0/7/5 to grounding point 11.
II. 12V (potential 15/1) at A4/3 PIN10 to central print (A12) X24/2 PIN1 on fuse F51.
III. 12V (potential 30) at A4/3 PIN14 to central print (A12) X24/2 PIN2 on fuse F14.
3. If the power supply to the two control modules is correct, check the entire CAN bus for short-circuits. On the CAN
bus, disconnect one control module after the other and reconnect it again, checking the status of the control units
("Control module status" function of the Service Tool). If the control unit status is ONLINE, the disconnected unit
is causing the problem.
4. If the power supply to the two control modules is correct, check the entire CAN bus for interruptions or defective
terminating resistors. If the CAN bus is interrupted, only those control modules are OFFLINE which are connected
to the CAN bus after the interruption.

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a) Check vehicle bus:
Diagnostics interface X9/17 (CANH PINC, CANL PIND),
Armrest X18/4 (CANH PIN17, CANL PIN18),
AUX1 X4/90 (CANH PIN3, CANL PIN2),
AUX2 X4/91 (CANH PIN3, CANL PIN2),
AUX3 X4/92 (CANH PIN3, CANL PIN2),
AUX4 X4/93 (CANH PIN3, CANL PIN2),
AUX5 X4/94 (CANH PIN3, CANL PIN2),
ECCU2 CN1a (CANH PIN15, CANL PIN16),
EDC X55 (CANH PIN50, CANL PIN52),
EEM3 X89/1 (CANH PIN35, CANL PIN34).
ICU P8/1 (CANH PIN3, CANL PIN4) via P8/2 (CANH PIN3, CANL PIN4) to ADIC CN3 (CANH PIN26, CANL
PIN25),
KEYPAD X4/63 (CANH PIN3, CANL PIN2),
Terminating resistor X3/10 (CANH PINA, CANL PINB).

b) Check transmission bus:

Diagnostics interface X9/17 (CANH PINF, CANL PING),
FMGR A4/3 (CANH PIN3, CANL PIN2),
SGR X16/21 (CANH PIN1, CANL PIN2),

c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN34 and PIN35 of EEM plug X89/1. Also check the terminating resistor in EEM box bet-
ween PIN34 and PIN35 with the EEM box disconnected (setpoint 120 ohms +/- 10%).

5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.

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FMGR - 246 Reception of vehicle side CAN bus signal AUX2 in regi-
ster 6 is faulty up to DBD100000
Cause:
The control unit detects that a time limit for a periodic data transmission between FMGR and AUX 2 has been excee-
ded.
Possible causes:
1. Temporary malfunction of CAN communications between FMGR and AUX2.
2. Short circuit on the CAN bus.
3. Bus termination incorrect or missing.
4. Contacts of the CAN bus plugs bent, broken or corroded.
5. Control unit hardware fault of FMGR or AUX2.
Remedy:
1. A temporary malfunction can be caused by a temporary bus overload. Ensure that the power supply to FMGR
and AUX2 is correct and that both control modules are ONLINE on the bus. Use the "Control module status"
function of the Service Tool to check this. If one of the control units is OFFLINE, go to step 2. If both control units
are ONLINE, this is a temporary fault. Store the fault using the Service Tool and then delete it. Make a test drive
to check the function. If the fault code does not occur again, no further action is required.
2. Check the power supply to the module which is OFFLINE.
a) Check supply to AUX2:
I. Ground at X4/91 PIN4 via weld point X0/9/21 to weld point X0/9/11 via X4/83 PIN2 to plug connection X5/1
on central print A12.
II. 12V (Potential 15/1) at X4/91 PIN1 via weld point X0/9/20 to weld point X0/9/10 via X4/83 PIN1 to plug
X24/2 PIN24 on fuse F47.
b) Check supply to FMGR:
I. Ground at A4/3 PIN13 runs via weld point X0/7/5 from grounding point 16 starter.
II. 12V (potential 15/1) at A4/3 PIN10. Runs from fuse F51 (10A) on A12 central print via connector X24/2 PIN1
to FMGR A4/3 PIN10.
III. 12V (potential 30) at A4/3 PIN14. Runs from fuse F14 (7.5A) on A12 central print via X24/2 PIN6 to FMGR
A4/3 PIN14.
3. If the power supply to the two control modules is correct, check the entire CAN bus for short-circuits. On the CAN
bus, disconnect one control module after the other and reconnect it again, checking the status of the control units
("Control module status" function of the Service Tool). If the control unit status is ONLINE, the disconnected unit
is causing the problem.
4. If the power supply to the two control modules is correct, check the entire CAN bus for interruptions or defective
terminating resistors. If the CAN bus is interrupted, only those control modules are OFFLINE which are connected
to the CAN bus after the interruption.

a) Check vehicle bus:

Diagnostics interface S31(CANH PIN8, CANL PIN7),
Armrest X18/4 (CANH PIN17, CANL PIN18),
AUX1 X4/90 (CANH PIN3, CANL PIN2),
AUX2 X4/91 (CANH PIN3, CANL PIN2),
AUX3 X4/92 (CANH PIN3, CANL PIN2),
AUX4 X4/93 (CANH PIN3, CANL PIN2),
AUX5 X4/94 (CANH PIN3, CANL PIN2),
ECCU2 CN1a (CANH PIN15, CANL PIN16),
EDC X55 (CANH PIN50, CANL PIN52),
EEM2 X70 (CANH PIN18, CANL PIN42).
ICU P8/1 (CANH PIN3, CANL PIN4) via P8/2 (CANH PIN3, CANL PIN4) to ADIC CN3 (CANH PIN26, CANL
PIN25),
KEYPAD X4/63 (CANH PIN3, CANL PIN2),
Also check whether the jumper on X70 of the EEM between PIN 66 and PIN 67 is present.
Terminating resistor X3/10 (CANH PINA, CANL PINB).

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b) Check transmission bus:
Diagnostics interface S31(CANH PIN2, CANL PIN1),
FMGR A4/3 (CANH PIN3, CANL PIN2),
SGR X16/21 (CANH PIN1, CANL PIN2),

c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN 42 and PIN18 of EEM plug X70. Also check the terminating resistor in EEM box A2
between PIN42 and PIN18 with the EEM box disconnected (setpoint 120 ohms +/- 10%).

5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.

FMGR - 246 Reception of vehicle side CAN bus signal AUX2

in register 6 is faulty from DBD100001
Cause:
The control unit detects that a time limit for a periodic data transmission between FMGR and AUX 2 has been excee-
ded.
Possible causes:
1. Temporary malfunction of CAN communications between FMGR and AUX2.
2. Short circuit on the CAN bus.
3. Bus termination incorrect or missing.
4. Contacts of the CAN bus plugs bent, broken or corroded.
5. Control unit hardware fault of FMGR or AUX2.
Remedy:
1. A temporary malfunction can be caused by a temporary bus overload. Ensure that the power supply to FMGR
and AUX2 is correct and that both control modules are ONLINE on the bus. Use the "Control module status"
function of the Service Tool to check this. If one of the control units is OFFLINE, go to step 2. If both control units
are ONLINE, this is a temporary fault. Store the fault using the Service Tool and then delete it. Make a test drive
to check the function. If the fault code does not occur again, no further action is required.
2. Check the power supply to the module which is OFFLINE.
a) Check supply to AUX2:
I. Ground at X4/91 PIN4 to weld point X0/9/11 via X4/83 PIN2 to weld point X0/7/5 on grounding point 11.
II. 12V (potential 15/1) at X4/91 PIN1 to weld point X0/9/10 via plug X4/83 PIN1 to plug X24/2 PIN24 on fuse
F47.
b) Check supply to FMGR:
I. Ground at A4/3 PIN13 via weld point X0/7/5 to grounding point 11.
II. 12V (potential 15/1) at A4/3 PIN10 to central print (A12) X24/2 PIN1 on fuse F51.
III. 12V (potential 30) at A4/3 PIN14 to central print (A12) X24/2 PIN2 on fuse F14.
3. If the power supply to the two control modules is correct, check the entire CAN bus for short-circuits. On the CAN
bus, disconnect one control module after the other and reconnect it again, checking the status of the control units
("Control module status" function of the Service Tool). If the control unit status is ONLINE, the disconnected unit
is causing the problem.
4. If the power supply to the two control modules is correct, check the entire CAN bus for interruptions or defective
terminating resistors. If the CAN bus is interrupted, only those control modules are OFFLINE which are connected
to the CAN bus after the interruption.

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a) Check vehicle bus:
Diagnostics interface X9/17 (CANH PINC, CANL PIND),
Armrest X18/4 (CANH PIN17, CANL PIN18),
AUX1 X4/90 (CANH PIN3, CANL PIN2),
AUX2 X4/91 (CANH PIN3, CANL PIN2),
AUX3 X4/92 (CANH PIN3, CANL PIN2),
AUX4 X4/93 (CANH PIN3, CANL PIN2),
AUX5 X4/94 (CANH PIN3, CANL PIN2),
ECCU2 CN1a (CANH PIN15, CANL PIN16),
EDC X55 (CANH PIN50, CANL PIN52),
EEM3 X89/1 (CANH PIN35, CANL PIN34).
ICU P8/1 (CANH PIN3, CANL PIN4) via P8/2 (CANH PIN3, CANL PIN4) to ADIC CN3 (CANH PIN26, CANL
PIN25),
KEYPAD X4/63 (CANH PIN3, CANL PIN2),
Terminating resistor X3/10 (CANH PINA, CANL PINB).

b) Check transmission bus:

Diagnostics interface X9/17 (CANH PINF, CANL PING),
FMGR A4/3 (CANH PIN3, CANL PIN2),
SGR X16/21 (CANH PIN1, CANL PIN2),

c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN34 and PIN35 of EEM plug X89/1. Also check the terminating resistor in EEM box bet-
ween PIN34 and PIN35 with the EEM box disconnected (setpoint 120 ohms +/- 10%).

5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.

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FMGR - 247 Reception of vehicle side CAN bus signal AUX3 in

register 7 is faulty up to DBD100000
Cause:
The control unit detects that a time limit for a periodic data transmission between FMGR and AUX 3 has been excee-
ded.
Possible causes:
1. Temporary malfunction of CAN communications between FMGR and AUX3.
2. Short circuit on the CAN bus.
3. Bus termination incorrect or missing.
4. Contacts of the CAN bus plugs bent, broken or corroded.
5. Control unit hardware fault of FMGR or AUX3
Remedy:
1. A temporary malfunction can be caused by a temporary bus overload. Ensure that the power supply to FMGR
and AUX3 is correct and that both control modules are ONLINE on the bus. Use the "Control module status"
function of the Service Tool to check this. If one of the control units is OFFLINE, go to step 2. If both control units
are ONLINE, this is a temporary fault. Store the fault using the Service Tool and then delete it. Make a test drive
to check the function. If the fault code does not occur again, no further action is required.
2. Check the power supply to the module which is OFFLINE.
a) Check supply to AUX3:
I. Ground at X4/92 PIN4 via weld point X0/9/31 to weld point X0/9/21 to weld point X0/9/11 via X4/83 PIN2 to
plug connection X5/1 on central print A12.
II. 12V (potential 15/1) at X4/92 PIN1 via weld point X0/9/30 to weld point X0/9/20 to weld point X0/9/10 via
X4/83 PIN1 to plug X24/2 PIN24 on fuse F47.
b) Check supply to FMGR:
I. Ground at A4/3 PIN13 runs via weld point X0/7/5 from grounding point 16 starter.
II. 12V (potential 15/1) at A4/3 PIN10. Runs from fuse F51 (10A) on A12 central print via connector X24/2 PIN1
to FMGR A4/3 PIN10.
III. 12V (potential 30) at A4/3 PIN14. Runs from fuse F14 (7.5A) on A12 central print via X24/2 PIN6 to FMGR
A4/3 PIN14.
3. If the power supply to the two control modules is correct, check the entire CAN bus for short-circuits. On the CAN
bus, disconnect one control module after the other and reconnect it again, checking the status of the control units
("Control module status" function of the Service Tool). If the control unit status is ONLINE, the disconnected unit
is causing the problem.
4. If the power supply to the two control modules is correct, check the entire CAN bus for interruptions or defective
terminating resistors. If the CAN bus is interrupted, only those control modules are OFFLINE which are connected
to the CAN bus after the interruption.

a) Check vehicle bus:

Diagnostics interface S31(CANH PIN8, CANL PIN7),
Armrest X18/4 (CANH PIN17, CANL PIN18),
AUX1 X4/90 (CANH PIN3, CANL PIN2),
AUX2 X4/91 (CANH PIN3, CANL PIN2),
AUX3 X4/92 (CANH PIN3, CANL PIN2),
AUX4 X4/93 (CANH PIN3, CANL PIN2),
AUX5 X4/94 (CANH PIN3, CANL PIN2),
ECCU2 CN1a (CANH PIN15, CANL PIN16),
EDC X55 (CANH PIN50, CANL PIN52),
EEM2 X70 (CANH PIN18, CANL PIN42).
ICU P8/1 (CANH PIN3, CANL PIN4) via P8/2 (CANH PIN3, CANL PIN4) to ADIC CN3 (CANH PIN26, CANL
PIN25),
KEYPAD X4/63 (CANH PIN3, CANL PIN2),
Also check whether the jumper on X70 of the EEM between PIN 66 and PIN 67 is present.
Terminating resistor X3/10 (CANH PINA, CANL PINB).

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b) Check transmission bus:
Diagnostics interface S31(CANH PIN2, CANL PIN1),
FMGR A4/3 (CANH PIN3, CANL PIN2),
SGR X16/21 (CANH PIN1, CANL PIN2),

c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN 42 and PIN18 of EEM plug X70. Also check the terminating resistor in EEM box A2
between PIN42 and PIN18 with the EEM box disconnected (setpoint 120 ohms +/- 10%).

5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.

FMGR - 247 Reception of vehicle side CAN bus signal AUX3

in register 7 is faulty from DBD100001
Cause:
The control unit detects that a time limit for a periodic data transmission between FMGR and AUX 3 has been excee-
ded.
Possible causes:
1. Temporary malfunction of CAN communications between FMGR and AUX3.
2. Short circuit on the CAN bus.
3. Bus termination incorrect or missing.
4. Contacts of the CAN bus plugs bent, broken or corroded.
5. Control unit hardware fault of FMGR or AUX3
Remedy:
1. A temporary malfunction can be caused by a temporary bus overload. Ensure that the power supply to FMGR
and AUX3 is correct and that both control modules are ONLINE on the bus. Use the "Control module status"
function of the Service Tool to check this. If one of the control units is OFFLINE, go to step 2. If both control units
are ONLINE, this is a temporary fault. Store the fault using the Service Tool and then delete it. Make a test drive
to check the function. If the fault code does not occur again, no further action is required.
2. Check the power supply to the module which is OFFLINE.
a) Check supply to AUX3:
I. Ground at X4/92 PIN4 to weld point X0/9/11 via X4/83 PIN2 to weld point X0/7/5 on grounding point 11.
II. 12V (potential 15/1) at X4/92 PIN1 to weld point X0/9/10 via plug X4/83 PIN1 to plug X24/2 PIN24 on fuse
F47.
b) Check supply to FMGR:
I. Ground at A4/3 PIN13 via weld point X0/7/5 to grounding point 11.
II. 12V (potential 15/1) at A4/3 PIN10 to central print (A12) X24/2 PIN1 on fuse F51.
III. 12V (potential 30) at A4/3 PIN14 to central print (A12) X24/2 PIN2 on fuse F14.
3. If the power supply to the two control modules is correct, check the entire CAN bus for short-circuits. On the CAN
bus, disconnect one control module after the other and reconnect it again, checking the status of the control units
("Control module status" function of the Service Tool). If the control unit status is ONLINE, the disconnected unit
is causing the problem.
4. If the power supply to the two control modules is correct, check the entire CAN bus for interruptions or defective
terminating resistors. If the CAN bus is interrupted, only those control modules are OFFLINE which are connected
to the CAN bus after the interruption.

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a) Check vehicle bus:
Diagnostics interface X9/17 (CANH PINC, CANL PIND),
Armrest X18/4 (CANH PIN17, CANL PIN18),
AUX1 X4/90 (CANH PIN3, CANL PIN2),
AUX2 X4/91 (CANH PIN3, CANL PIN2),
AUX3 X4/92 (CANH PIN3, CANL PIN2),
AUX4 X4/93 (CANH PIN3, CANL PIN2),
AUX5 X4/94 (CANH PIN3, CANL PIN2),
ECCU2 CN1a (CANH PIN15, CANL PIN16),
EDC X55 (CANH PIN50, CANL PIN52),
EEM3 X89/1 (CANH PIN35, CANL PIN34).
ICU P8/1 (CANH PIN3, CANL PIN4) via P8/2 (CANH PIN3, CANL PIN4) to ADIC CN3 (CANH PIN26, CANL
PIN25),
KEYPAD X4/63 (CANH PIN3, CANL PIN2),
Terminating resistor X3/10 (CANH PINA, CANL PINB).

b) Check transmission bus:

Diagnostics interface X9/17 (CANH PINF, CANL PING),
FMGR A4/3 (CANH PIN3, CANL PIN2),
SGR X16/21 (CANH PIN1, CANL PIN2),

c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN34 and PIN35 of EEM plug X89/1. Also check the terminating resistor in EEM box bet-
ween PIN34 and PIN35 with the EEM box disconnected (setpoint 120 ohms +/- 10%).

5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.

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FMGR - 248 Reception of vehicle side CAN bus signal AUX4 in

register 8 is faulty up to DBD100000
Cause:
The control unit detects that a time limit for a periodic data transmission between FMGR and AUX 4 has been excee-
ded.
Possible causes:
1. Temporary malfunction of CAN communications between FMGR and AUX4.
2. Short circuit on the CAN bus.
3. Bus termination incorrect or missing.
4. Contacts of the CAN bus plugs bent, broken or corroded.
5. Control unit hardware fault of FMGR or AUX4
Remedy:
1. A temporary malfunction can be caused by a temporary bus overload. Ensure that the power supply to FMGR
and AUX4 is correct and that both control modules are ONLINE on the bus. Use the "Control module status"
function of the Service Tool to check this. If one of the control units is OFFLINE, go to step 2. If both control units
are ONLINE, this is a temporary fault. Store the fault using the Service Tool and then delete it. Make a test drive
to check the function. If the fault code does not occur again, no further action is required.
2. Check the power supply to the module which is OFFLINE.
a) Check supply to AUX4:
I. Ground at X4/93 PIN4 via weld point X0/9/41 via weld point X0/9/31 to weld point X0/9/21 to weld point
X0/9/11 via X4/83 PIN2 to plug connection X5/1 on central print A12.
II. 12V (potential 15/1) at X4/93 PIN1 via weld point X0/9/40 via weld point X0/9/30 to weld point X0/9/20 to
weld point X0/9/10 via X4/83 PIN1 to plug X24/2 PIN24 on fuse F47.
b) Check supply to FMGR:
I. Ground at A4/3 PIN13 runs via weld point X0/7/5 from grounding point 16 starter.
II. 12V (potential 15/1) at A4/3 PIN10. Runs from fuse F51 (10A) on A12 central print via connector X24/2 PIN1
to FMGR A4/3 PIN10.
III. 12V (potential 30) at A4/3 PIN14. Runs from fuse F14 (7.5A) on A12 central print via X24/2 PIN6 to FMGR
A4/3 PIN14.
3. If the power supply to the two control modules is correct, check the entire CAN bus for short-circuits. On the CAN
bus, disconnect one control module after the other and reconnect it again, checking the status of the control units
("Control module status" function of the Service Tool). If the control unit status is ONLINE, the disconnected unit
is causing the problem.
4. If the power supply to the two control modules is correct, check the entire CAN bus for interruptions or defective
terminating resistors. If the CAN bus is interrupted, only those control modules are OFFLINE which are connected
to the CAN bus after the interruption.

a) Check vehicle bus:

Diagnostics interface S31(CANH PIN8, CANL PIN7),
Armrest X18/4 (CANH PIN17, CANL PIN18),
AUX1 X4/90 (CANH PIN3, CANL PIN2),
AUX2 X4/91 (CANH PIN3, CANL PIN2),
AUX3 X4/92 (CANH PIN3, CANL PIN2),
AUX4 X4/93 (CANH PIN3, CANL PIN2),
AUX5 X4/94 (CANH PIN3, CANL PIN2),
ECCU2 CN1a (CANH PIN15, CANL PIN16),
EDC X55 (CANH PIN50, CANL PIN52),
EEM2 X70 (CANH PIN18, CANL PIN42).
ICU P8/1 (CANH PIN3, CANL PIN4) via P8/2 (CANH PIN3, CANL PIN4) to ADIC CN3 (CANH PIN26, CANL
PIN25),
KEYPAD X4/63 (CANH PIN3, CANL PIN2),
Also check whether the jumper on X70 of the EEM between PIN 66 and PIN 67 is present.
Terminating resistor X3/10 (CANH PINA, CANL PINB).

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b) Check transmission bus:
Diagnostics interface S31(CANH PIN2, CANL PIN1),
FMGR A4/3 (CANH PIN3, CANL PIN2),
SGR X16/21 (CANH PIN1, CANL PIN2),

c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN 42 and PIN18 of EEM plug X70. Also check the terminating resistor in EEM box A2
between PIN42 and PIN18 with the EEM box disconnected (setpoint 120 ohms +/- 10%).

5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.

FMGR - 248 Reception of vehicle side CAN bus signal AUX4

in register 8 is faulty from DBD100001
Cause:
The control unit detects that a time limit for a periodic data transmission between FMGR and AUX 4 has been excee-
ded.
Possible causes:
1. Temporary malfunction of CAN communications between FMGR and AUX4.
2. Short circuit on the CAN bus.
3. Bus termination incorrect or missing.
4. Contacts of the CAN bus plugs bent, broken or corroded.
5. Control unit hardware fault of FMGR or AUX4
Remedy:
1. A temporary malfunction can be caused by a temporary bus overload. Ensure that the power supply to FMGR
and AUX4 is correct and that both control modules are ONLINE on the bus. Use the "Control module status"
function of the Service Tool to check this. If one of the control units is OFFLINE, go to step 2. If both control units
are ONLINE, this is a temporary fault. Store the fault using the Service Tool and then delete it. Make a test drive
to check the function. If the fault code does not occur again, no further action is required.
2. Check the power supply to the module which is OFFLINE.
a) Check supply to AUX4:
I. Ground at X4/93 PIN4 to weld point X0/9/11 via X4/83 PIN2 to weld point X0/7/5 on grounding point 11.
II. 12V (potential 15/1) at X4/93 PIN1 to weld point X0/9/10 via plug X4/83 PIN1 to plug X24/2 PIN24 on fuse
F47.
b) Check supply to FMGR:
I. Ground at A4/3 PIN13 via weld point X0/7/5 to grounding point 11.
II. 12V (potential 15/1) at A4/3 PIN10 to central print (A12) X24/2 PIN1 on fuse F51.
III. 12V (potential 30) at A4/3 PIN14 to central print (A12) X24/2 PIN2 on fuse F14.
3. If the power supply to the two control modules is correct, check the entire CAN bus for short-circuits. On the CAN
bus, disconnect one control module after the other and reconnect it again, checking the status of the control units
("Control module status" function of the Service Tool). If the control unit status is ONLINE, the disconnected unit
is causing the problem.
4. If the power supply to the two control modules is correct, check the entire CAN bus for interruptions or defective
terminating resistors. If the CAN bus is interrupted, only those control modules are OFFLINE which are connected
to the CAN bus after the interruption.

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a) Check vehicle bus:
Diagnostics interface X9/17 (CANH PINC, CANL PIND),
Armrest X18/4 (CANH PIN17, CANL PIN18),
AUX1 X4/90 (CANH PIN3, CANL PIN2),
AUX2 X4/91 (CANH PIN3, CANL PIN2),
AUX3 X4/92 (CANH PIN3, CANL PIN2),
AUX4 X4/93 (CANH PIN3, CANL PIN2),
AUX5 X4/94 (CANH PIN3, CANL PIN2),
ECCU2 CN1a (CANH PIN15, CANL PIN16),
EDC X55 (CANH PIN50, CANL PIN52),
EEM3 X89/1 (CANH PIN35, CANL PIN34).
ICU P8/1 (CANH PIN3, CANL PIN4) via P8/2 (CANH PIN3, CANL PIN4) to ADIC CN3 (CANH PIN26, CANL
PIN25),
KEYPAD X4/63 (CANH PIN3, CANL PIN2),
Terminating resistor X3/10 (CANH PINA, CANL PINB).

b) Check transmission bus:

Diagnostics interface X9/17 (CANH PINF, CANL PING),
FMGR A4/3 (CANH PIN3, CANL PIN2),
SGR X16/21 (CANH PIN1, CANL PIN2),

c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN34 and PIN35 of EEM plug X89/1. Also check the terminating resistor in EEM box bet-
ween PIN34 and PIN35 with the EEM box disconnected (setpoint 120 ohms +/- 10%).

5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.

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FMGR - 249 Reception of vehicle side CAN bus signal AUX5 in

register 9 is faulty up to DBD100000
Cause:
The control unit detects that a time limit for a periodic data transmission between FMGR and AUX 5 has been excee-
ded.
Possible causes:
1. Temporary malfunction of CAN communications between FMGR and AUX5.
2. Short circuit on the CAN bus.
3. Bus termination incorrect or missing.
4. Contacts of the CAN bus plugs bent, broken or corroded.
5. Control unit hardware fault of FMGR or AUX5
Remedy:
1. A temporary malfunction can be caused by a temporary bus overload. Ensure that the power supply to FMGR
and AUX5 is correct and that both control modules are ONLINE on the bus. Use the "Control module status"
function of the Service Tool to check this. If one of the control units is OFFLINE, go to step 2. If both control units
are ONLINE, this is a temporary fault. Store the fault using the Service Tool and then delete it. Make a test drive
to check the function. If the fault code does not occur again, no further action is required.
2. Check the power supply to the module which is OFFLINE.
a) Check supply to AUX5:
I. Ground at X4/94 PIN4 via weld point X0/9/41 via weld point X0/9/31 to weld point X0/9/21 to weld point
X0/9/11 via X4/83 PIN2 to plug connection X5/1 on central print A12.
II. 12V (potential 15/1) at X4/94 PIN1 via weld point X0/9/40 via weld point X0/9/30 to weld point X0/9/20 to
weld point X0/9/10 via X4/83 PIN1 to plug X24/2 PIN24 on fuse F47.
b) Check supply to FMGR:
I. Ground at A4/3 PIN13 runs via weld point X0/7/5 from grounding point 16 starter.
II. 12V (potential 15/1) at A4/3 PIN10. Runs from fuse F51 (10A) on A12 central print via connector X24/2 PIN1
to FMGR A4/3 PIN10.
III. 12V (potential 30) at A4/3 PIN14. Runs from fuse F14 (7.5A) on A12 central print via X24/2 PIN6 to FMGR
A4/3 PIN14.
3. If the power supply to the two control modules is correct, check the entire CAN bus for short-circuits. On the CAN
bus, disconnect one control module after the other and reconnect it again, checking the status of the control units
("Control module status" function of the Service Tool). If the control unit status is ONLINE, the disconnected unit
is causing the problem.
4. If the power supply to the two control modules is correct, check the entire CAN bus for interruptions or defective
terminating resistors. If the CAN bus is interrupted, only those control modules are OFFLINE which are connected
to the CAN bus after the interruption.

a) Check vehicle bus:

Diagnostics interface S31(CANH PIN8, CANL PIN7),
Armrest X18/4 (CANH PIN17, CANL PIN18),
AUX1 X4/90 (CANH PIN3, CANL PIN2),
AUX2 X4/91 (CANH PIN3, CANL PIN2),
AUX3 X4/92 (CANH PIN3, CANL PIN2),
AUX4 X4/93 (CANH PIN3, CANL PIN2),
AUX5 X4/94 (CANH PIN3, CANL PIN2),
ECCU2 CN1a (CANH PIN15, CANL PIN16),
EDC X55 (CANH PIN50, CANL PIN52),
EEM2 X70 (CANH PIN18, CANL PIN42).
ICU P8/1 (CANH PIN3, CANL PIN4) via P8/2 (CANH PIN3, CANL PIN4) to ADIC CN3 (CANH PIN26, CANL
PIN25),
KEYPAD X4/63 (CANH PIN3, CANL PIN2),
Also check whether the jumper on X70 of the EEM between PIN 66 and PIN 67 is present.
Terminating resistor X3/10 (CANH PINA, CANL PINB).

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b) Check transmission bus:
Diagnostics interface S31(CANH PIN2, CANL PIN1),
FMGR A4/3 (CANH PIN3, CANL PIN2),
SGR X16/21 (CANH PIN1, CANL PIN2),

c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN 42 and PIN18 of EEM plug X70. Also check the terminating resistor in EEM box A2
between PIN42 and PIN18 with the EEM box disconnected (setpoint 120 ohms +/- 10%).

5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.

FMGR - 249 Reception of vehicle side CAN bus signal AUX5

in register 9 is faulty from DBD100001
Cause:
The control unit detects that a time limit for a periodic data transmission between FMGR and AUX 5 has been excee-
ded.
Possible causes:
1. Temporary malfunction of CAN communications between FMGR and AUX5.
2. Short circuit on the CAN bus.
3. Bus termination incorrect or missing.
4. Contacts of the CAN bus plugs bent, broken or corroded.
5. Control unit hardware fault of FMGR or AUX5
Remedy:
1. A temporary malfunction can be caused by a temporary bus overload. Ensure that the power supply to FMGR
and AUX5 is correct and that both control modules are ONLINE on the bus. Use the "Control module status"
function of the Service Tool to check this. If one of the control units is OFFLINE, go to step 2. If both control units
are ONLINE, this is a temporary fault. Store the fault using the Service Tool and then delete it. Make a test drive
to check the function. If the fault code does not occur again, no further action is required.
2. Check the power supply to the module which is OFFLINE.
a) Check supply to AUX5:
I. Ground at X4/94 PIN4 to weld point X0/9/11 via X4/83 PIN2 to weld point X0/7/5 on grounding point 11.
II. 12V (potential 15/1) at X4/94 PIN1 to weld point X0/9/10 via plug X4/83 PIN1 to plug X24/2 PIN24 on fuse
F47.
b) Check supply to FMGR:
I. Ground at A4/3 PIN13 via weld point X0/7/5 to grounding point 11.
II. 12V (potential 15/1) at A4/3 PIN10 to central print (A12) X24/2 PIN1 on fuse F51.
III. 12V (potential 30) at A4/3 PIN14 to central print (A12) X24/2 PIN2 on fuse F14.
3. If the power supply to the two control modules is correct, check the entire CAN bus for short-circuits. On the CAN
bus, disconnect one control module after the other and reconnect it again, checking the status of the control units
("Control module status" function of the Service Tool). If the control unit status is ONLINE, the disconnected unit
is causing the problem.
4. If the power supply to the two control modules is correct, check the entire CAN bus for interruptions or defective
terminating resistors. If the CAN bus is interrupted, only those control modules are OFFLINE which are connected
to the CAN bus after the interruption.

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a) Check vehicle bus:
Diagnostics interface X9/17 (CANH PINC, CANL PIND),
Armrest X18/4 (CANH PIN17, CANL PIN18),
AUX1 X4/90 (CANH PIN3, CANL PIN2),
AUX2 X4/91 (CANH PIN3, CANL PIN2),
AUX3 X4/92 (CANH PIN3, CANL PIN2),
AUX4 X4/93 (CANH PIN3, CANL PIN2),
AUX5 X4/94 (CANH PIN3, CANL PIN2),
ECCU2 CN1a (CANH PIN15, CANL PIN16),
EDC X55 (CANH PIN50, CANL PIN52),
EEM3 X89/1 (CANH PIN35, CANL PIN34).
ICU P8/1 (CANH PIN3, CANL PIN4) via P8/2 (CANH PIN3, CANL PIN4) to ADIC CN3 (CANH PIN26, CANL
PIN25),
KEYPAD X4/63 (CANH PIN3, CANL PIN2),
Terminating resistor X3/10 (CANH PINA, CANL PINB).

b) Check transmission bus:

Diagnostics interface X9/17 (CANH PINF, CANL PING),
FMGR A4/3 (CANH PIN3, CANL PIN2),
SGR X16/21 (CANH PIN1, CANL PIN2),

c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN34 and PIN35 of EEM plug X89/1. Also check the terminating resistor in EEM box bet-
ween PIN34 and PIN35 with the EEM box disconnected (setpoint 120 ohms +/- 10%).

5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.

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FMGR - 250 Reception of vehicle side CAN bus signal ICU in

register 10 is faulty up to DBD100000
Cause:
The control unit detects that a time limit for a periodic data transmission between FMGR and ICU has been exceeded.
The fault is stored and signalled on screen by a warning triangle.
Possible causes:
1. Temporary malfunction of CAN communications between FMGR and ICU.
2. Short circuit on the CAN bus.
3. Bus termination incorrect or missing.
4. Contacts of the CAN bus plugs bent, broken or corroded.
5. Control unit hardware fault of the FMGR or ICU
Remedy:
1. A temporary malfunction can be caused by a temporary bus overload. Ensure that the power supply to FMGR
and ICU is correct and that both control modules are ONLINE on the bus. Use the "Control module status"
function of the Service Tool to check this. If one of the control units is OFFLINE, go to step 2. If both control units
are ONLINE, this is a temporary fault. Store the fault using the Service Tool and then delete it. Make a test drive
to check the function. If the fault code does not occur again, no further action is required.
2. Check the power supply to the module which is OFFLINE.
a) Check supply to ICU:
I. Ground from P8 PIN 3 to X0/28/12 to grounding point 8.
II. 12V (potential 15/1) at P8 PIN7 to roof electrics print A13 X6/2 PIN1X10/12 PIN6 on F45 (A12)..
III. Continuous plus P8 PIN5 to X0/28/1 via X14/14 PIN4 and X23/1 PIN Q and X20/1 PIN8 on F93
b) Check supply to FMGR:
I. Ground at A4/3 PIN13 runs via weld point X0/7/5 from grounding point 16 starter.
II. 12V (potential 15/1) at A4/3 PIN10. Runs from fuse F51 (10A) on A12 central print via connector X24/2 PIN1
to FMGR A4/3 PIN10.
III. 12V (potential 30) at A4/3 PIN14. Runs from fuse F14 (7.5A) on A12 central print via X24/2 PIN6 to FMGR
A4/3 PIN14.
3. If the power supply to the two control modules is correct, check the entire CAN bus for short-circuits. On the CAN
bus, disconnect one control module after the other and reconnect it again, checking the status of the control units
("Control module status" function of the Service Tool). If the control unit status is ONLINE, the disconnected unit
is causing the problem.
4. If the power supply to the two control modules is correct, check the entire CAN bus for interruptions or defective
terminating resistors. If the CAN bus is interrupted, only those control modules are OFFLINE which are connected
to the CAN bus after the interruption.

a) Check vehicle bus:

Diagnostics interface S31(CANH PIN8, CANL PIN7),
Armrest X18/4 (CANH PIN17, CANL PIN18),
AUX1 X4/90 (CANH PIN3, CANL PIN2),
AUX2 X4/91 (CANH PIN3, CANL PIN2),
AUX3 X4/92 (CANH PIN3, CANL PIN2),
AUX4 X4/93 (CANH PIN3, CANL PIN2),
AUX5 X4/94 (CANH PIN3, CANL PIN2),
ECCU2 CN1a (CANH PIN15, CANL PIN16),
EDC X55 (CANH PIN50, CANL PIN52),
EEM2 X70 (CANH PIN18, CANL PIN42).
ICU P8/1 (CANH PIN3, CANL PIN4) via P8/2 (CANH PIN3, CANL PIN4) to ADIC CN3 (CANH PIN26, CANL
PIN25),
KEYPAD X4/63 (CANH PIN3, CANL PIN2),
Also check whether the jumper on X70 of the EEM between PIN 66 and PIN 67 is present.
Terminating resistor X3/10 (CANH PINA, CANL PINB).

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b) Check transmission bus:
Diagnostics interface S31(CANH PIN2, CANL PIN1),
FMGR A4/3 (CANH PIN3, CANL PIN2),
SGR X16/21 (CANH PIN1, CANL PIN2),

c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN 42 and PIN18 of EEM plug X70. Also check the terminating resistor in EEM box A2
between PIN42 and PIN18 with the EEM box disconnected (setpoint 120 ohms +/- 10%).

5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.

FMGR - 250 Reception of vehicle side CAN bus signal ICU

in register 10 is faulty from DBD100001
Cause:
The control unit detects that a time limit for a periodic data transmission between FMGR and ICU has been exceeded.
The fault is stored and signalled on screen by a warning triangle.
Possible causes:
1. Temporary malfunction of CAN communications between FMGR and ICU.
2. Short circuit on the CAN bus.
3. Bus termination incorrect or missing.
4. Contacts of the CAN bus plugs bent, broken or corroded.
5. Control unit hardware fault of the FMGR or ICU
Remedy:
1. A temporary malfunction can be caused by a temporary bus overload. Ensure that the power supply to FMGR
and ICU is correct and that both control modules are ONLINE on the bus. Use the "Control module status"
function of the Service Tool to check this. If one of the control units is OFFLINE, go to step 2. If both control units
are ONLINE, this is a temporary fault. Store the fault using the Service Tool and then delete it. Make a test drive
to check the function. If the fault code does not occur again, no further action is required.
2. Check the power supply to the module which is OFFLINE.
a) Check supply to ICU:
I. Ground from plug P8 PIN3 to weld point X0/28/12 to grounding point 8.
II. 12V (potential 15/1) at plug P8 PIN7 to roof electrics print A13 plug X10/12 PIN6 and plug X10/11 PIN7 to
central print (A12) plug X14/15 PIN12 on fuse F45.
III. 12V (potential 30) at plug P8 PIN5 to weld point X0/28/1 via plug X14/14 PIN4 and plug X10/14 PIN7 to
weld point X0/3/14 to engine print (A14) plug X10/3 PIN6 on fuse F212.
b) Check supply to FMGR:
I. Ground at A4/3 PIN13 via weld point X0/7/5 to grounding point 11.
II. 12V (potential 15/1) at A4/3 PIN10 to central print (A12) X24/2 PIN1 on fuse F51.
III. 12V (potential 30) at A4/3 PIN14 to central print (A12) X24/2 PIN2 on fuse F14.
3. If the power supply to the two control modules is correct, check the entire CAN bus for short-circuits. On the CAN
bus, disconnect one control module after the other and reconnect it again, checking the status of the control units
("Control module status" function of the Service Tool). If the control unit status is ONLINE, the disconnected unit
is causing the problem.
4. If the power supply to the two control modules is correct, check the entire CAN bus for interruptions or defective
terminating resistors. If the CAN bus is interrupted, only those control modules are OFFLINE which are connected
to the CAN bus after the interruption.

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a) Check vehicle bus:
Diagnostics interface X9/17 (CANH PINC, CANL PIND),
Armrest X18/4 (CANH PIN17, CANL PIN18),
AUX1 X4/90 (CANH PIN3, CANL PIN2),
AUX2 X4/91 (CANH PIN3, CANL PIN2),
AUX3 X4/92 (CANH PIN3, CANL PIN2),
AUX4 X4/93 (CANH PIN3, CANL PIN2),
AUX5 X4/94 (CANH PIN3, CANL PIN2),
ECCU2 CN1a (CANH PIN15, CANL PIN16),
EDC X55 (CANH PIN50, CANL PIN52),
EEM3 X89/1 (CANH PIN35, CANL PIN34).
ICU P8/1 (CANH PIN3, CANL PIN4) via P8/2 (CANH PIN3, CANL PIN4) to ADIC CN3 (CANH PIN26, CANL
PIN25),
KEYPAD X4/63 (CANH PIN3, CANL PIN2),
Terminating resistor X3/10 (CANH PINA, CANL PINB).

b) Check transmission bus:

Diagnostics interface X9/17 (CANH PINF, CANL PING),
FMGR A4/3 (CANH PIN3, CANL PIN2),
SGR X16/21 (CANH PIN1, CANL PIN2),

c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN34 and PIN35 of EEM plug X89/1. Also check the terminating resistor in EEM box bet-
ween PIN34 and PIN35 with the EEM box disconnected (setpoint 120 ohms +/- 10%).

5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.

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FMGR - 251 Reception of vehicle side CAN bus signal ECCU1 in

register 11 is faulty up to DBD100000
Cause:
The control unit detects that a time limit for a periodic data transmission between FMGR and ECCU has been excee-
ded.
Possible causes:
1. Temporary malfunction of CAN communications between FMGR and ECCU.
2. Short circuit on the CAN bus.
3. Bus termination incorrect or missing.
4. Contacts of the CAN bus plugs bent, broken or corroded.
5. Control unit hardware fault of the FMGR or ECCU
Remedy:
1. A temporary malfunction can be caused by a temporary bus overload. Ensure that the power supply to FMGR
and ECCU is correct and that both control modules are ONLINE on the bus. Use the "Control module status"
function of the Service Tool to check this. If one of the control units is OFFLINE, go to step 2. If both control units
are ONLINE, this is a temporary fault. Store the fault using the Service Tool and then delete it. Make a test drive
to check the function. If the fault code does not occur again, no further action is required.
2. Check the power supply to the module which is OFFLINE.
a) Check supply to ECCU:
I. Ground from CN1a PIN 19, PIN 25 and PIN 26 to weld point X0/7/5 and grounding point 16 starter.
Ground from CN2/E PIN 21 and PIN 26 to weld point X0/7/5 and grounding point 16 starter.
II. 12V (potential 15/1) from CN1a PIN1, PIN 2 and PIN3 to weld point X0/7/8 to plug X4/85a and X4/85b and
X24/2.
From CN3b PIN25 and PIN34 to weld point X0/7/8.
From weld point X0/7/8 to central print A12 X24/2 PIN 8 and PIN 9 to F50.
III. Continuous plus CN1a PIN14 to central print A12 X24/2 PIN22 to F10.
b) Check supply to FMGR:
I. Ground at A4/3 PIN13 runs via weld point X0/7/5 from grounding point 16 starter.
II. 12V (potential 15/1) at A4/3 PIN10. Runs from fuse F51 (10A) on A12 central print via connector X24/2 PIN1
to FMGR A4/3 PIN10.
III. 12V (potential 30) at A4/3 PIN14. Runs from fuse F14 (7.5A) on A12 central print via X24/2 PIN6 to FMGR
A4/3 PIN14.
3. If the power supply to the two control modules is correct, check the entire CAN bus for short-circuits. On the CAN
bus, disconnect one control module after the other and reconnect it again, checking the status of the control units
("Control module status" function of the Service Tool). If the control unit status is ONLINE, the disconnected unit
is causing the problem.
4. If the power supply to the two control modules is correct, check the entire CAN bus for interruptions or defective
terminating resistors. If the CAN bus is interrupted, only those control modules are OFFLINE which are connected
to the CAN bus after the interruption.
a) Check vehicle bus:
Diagnostics interface S31(CANH PIN8, CANL PIN7),
Armrest X18/4 (CANH PIN17, CANL PIN18),
AUX1 X4/90 (CANH PIN3, CANL PIN2),
AUX2 X4/91 (CANH PIN3, CANL PIN2),
AUX3 X4/92 (CANH PIN3, CANL PIN2),
AUX4 X4/93 (CANH PIN3, CANL PIN2),
AUX5 X4/94 (CANH PIN3, CANL PIN2),
ECCU2 CN1a (CANH PIN15, CANL PIN16),
EDC X55 (CANH PIN50, CANL PIN52),
EEM2 X70 (CANH PIN18, CANL PIN42).
ICU P8/1 (CANH PIN3, CANL PIN4) via P8/2 (CANH PIN3, CANL PIN4) to ADIC CN3 (CANH PIN26, CANL
PIN25),
KEYPAD X4/63 (CANH PIN3, CANL PIN2),
Also check whether the jumper on X70 of the EEM between PIN 66 and PIN 67 is present.
Terminating resistor X3/10 (CANH PINA, CANL PINB).

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b) Check transmission bus:
Diagnostics interface S31(CANH PIN2, CANL PIN1),
FMGR A4/3 (CANH PIN3, CANL PIN2),
SGR X16/21 (CANH PIN1, CANL PIN2),

c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN 42 and PIN18 of EEM plug X70. Also check the terminating resistor in EEM box A2
between PIN42 and PIN18 with the EEM box disconnected (setpoint 120 ohms +/- 10%).

5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.

FMGR - 251 Reception of vehicle side CAN bus signal ECCU1 in

register 11 is faulty from DBD100001
Cause:
The control unit detects that a time limit for a periodic data transmission between FMGR and ECCU has been excee-
ded.
Possible causes:
1. Temporary malfunction of CAN communications between FMGR and ECCU.
2. Short circuit on the CAN bus.
3. Bus termination incorrect or missing.
4. Contacts of the CAN bus plugs bent, broken or corroded.
5. Control unit hardware fault of the FMGR or ECCU
Remedy:
1. A temporary malfunction can be caused by a temporary bus overload. Ensure that the power supply to FMGR
and ECCU is correct and that both control modules are ONLINE on the bus. Use the "Control module status"
function of the Service Tool to check this. If one of the control units is OFFLINE, go to step 2. If both control units
are ONLINE, this is a temporary fault. Store the fault using the Service Tool and then delete it. Make a test drive
to check the function. If the fault code does not occur again, no further action is required.
2. Check the power supply to the module which is OFFLINE.
a) Check supply to ECCU:
I. Ground from plug CN1a PIN19, PIN25 and PIN26 to weld point X0/7/5 and grounding point 11.
Ground from plug CN2/E PIN21 and PIN26 to weld point X0/7/5 and grounding point 11.
II. 12V (potential 15/1) from plug CN1a PIN1, PIN2 and PIN3 to weld point X0/7/8 to plug X4/85/a and
X4/85/b and X24/2.
From plug CN3b PIN25 and PIN34 to weld point X0/7/8.
From weld point X0/7/8 to central print A12 plug X24/2 PIN8 and PIN9 to fuseF50.
III. 12V (potential 30) plug CN1a PIN14 to central print A12 plug X24/2 PIN22 to fuse F10.
b) Check supply to FMGR:
I. Ground at A4/3 PIN13 via weld point X0/7/5 to grounding point 11.
II. 12V (potential 15/1) at A4/3 PIN10 to central print (A12) X24/2 PIN1 on fuse F51.
III. 12V (potential 30) at A4/3 PIN14 to central print (A12) X24/2 PIN2 on fuse F14.
3. If the power supply to the two control modules is correct, check the entire CAN bus for short-circuits. On the CAN
bus, disconnect one control module after the other and reconnect it again, checking the status of the control units
("Control module status" function of the Service Tool). If the control unit status is ONLINE, the disconnected unit
is causing the problem.
4. If the power supply to the two control modules is correct, check the entire CAN bus for interruptions or defective
terminating resistors. If the CAN bus is interrupted, only those control modules are OFFLINE which are connected
to the CAN bus after the interruption.

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a) Check vehicle bus:
Diagnostics interface X9/17 (CANH PINC, CANL PIND),
Armrest X18/4 (CANH PIN17, CANL PIN18),
AUX1 X4/90 (CANH PIN3, CANL PIN2),
AUX2 X4/91 (CANH PIN3, CANL PIN2),
AUX3 X4/92 (CANH PIN3, CANL PIN2),
AUX4 X4/93 (CANH PIN3, CANL PIN2),
AUX5 X4/94 (CANH PIN3, CANL PIN2),
ECCU2 CN1a (CANH PIN15, CANL PIN16),
EDC X55 (CANH PIN50, CANL PIN52),
EEM3 X89/1 (CANH PIN35, CANL PIN34).
ICU P8/1 (CANH PIN3, CANL PIN4) via P8/2 (CANH PIN3, CANL PIN4) to ADIC CN3 (CANH PIN26, CANL
PIN25),
KEYPAD X4/63 (CANH PIN3, CANL PIN2),
Terminating resistor X3/10 (CANH PINA, CANL PINB).

b) Check transmission bus:

Diagnostics interface X9/17 (CANH PINF, CANL PING),
FMGR A4/3 (CANH PIN3, CANL PIN2),
SGR X16/21 (CANH PIN1, CANL PIN2),

c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN34 and PIN35 of EEM plug X89/1. Also check the terminating resistor in EEM box bet-
ween PIN34 and PIN35 with the EEM box disconnected (setpoint 120 ohms +/- 10%).

5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.

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FMGR - 252 Reception of vehicle side CAN bus signal ECCU2 in

register 12 is faulty up to DBD100000
Cause:
The control unit detects that a time limit for a periodic data transmission between FMGR and ECCU has been excee-
ded.
Possible causes:
1. Temporary malfunction of CAN communications between FMGR and ECCU.
2. Short circuit on the CAN bus.
3. Bus termination incorrect or missing.
4. Contacts of the CAN bus plugs bent, broken or corroded.
5. Control unit hardware fault of the FMGR or ECCU
Remedy:
1. A temporary malfunction can be caused by a temporary bus overload. Ensure that the power supply to FMGR
and ECCU is correct and that both control modules are ONLINE on the bus. Use the "Control module status"
function of the Service Tool to check this. If one of the control units is OFFLINE, go to step 2. If both control units
are ONLINE, this is a temporary fault. Store the fault using the Service Tool and then delete it. Make a test drive
to check the function. If the fault code does not occur again, no further action is required.
2. Check the power supply to the module which is OFFLINE.
a) Check supply to ECCU:
I. Ground from CN1a PIN 19, PIN 25 and PIN 26 to weld point X0/7/5 and grounding point 16 starter.
Ground from CN2/E PIN 21 and PIN 26 to weld point X0/7/5 and grounding point 16 starter.
II. 12V (potential 15/1) from CN1a PIN1, PIN 2 and PIN3 to weld point X0/7/8 to plug X4/85a and X4/85b and
X24/2.
From CN3b PIN25 and PIN34 to weld point X0/7/8.
From weld point X0/7/8 to central print A12 X24/2 PIN 8 and PIN 9 to F50.
III. Continuous plus CN1a PIN14 to central print A12 X24/2 PIN22 to F10.
b) Check supply to FMGR:
I. Ground at A4/3 PIN13 runs via weld point X0/7/5 from grounding point 16 starter.
II. 12V (potential 15/1) at A4/3 PIN10. Runs from fuse F51 (10A) on A12 central print via connector X24/2 PIN1
to FMGR A4/3 PIN10.
III. 12V (potential 30) at A4/3 PIN14. Runs from fuse F14 (7.5A) on A12 central print via X24/2 PIN6 to FMGR
A4/3 PIN14.
3. If the power supply to the two control modules is correct, check the entire CAN bus for short-circuits. On the CAN
bus, disconnect one control module after the other and reconnect it again, checking the status of the control units
("Control module status" function of the Service Tool). If the control unit status is ONLINE, the disconnected unit
is causing the problem.
4. If the power supply to the two control modules is correct, check the entire CAN bus for interruptions or defective
terminating resistors. If the CAN bus is interrupted, only those control modules are OFFLINE which are connected
to the CAN bus after the interruption.

a) Check vehicle bus:

Diagnostics interface S31(CANH PIN8, CANL PIN7),
Armrest X18/4 (CANH PIN17, CANL PIN18),
AUX1 X4/90 (CANH PIN3, CANL PIN2),
AUX2 X4/91 (CANH PIN3, CANL PIN2),
AUX3 X4/92 (CANH PIN3, CANL PIN2),
AUX4 X4/93 (CANH PIN3, CANL PIN2),
AUX5 X4/94 (CANH PIN3, CANL PIN2),
ECCU2 CN1a (CANH PIN15, CANL PIN16),
EDC X55 (CANH PIN50, CANL PIN52),
EEM2 X70 (CANH PIN18, CANL PIN42).
ICU P8/1 (CANH PIN3, CANL PIN4) via P8/2 (CANH PIN3, CANL PIN4) to ADIC CN3 (CANH PIN26, CANL
PIN25),
KEYPAD X4/63 (CANH PIN3, CANL PIN2),
Also check whether the jumper on X70 of the EEM between PIN 66 and PIN 67 is present.
Terminating resistor X3/10 (CANH PINA, CANL PINB).

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b) Check transmission bus:
Diagnostics interface S31(CANH PIN2, CANL PIN1),
FMGR A4/3 (CANH PIN3, CANL PIN2),
SGR X16/21 (CANH PIN1, CANL PIN2),

c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN 42 and PIN18 of EEM plug X70. Also check the terminating resistor in EEM box A2
between PIN42 and PIN18 with the EEM box disconnected (setpoint 120 ohms +/- 10%).

5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.

FMGR - 252 Reception of vehicle side CAN bus signal ECCU2 in

register 12 is faulty from DBD100001
Cause:
The control unit detects that a time limit for a periodic data transmission between FMGR and ECCU has been excee-
ded.
Possible causes:
1. Temporary malfunction of CAN communications between FMGR and ECCU.
2. Short circuit on the CAN bus.
3. Bus termination incorrect or missing.
4. Contacts of the CAN bus plugs bent, broken or corroded.
5. Control unit hardware fault of the FMGR or ECCU
Remedy:
1. A temporary malfunction can be caused by a temporary bus overload. Ensure that the power supply to FMGR
and ECCU is correct and that both control modules are ONLINE on the bus. Use the "Control module status"
function of the Service Tool to check this. If one of the control units is OFFLINE, go to step 2. If both control units
are ONLINE, this is a temporary fault. Store the fault using the Service Tool and then delete it. Make a test drive
to check the function. If the fault code does not occur again, no further action is required.
2. Check the power supply to the module which is OFFLINE.
a) Check supply to ECCU:
I. Ground from plug CN1a PIN19, PIN25 and PIN26 to weld point X0/7/5 and grounding point 11.
Ground from plug CN2/E PIN21 and PIN26 to weld point X0/7/5 and grounding point 11.
II. 12V (potential 15/1) from plug CN1a PIN1, PIN2 and PIN3 to weld point X0/7/8 to plug X4/85/a and
X4/85/b and X24/2.
From plug CN3b PIN25 and PIN34 to weld point X0/7/8.
From weld point X0/7/8 to central print A12 plug X24/2 PIN8 and PIN9 to fuseF50.
III. 12V (potential 30) plug CN1a PIN14 to central print A12 plug X24/2 PIN22 to fuse F10.
b) Check supply to FMGR:
I. Ground at A4/3 PIN13 via weld point X0/7/5 to grounding point 11.
II. 12V (potential 15/1) at A4/3 PIN10 to central print (A12) X24/2 PIN1 on fuse F51.
III. 12V (potential 30) at A4/3 PIN14 to central print (A12) X24/2 PIN2 on fuse F14.
3. If the power supply to the two control modules is correct, check the entire CAN bus for short-circuits. On the CAN
bus, disconnect one control module after the other and reconnect it again, checking the status of the control units
("Control module status" function of the Service Tool). If the control unit status is ONLINE, the disconnected unit
is causing the problem.
4. If the power supply to the two control modules is correct, check the entire CAN bus for interruptions or defective
terminating resistors. If the CAN bus is interrupted, only those control modules are OFFLINE which are connected
to the CAN bus after the interruption.

a) Check vehicle bus:

Diagnostics interface X9/17 (CANH PINC, CANL PIND),
Armrest X18/4 (CANH PIN17, CANL PIN18),
AUX1 X4/90 (CANH PIN3, CANL PIN2),
AUX2 X4/91 (CANH PIN3, CANL PIN2),

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AUX3 X4/92 (CANH PIN3, CANL PIN2),
AUX4 X4/93 (CANH PIN3, CANL PIN2),
AUX5 X4/94 (CANH PIN3, CANL PIN2),
ECCU2 CN1a (CANH PIN15, CANL PIN16),
EDC X55 (CANH PIN50, CANL PIN52),
EEM3 X89/1 (CANH PIN35, CANL PIN34).
ICU P8/1 (CANH PIN3, CANL PIN4) via P8/2 (CANH PIN3, CANL PIN4) to ADIC CN3 (CANH PIN26, CANL
PIN25),
KEYPAD X4/63 (CANH PIN3, CANL PIN2),
Terminating resistor X3/10 (CANH PINA, CANL PINB).

b) Check transmission bus:

Diagnostics interface X9/17 (CANH PINF, CANL PING),
FMGR A4/3 (CANH PIN3, CANL PIN2),
SGR X16/21 (CANH PIN1, CANL PIN2),

c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN34 and PIN35 of EEM plug X89/1. Also check the terminating resistor in EEM box bet-
ween PIN34 and PIN35 with the EEM box disconnected (setpoint 120 ohms +/- 10%).

5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.

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FMGR - 253 Reception of vehicle side CAN bus signal ECCU3 in

register 13 is faulty up to DBD100000
Cause:
The control unit detects that a time limit for a periodic data transmission between FMGR and ECCU has been excee-
ded.
Possible causes:
1. Temporary malfunction of CAN communications between FMGR and ECCU.
2. Short circuit on the CAN bus.
3. Bus termination incorrect or missing.
4. Contacts of the CAN bus plugs bent, broken or corroded.
5. Control unit hardware fault of the FMGR or ECCU
Remedy:
1. A temporary malfunction can be caused by a temporary bus overload. Ensure that the power supply to FMGR
and ECCU is correct and that both control modules are ONLINE on the bus. Use the "Control module status"
function of the Service Tool to check this. If one of the control units is OFFLINE, go to step 2. If both control units
are ONLINE, this is a temporary fault. Store the fault using the Service Tool and then delete it. Make a test drive
to check the function. If the fault code does not occur again, no further action is required.
2. Check the power supply to the module which is OFFLINE.
a) Check supply to ECCU:
I. Ground from CN1a PIN 19, PIN 25 and PIN 26 to weld point X0/7/5 and grounding point 16 starter.
Ground from CN2/E PIN 21 and PIN 26 to weld point X0/7/5 and grounding point 16 starter.
II. 12V (potential 15/1) from CN1a PIN1, PIN 2 and PIN3 to weld point X0/7/8 to plug X4/85a and X4/85b and
X24/2.
From CN3b PIN25 and PIN34 to weld point X0/7/8.
From weld point X0/7/8 to central print A12 X24/2 PIN 8 and PIN 9 to F50.
III. Continuous plus CN1a PIN14 to central print A12 X24/2 PIN22 to F10.
b) Check supply to FMGR:
I. Ground at A4/3 PIN13 runs via weld point X0/7/5 from grounding point 16 starter.
II. 12V (potential 15/1) at A4/3 PIN10. Runs from fuse F51 (10A) on A12 central print via connector X24/2 PIN1
to FMGR A4/3 PIN10.
III. 12V (potential 30) at A4/3 PIN14. Runs from fuse F14 (7.5A) on A12 central print via X24/2 PIN6 to FMGR
A4/3 PIN14.
3. If the power supply to the two control modules is correct, check the entire CAN bus for short-circuits. On the CAN
bus, disconnect one control module after the other and reconnect it again, checking the status of the control units
("Control module status" function of the Service Tool). If the control unit status is ONLINE, the disconnected unit
is causing the problem.
4. If the power supply to the two control modules is correct, check the entire CAN bus for interruptions or defective
terminating resistors. If the CAN bus is interrupted, only those control modules are OFFLINE which are connected
to the CAN bus after the interruption.

a) Check vehicle bus:

Diagnostics interface S31(CANH PIN8, CANL PIN7),
Armrest X18/4 (CANH PIN17, CANL PIN18),
AUX1 X4/90 (CANH PIN3, CANL PIN2),
AUX2 X4/91 (CANH PIN3, CANL PIN2),
AUX3 X4/92 (CANH PIN3, CANL PIN2),
AUX4 X4/93 (CANH PIN3, CANL PIN2),
AUX5 X4/94 (CANH PIN3, CANL PIN2),
ECCU2 CN1a (CANH PIN15, CANL PIN16),
EDC X55 (CANH PIN50, CANL PIN52),
EEM2 X70 (CANH PIN18, CANL PIN42).
ICU P8/1 (CANH PIN3, CANL PIN4) via P8/2 (CANH PIN3, CANL PIN4) to ADIC CN3 (CANH PIN26, CANL
PIN25),
KEYPAD X4/63 (CANH PIN3, CANL PIN2),
Also check whether the jumper on X70 of the EEM between PIN 66 and PIN 67 is present.
Terminating resistor X3/10 (CANH PINA, CANL PINB).

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b) Check transmission bus:
Diagnostics interface S31(CANH PIN2, CANL PIN1),
FMGR A4/3 (CANH PIN3, CANL PIN2),
SGR X16/21 (CANH PIN1, CANL PIN2),

c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN 42 and PIN18 of EEM plug X70. Also check the terminating resistor in EEM box A2
between PIN42 and PIN18 with the EEM box disconnected (setpoint 120 ohms +/- 10%).

5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.

FMGR - 253 Reception of vehicle side CAN bus signal ECCU3 in

register 13 is faulty from DBD100001
Cause:
The control unit detects that a time limit for a periodic data transmission between FMGR and ECCU has been excee-
ded.
Possible causes:
1. Temporary malfunction of CAN communications between FMGR and ECCU.
2. Short circuit on the CAN bus.
3. Bus termination incorrect or missing.
4. Contacts of the CAN bus plugs bent, broken or corroded.
5. Control unit hardware fault of the FMGR or ECCU
Remedy:
1. A temporary malfunction can be caused by a temporary bus overload. Ensure that the power supply to FMGR
and ECCU is correct and that both control modules are ONLINE on the bus. Use the "Control module status"
function of the Service Tool to check this. If one of the control units is OFFLINE, go to step 2. If both control units
are ONLINE, this is a temporary fault. Store the fault using the Service Tool and then delete it. Make a test drive
to check the function. If the fault code does not occur again, no further action is required.
2. Check the power supply to the module which is OFFLINE.
a) Check supply to ECCU:
I. Ground from plug CN1a PIN19, PIN25 and PIN26 to weld point X0/7/5 and grounding point 11.
Ground from plug CN2/E PIN21 and PIN26 to weld point X0/7/5 and grounding point 11.
II. 12V (potential 15/1) from plug CN1a PIN1, PIN2 and PIN3 to weld point X0/7/8 to plug X4/85/a and
X4/85/b and X24/2.
From plug CN3b PIN25 and PIN34 to weld point X0/7/8.
From weld point X0/7/8 to central print A12 plug X24/2 PIN8 and PIN9 to fuseF50.
III. 12V (potential 30) plug CN1a PIN14 to central print A12 plug X24/2 PIN22 to fuse F10.
b) Check supply to FMGR:
I. Ground at A4/3 PIN13 via weld point X0/7/5 to grounding point 11.
II. 12V (potential 15/1) at A4/3 PIN10 to central print (A12) X24/2 PIN1 on fuse F51.
III. 12V (potential 30) at A4/3 PIN14 to central print (A12) X24/2 PIN2 on fuse F14.
3. If the power supply to the two control modules is correct, check the entire CAN bus for short-circuits. On the CAN
bus, disconnect one control module after the other and reconnect it again, checking the status of the control units
("Control module status" function of the Service Tool). If the control unit status is ONLINE, the disconnected unit
is causing the problem.
4. If the power supply to the two control modules is correct, check the entire CAN bus for interruptions or defective
terminating resistors. If the CAN bus is interrupted, only those control modules are OFFLINE which are connected
to the CAN bus after the interruption.

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a) Check vehicle bus:
Diagnostics interface X9/17 (CANH PINC, CANL PIND),
Armrest X18/4 (CANH PIN17, CANL PIN18),
AUX1 X4/90 (CANH PIN3, CANL PIN2),
AUX2 X4/91 (CANH PIN3, CANL PIN2),
AUX3 X4/92 (CANH PIN3, CANL PIN2),
AUX4 X4/93 (CANH PIN3, CANL PIN2),
AUX5 X4/94 (CANH PIN3, CANL PIN2),
ECCU2 CN1a (CANH PIN15, CANL PIN16),
EDC X55 (CANH PIN50, CANL PIN52),
EEM3 X89/1 (CANH PIN35, CANL PIN34).
ICU P8/1 (CANH PIN3, CANL PIN4) via P8/2 (CANH PIN3, CANL PIN4) to ADIC CN3 (CANH PIN26, CANL
PIN25),
KEYPAD X4/63 (CANH PIN3, CANL PIN2),
Terminating resistor X3/10 (CANH PINA, CANL PINB).

b) Check transmission bus:

Diagnostics interface X9/17 (CANH PINF, CANL PING),
FMGR A4/3 (CANH PIN3, CANL PIN2),
SGR X16/21 (CANH PIN1, CANL PIN2),

c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN34 and PIN35 of EEM plug X89/1. Also check the terminating resistor in EEM box bet-
ween PIN34 and PIN35 with the EEM box disconnected (setpoint 120 ohms +/- 10%).

5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.

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FMGR - 255 CAN bus OFF up to DBD100000

Cause:
The control unit detects that data transfer between FMGR and the vehicle bus is interrupted.
Possible causes:
1. Temporary malfunction of CAN communications between FMGR and the vehicle bus.
2. Short circuit on the CAN bus.
3. Bus termination incorrect or missing.
4. Contacts of the CAN bus plugs bent, broken or corroded.
5. Control unit defective.
Remedy:
1. A temporary malfunction can be caused by a temporary bus overload. Ensure that the power supply to the FMGR
is correct and it is ONLINE on the bus. Use the "Control module status" function of the Service Tool to check this.
If the FMGR is OFFLINE, go to step 2. If the FMGR is ONLINE, this is a temporary fault. Store the fault using the
Service Tool and then cancel it. Make a test drive to check the function. If the fault code does not occur again, no
further action is required.
2. Check supply to FMGR:
a) Ground at A4/3 PIN13 runs via weld point X0/7/5 from grounding point 16, starter.
b) 12V (potential 15/1) at A4/3 PIN10. Runs from fuse F51 (10A) on A12 central print via terminal X24/2 PIN1 to
FMGR A4/3 PIN10.
c) 12V (potential 30) at A4/3 PIN14. Runs from fuse F14 (7.5A) on A12 central print via X24/2 PIN6 to FMGR
A4/3 PIN14.
3. If the power supply to the FMGR is correct, check the entire CAN bus for short-circuits. On the CAN bus, discon-
nect one control module after the other and reconnect it again, checking the status of the control units ("Control
module status" function of the Service Tool). If the control unit status is ONLINE, the disconnected unit is causing
the problem.
4. If the power supply to the FMGR is correct, check the entire CAN bus for interruptions or defective terminating
resistors. If the CAN bus is interrupted, only those control modules are OFFLINE which are connected to the CAN
bus after the interruption.
a) Check vehicle bus:
Diagnostics interface S31(CANH PIN8, CANL PIN7),
Armrest X18/4 (CANH PIN17, CANL PIN18),
AUX1 X4/90 (CANH PIN3, CANL PIN2),
AUX2 X4/91 (CANH PIN3, CANL PIN2),
AUX3 X4/92 (CANH PIN3, CANL PIN2),
AUX4 X4/93 (CANH PIN3, CANL PIN2),
AUX5 X4/94 (CANH PIN3, CANL PIN2),
ECCU2 CN1a (CANH PIN15, CANL PIN16),
EDC X55 (CANH PIN50, CANL PIN52),
EEM2 X70 (CANH PIN18, CANL PIN42).
ICU P8/1 (CANH PIN3, CANL PIN4) via P8/2 (CANH PIN3, CANL PIN4) to ADIC CN3 (CANH PIN26, CANL
PIN25),
KEYPAD X4/63 (CANH PIN3, CANL PIN2),
Also check whether the jumper on X70 of the EEM between PIN 66 and PIN 67 is present.
Terminating resistor X3/10 (CANH PINA, CANL PINB).

b) Check transmission bus:

Diagnostics interface S31(CANH PIN2, CANL PIN1),
FMGR A4/3 (CANH PIN3, CANL PIN2),
SGR X16/21 (CANH PIN1, CANL PIN2),

c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm 10%) by
measuring between PIN 42 and PIN18 of EEM plug X70. Also check the terminating resistor in EEM box A2 bet-
ween PIN42 and PIN18 with the EEM box disconnected (setpoint 120 ohms 10%).

5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.

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FMGR - 255 CAN bus OFF from DBD100001

Cause:
The control unit detects that data transfer between FMGR and the vehicle bus is interrupted.
Possible causes:
1. Temporary malfunction of CAN communications between FMGR and the vehicle bus.
2. Short circuit on the CAN bus.
3. Bus termination incorrect or missing.
4. Contacts of the CAN bus plugs bent, broken or corroded.
5. Control unit defective.
Remedy:
1. A temporary malfunction can be caused by a temporary bus overload. Ensure that the power supply to the FMGR
is correct and it is ONLINE on the bus. Use the "Control module status" function of the Service Tool to check this.
If the FMGR is OFFLINE, go to step 2. If the FMGR is ONLINE, this is a temporary fault. Store the fault using the
Service Tool and then cancel it. Make a test drive to check the function. If the fault code does not occur again, no
further action is required.
2. Check supply to FMGR:
a) Ground at A4/3 PIN13 via weld point X0/7/5 to grounding point 11.
b) 12V (potential 15/1) at A4/3 PIN10 to central print (A12) X24/2 PIN1 on fuse F51.
c) 12V (potential 30) at A4/3 PIN14 to central print (A12) X24/2 PIN2 on fuse F14.
3. If the power supply to the FMGR is correct, check the entire CAN bus for short-circuits. On the CAN bus, discon-
nect one control module after the other and reconnect it again, checking the status of the control units ("Control
module status" function of the Service Tool). If the control unit status is ONLINE, the disconnected unit is causing
the problem.
4. If the power supply to the FMGR is correct, check the entire CAN bus for interruptions or defective terminating
resistors. If the CAN bus is interrupted, only those control modules are OFFLINE which are connected to the CAN
bus after the interruption.

a) Check vehicle bus:

Diagnostics interface X9/17 (CANH PINC, CANL PIND),
Armrest X18/4 (CANH PIN17, CANL PIN18),
AUX1 X4/90 (CANH PIN3, CANL PIN2),
AUX2 X4/91 (CANH PIN3, CANL PIN2),
AUX3 X4/92 (CANH PIN3, CANL PIN2),
AUX4 X4/93 (CANH PIN3, CANL PIN2),
AUX5 X4/94 (CANH PIN3, CANL PIN2),
ECCU2 CN1a (CANH PIN15, CANL PIN16),
EDC X55 (CANH PIN50, CANL PIN52),
EEM3 X89/1 (CANH PIN35, CANL PIN34).
ICU P8/1 (CANH PIN3, CANL PIN4) via P8/2 (CANH PIN3, CANL PIN4) to ADIC CN3 (CANH PIN26, CANL
PIN25),
KEYPAD X4/63 (CANH PIN3, CANL PIN2),
Terminating resistor X3/10 (CANH PINA, CANL PINB).

b) Check transmission bus:

Diagnostics interface X9/17 (CANH PINF, CANL PING),
FMGR A4/3 (CANH PIN3, CANL PIN2),
SGR X16/21 (CANH PIN1, CANL PIN2),

c) Disconnect the EEM control unit (ignition OFF), check terminating resistor X3/10 (setpoint 120 Ohm +/- 10%)
by measuring between PIN34 and PIN35 of EEM plug X89/1. Also check the terminating resistor in EEM box bet-
ween PIN34 and PIN35 with the EEM box disconnected (setpoint 120 ohms +/- 10%).

5. If the connection is ok, check FMGR plug A4/3 for bent, broken or corroded contacts and repair them if required.
6. Use the "Control module status" Service Tool function once again to check which of the control units is OFFLINE
and replace it.

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COMPONENTS SUMMARY
(8) Ground point roof, front right............................................................................................................. Fig. 1
(11) Ground point engine device carrier, rear up to DBD100000 ............................................................. Fig. 2
(11) Ground point engine cable carrier, rear from DBD100001 ............................................................... Fig. 3
(16) Ground point starter .......................................................................................................................... Fig. 4
AUX1 1st remote control valve.................................................................................................................... Fig. 5
AUX2 2nd remote control valve .................................................................................................................. Fig. 5
AUX3 3th remote control valve ................................................................................................................... Fig. 5
AUX4 4th remote control valve ................................................................................................................... Fig. 5
AUX5 5th remote control valve ................................................................................................................... Fig. 5
A2 EEM2 control unit up to DBD100000 ................................................................................................ Fig. 6
A3 EEM3 control unit from DBD100001................................................................................................. Fig. 7
A4 FMGR ............................................................................................................................................... Fig. 8
A4/1 FMGR plug connection - white [1] .................................................................................................... Fig. 9
A4/2 FMGR plug connection - dark grey [2] .............................................................................................. Fig. 9
A4/3 FMGR plug connection - blue [3] ...................................................................................................... Fig. 9
A4/4 FMGR plug connection - grey [4] ...................................................................................................... Fig. 9
A21 SGR transmission controller .......................................................................................................... Fig. 10
A60 ECCU2.............................................................................................................................................Fig. 11
B17 Angle of rotation sensor, clutch ...................................................................................................... Fig. 12
B17/1 Angle of rotation sensor, clutch, reversing facility ........................................................................... Fig. 13
CN1a ECCU2 plug connection ................................................................................................................. Fig. 14
CN2/E ECCU2 plug connection ................................................................................................................. Fig. 14
P8 ICU.................................................................................................................................................... Fig. 5
P8 ICU plug connection ....................................................................................................................... Fig. 15
R8 Potentiometer, accelerator pedal ................................................................................................... Fig. 16
R8/1 Potentiometer, accelerator pedal, reversing facility ........................................................................ Fig. 25
R23 Limit load potentiometer ................................................................................................................ Fig. 17
S2/58/1 Switch for speed ranges[RANGE] .................................................................................................. Fig. 18
S2/58/2 Switch for manual mode [MAN.MOD] ............................................................................................. Fig. 18
S2/59 Switch for 4-wheel drive management [4 WD]................................................................................ Fig. 19
S2/61 Parking interlock switch ................................................................................................................. Fig. 20
S2/61/1 Parking interlock switch, reversing facility ...................................................................................... Fig. 21
S4/4 Shuttle lever ................................................................................................................................... Fig. 17
S4/4/1 Forwards - reverse switch [V/R]...................................................................................................... Fig. 21
S5 Brake light switch ............................................................................................................................ Fig. 22
S5/1 Brake light switch, reversing facility ................................................................................................ Fig. 23
S20 Switch, engine back pressure brake .............................................................................................. Fig. 24
S21 Switch, handbrake .......................................................................................................................... Fig. 22
S25 Switch, steering brake ................................................................................................................... Fig. 22

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S46 Clutch switch 80% ..........................................................................................................................Fig. 12

S46/1 Clutch switch 80%, reversing facility [KUPPL].................................................................................Fig. 23
S60/2 Cruise control button ......................................................................................................................Fig. 25
S60/3 Speed button + ................................................................................................................................Fig. 25
S60/4 Speed button - .................................................................................................................................Fig. 25
X3/10 Plug connection, terminal resistance ...............................................................................................Fig. 26
X3/23 Plug connection, full-load potentiometer ........................................................................................Fig. 27
X4/14 Plug connection, brake light, Optistop ............................................................................................Fig. 28
X4/25 Plug connection, handbrake switch [25] ..........................................................................................Fig. 29
X4/25/1 Plug connection, handbrake switch, reversing facility [HANDBREMSE] .........................................Fig. 30
X4/59/a Plug connection, LIMP HOME [A] ...................................................................................................Fig. 31
X4/61 Plug connection, Grammer seat .....................................................................................................Fig. 32
X4/70 Plug connection, accelerator pedal [70] ..........................................................................................Fig. 33
X4/70/1 Plug connection, accelerator pedal, reversing facility [FAHRPEDAL] .............................................Fig. 30
X4/83 Plug connection, remote control valves ...........................................................................................Fig. 34
X4/85/a Plug connection, cab wiring harness, right - ISO BUS preparation ................................................Fig. 34
X4/85/b Plug connection, cab wiring harness, right - ISO BUS preparation ................................................Fig. 34
X4/90 Plug connection, AUX1....................................................................................................................Fig. 35
X4/91 Plug connection, AUX2....................................................................................................................Fig. 35
X4/92 Plug connection, AUX3....................................................................................................................Fig. 35
X4/93 Plug connection, AUX4....................................................................................................................Fig. 36
X4/94 Plug connection, AUX5....................................................................................................................Fig. 36
X6/3 Plug connection, instruments wiring harness - steering column [3].................................................Fig. 37
X6/27 Plug connection, seat switch, ARU console, reversing facility ........................................................Fig. 38
X6/58 Plug connection, seat switch, reversing facility [SITZ RF] ...............................................................Fig. 39
X10/3 Plug connection, engine print - instruments wiring harness from DBD100001................................Fig. 40
X10/4 Plug connection, EDC print armrest (GSV) .....................................................................................Fig. 41
X10/11 Plug connection, roof print supply ..................................................................................................Fig. 42
X10/12 Plug connection, roof wiring harness - roof print .............................................................................Fig. 43
X10/14 Plug connection, wiring harness for roof supply .............................................................................Fig. 44
X12/1 Plug connection, engine wiring harness - engine print from DBD100001 .......................................Fig. 45
X14/4 Plug connection, EDC print - control panel .....................................................................................Fig. 46
X14/14 Plug connection, roof supply [14] ....................................................................................................Fig. 47
X14/15 Plug connection, central print - wiring harness for roof supply [15] ................................................Fig. 48
X16/21 Plug connection, SGR .....................................................................................................................Fig. 49
X18/4 Plug connection, wiring harness, cab right - armrest.......................................................................Fig. 50
X20/1 Plug connection, engine wiring harness (Würth) up to DBD100000 ...............................................Fig. 51
X21 Plug connection, multicontroller - print ...........................................................................................Fig. 52
X23/1 Plug connection, instruments wiring harness - engine wiring harness up to DBD100000...............Fig. 53

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X24/2 Plug connection, wiring harness, cab right ..................................................................................... Fig. 54

X24/3 Plug connection, instruments wiring harness - wiring harness, cab right [3] .................................. Fig. 55
X24/5 Plug connection, wiring harness, cab right - control panel.............................................................. Fig. 56
X24/12 Plug connection, engine wiring harness (Berifors) up to DBD100000 ............................................ Fig. 51
X70 Plug connection, engine control unit EEM2 up to DBD100000 ...................................................... Fig. 57
X89/1 Plug connection, EEM3 engine control unit - engine wiring harness from DBD100001 ................. Fig. 58
Y11 Solenoid valve for brake oil cooling 1 up to DBD100000................................................................ Fig. 59
Y11 Solenoid valve for brake oil cooling 2 from DBD100001 ................................................................ Fig. 60
Y12 Solenoid valve for brake oil cooling 2 up to DBD100000................................................................ Fig. 61
Y12 Solenoid valve for brake oil cooling 1 from DBD100001 ................................................................ Fig. 62

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Fig. 1 Fig. 5

Fig. 2 up to DBD100000 Fig. 6 up to DBD100000

Fig. 3 from DBD100001 Fig. 7 from DBD100001

Fig. 4 Fig. 8

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 4011-602

Fig. 9 up to DBD100000 Fig. 9 from DBD100001

Fig. 10

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FMGR 4011-603

Fig. 11 Fig. 14 up to DBD100000

Fig. 12 up to DBD100000

Fig. 14 from DBD100001

Fig. 12 from DBD100001

Fig. 13

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Fig. 15 Fig. 18

Fig. 16

Fig. 19

Fig. 17

Fig. 20 up to DBD100000

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FMGR 4011-605

Fig. 20 from DBD100001 Fig. 23

Fig. 21 Fig. 24 up to DBD100000

Fig. 24 from DBD100001

Fig. 22

Fig. 25

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Fig. 26 Fig. 29 up to DBD100000

Fig. 27 Fig. 29 from DBD100001

Fig. 28 up to DBD100000 Fig. 30

Fig. 28 from DBD100001

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FMGR 4011-607

Fig. 31 up to DBD100000 Fig. 32 up to DBD100000

Fig. 32 from DBD100001

Fig. 31 from DBD100001

Fig. 33 up to DBD100000

Fig. 33 from DBD100001

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Fig. 34 up to DBD100000 Fig. 35 up to DBD100000

Fig. 34 from DBD100001 Fig. 35 from DBD100001

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FMGR 4011-609

Fig. 36 up to DBD100000 Fig. 37 up to DBD100000

Fig. 37 from DBD100001

Fig. 36 from DBD100001

Fig. 38

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Fig. 39 Fig. 42 up to DBD100000

Fig. 42 from DBD100001

Fig. 40 from DBD100001

Fig. 43 up to DBD100000

Fig. 41

Fig. 43 from DBD100001

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FMGR 4011-611

Fig. 44 up to DBD100000 Fig. 46 from DBD100001

Fig. 44 from DBD100001 Fig. 47 up to DBD100000

Fig. 45 from DBD100001

Fig. 46 up to DBD100000

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Fig. 47 from DBD100001 Fig. 49 up to DBD100000

Fig. 49 from DBD100001

Fig. 48 up to DBD100000

Fig. 50 up to DBD100000

Fig. 48 from DBD100001

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FMGR 4011-613

Fig. 50 from DBD100001 Fig. 53 up to DBD100000

Fig. 51 up to DBD100000 Fig. 54 up to DBD100000

Fig. 52 Fig. 54 from DBD100001

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Fig. 55 up to DBD100000 Fig. 56 up to DBD100000

Fig. 55 from DBD100001

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FMGR 4011-615

Fig. 56 from DBD100001 Fig. 57 up to DBD100000

Fig. 58 from DBD100001

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Fig. 59 up to DBD100000

Fig. 60 from DBD100001

Fig. 61 up to DBD100000

Fig. 62 from DBD100001

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FMGR 4011-617

*) see Note page 8

FUNCTIONAL SCHEMATIC DIAGRAM FOR FMGR - SGR UP TO DBD100000
X24/2
ARMREST (16) F19 5A
17 +15/1 F51 10A F18 5A
F20 5A +15/1 +15/1
*A28 PLUG MODULE 18 F14 7.5A A12 F9 10A
F16 5A GND +30 +30 A24 HYDROSTAT
X21 X11 *A30 PRINT ARU X1 X18/4 2 +15/2
3R7
A31 2 9 8 10
X5/1 X24/2 1 6 X24/2 21 23 M
1 1 7 13
S60/1 9 9
13 3 (16) (16) 3R7
X7 15 A4/3 10 14 13 A4/4 X16/21 13 12 3
CAN - CAN H
S60/2 2 16 1 A4 FMGR 17 1 A21 SGR
CAN H CAN L X6/9 E F L M H K B
11 11 3 17 3 18 2
CAN L Supply Supply
4 18 2

GND
11 V
S60/3
10 12 S4/4
X6/3 X24/3 A4/2 1 12 2 11 9 10 3
S60/4

0 V or 5 V
3 10 8 NEUTRAL LIMP HOME circuit
9 4 X16/21
2 11 7 DEAD MAN GND
GSV2 10
S60/5 4 12 6 12 V
Shuttle lever 14 Select 0 V** for FORWARDS
12 5 1 2 2 12 V
8 Select 0 V** for REVERSE
5 1 1 7 11 FORWARDS
*YA1 21 17 15 13 11 8 6 4 2 3 1 33 5 7 A23 ELECTRONICS
6 3 3 8 10 REVERSE **) Only if the
X4/59/b (A) and X4/59/c (B) A23 8 5 7 6

X4/59/b
X4/59/a
*YB1 21 17 15 13 11 8 6 4 2 3 1 33 5 7 plug connection is linked.
A21/4
* A27 CAN MODULE 11 X6/1

CAN H

CAN +
CAN L
12 4

CAN -
X24/3
2 19 A21/5 1
A12 X14/15 X10/11 A13 X10/12 P8 P8 ICU P8/1 1 21 3 3
F45 5A
+15/1 12 7 6 7 4 3 20 9 2
5 3 X4/59/c
3 2 A24 Hydrostat X5/1 Plug connection
Brake
X14/14 4 1 A27 CAN module ---> DBD..... X6/1 4-pin plug connection
X4/14 X24/3 A4/2 A28 Plug module ---> DBD..... X6/3 6-pin plug connection
P8/2 3 4 1 GSV2
6 A30 Print ARU DBD..... ---> X6/9 7-pin plug connection
A14 X20/1 X23/1 X10/14 12
F93 5A (7) S25 3.9 Ω A31 Multi controller X7 4-pin plug connection
+30 8 Q 7 (8) 3 4 14 3 V B17 Angle of rotation sensor, clutch X10/11 10-pin plug connection
S5 2 5 13 3 V CN3 26-pin plug connection X10/12 10-pin plug connection
P8 ICU X10/14 10-pin plug connection
P8 10-pin plug connection X11 16-pin plug connection
CN3 X24/3 A4/2 Clutch P8/1 4-pin plug connection X14/14 14-pin plug connection
A1 ADIC CAN L GSV2 P8/2 4-pin plug connection X14/15 14-pin plug connection
25 1 12 6
3.9 Ω R8 Potentiometer, accelerator pedal X16/21 16-pin plug connection
CAN H S46
26 A4/1 S4/4 Shuttle lever X18/4 18-pin plug connection
2 24 15 3 V S5 Switch for brake light X20/1 20-pin plug connection
S25 Switch for steering brake X21 14-pin plug connection
A4/4 S46 Switch, clutch X23/1 23-pin plug connection
A1 ADIC GND
1 13 4 S60/1 F/R button X23/2 23-pin plug connection
CAN H

A2 EEM2
CAN L

B17 5.6V S60/2 Cruise control button X24/2 24-pin plug connection
A4 FMGR 2 14 11
S60/3 Speed button + X24/3 24-pin plug connection
A4/1 18-pin plug connection U 3 15 12 1.1 to 4 V S60/4 Speed button - X70 70-pin plug connection
A4/2 18-pin plug connection S60/5 HTS button YA1 44-pin plug connection
A4/3 15-pin plug connection X1 14-pin plug connection ---> DBD.....
A4/4 18-pin plug connection X4/70 A4/4 Accelerator pedal X4/14 4-pin plug connection YB1 44-pin plug connection
A12 Central print GND X4/59/a 3-pin plug connection ---> DBD.....
1 1
A13 Roof print
X70 18 42 3 X4/59/b 3-pin plug connection (7) Ground point, roof hood, left
A14 Engine print R8 6 4.4 to 0.8 V X4/59/c 3-pin plug connection (8) Ground point, roof hood, right
A21 SGR transmission controller
A2 EEM2 5.8V
2 10 X4/70 4-pin plug connection (16) Ground point, starter
A21/4 12-pin plug connection
A21/5 12-pin plug connection 4 3 0.8 to 4.4 V
A23 Electronics X70 X23/2
A23 12-pin plug connection 36 U

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BLANK PAGE

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FMGR 4011-619

A4 FMGR
A4/2 A21/2 A21 SGR
GSV3 5V
1 p 1 4
B47 GND
S8 2 7 A21/3 Y41
U 4V
X4/61 X4/61 A4/2 3 6 0.2 to 3.1 V 6 1
GND
2 1 17 Seat contact A21/2 7
5V
S21 p 1 11 2
GND
X4/25 X4/25 A4/2 B51 2 8
2 1 16 Parking brake (open) U 3 5 0.2 to 1.2 V A21/3 Y42
4V
5 1
S20 A21/2 GND
t 8
A4/1 Engine back pressure 1 3
B32 PTC 1 kΩ to 4.4 kΩ 2
2 1 3 brake R 2 10
X5 A21/4 A21/3 Y43
GND 4V
1 2 9 4 1
A16 X14/4 A4/1 GND
GSV1 S49/1 2 1 3 GND 9
8 18 p Opens at a difference in pressure of 2
> 5 bar
1 2 X10/4 S2/58/1
Speed ranges 12 V
1 A21/3 Y44
0
X24/5 A4/1 3 4V
1
1 23 16 increase "+" Y11 GND
2 10
7 5 17 decrease "-" 2
3 Sensors and 2
1 A4/3 solenoid valves
12 V
S2/58/2 5 1 A21/3 Y45
Brake oil cooling Y12 4V
8 2 1
GND
OFF
ON
2 11
X24/5 A4/1 2
A21/7
5 1 8 5 Manual mode
(16) n 1 A21/3 Y46
S2/59 B24 10 to 6000 Hz 4V
f 2 1 1
GND
0 12
1
X24/5 A4/1 A21/8
2
Management 2
5 3 1 n 1
3 and B25 10 to 6000 Hz
1 4 2 all-wheel f 2

A21/9
X3/23 X24/5 A4/4 1
5.8 V n
a 1 11 14 Potentiometer B26 10 to 6000 Hz
f 2 Y57
R23 b 3 12 15 0 to 5.8 V for limit load
S2/61 GND A21/5 1
c 2 13 5 A21/10 10 V
4
n 1 GND
OFF
A4/1 B27 10 to 6000 Hz 8 2
ON
f 2
X24/3 13 3.0 V X17
Switch for parking Y58
1 3 18 A4/2 A21/6
GSV2 interlock 2
12 6 n 1
B35 10 to 6000 Hz A21/5
f 2 10 V
A4 FMGR A21/9 2-pin plug connection S2/58/2 Switch, manual mode 5 1
A4/1 18-pin plug connection A21/10 2-pin plug connection S2/59 Switch, all-wheel X24/5 24-pin plug connection
A4/2 18-pin plug connection B24 Speed sensor, cartridge input S2/61 Switch for parking interlock X17 Y - distributor
A4/3 15-pin plug connection B25 Speed sensor, planetary carrier 3/4 S8 Seat switch Y11 Solenoid valve for brake oil cooling
A4/4 18-pin plug connection B26 Speed sensor, cartridge output S20 Switch, engine back pressure brake Y12 Solenoid valve for brake oil cooling
A16 EDC print B27 Speed sensor, cartridge output S21 Switch, parking brake Y41 Solenoid valve, clutch 1
A21 SGR transmission controller B32 Temperature sensor, transmission oil S49/1 Switch, pressure filter Y42 Solenoid valve, clutch 2
A21/2 12-pin plug connection B35 Speed sensor, planetary carrier 1/2 X3/23 3-pin plug connection Y43 Solenoid valve, clutch 3 Y59
A21/3 12-pin plug connection B47 Pressure sensor for transmission X4/25 4-pin plug connection Y44 Solenoid valve, clutch 4 1
system pressure Y45 Solenoid valve, clutch, forward A21/5
A21/4 12-pin plug connection X4/61 4-pin plug connection 4V
A21/5 12-pin plug connection B51 Pressure sensor for transmission X5 2-pin plug connection Y46 Solenoid valve, clutch, reverse 6
lubrication pressure Y57 Solenoid valve, parking interlock ON GND
A21/6 2-pin plug connection X10/4 10-pin plug connection Y58 Solenoid valve, parking interlock OFF 7 2
A21/7 2-pin plug connection R23 Potentiometer for limit load X14/4 14-pin plug connection Y59 Solenoid valve, all-wheel
A21/8 2-pin plug connection S2/58/1 Switch, speed ranges X24/3 24-pin plug connection (16) Ground point, starter

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BLANK PAGE

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FMGR 4011-621

FUNCTIONAL SCHEMATIC DIAGRAM FOR FMGR - SGR FROM DBD100001

ARMREST
A12 A24 HYDROSTAT

X30/11
F19 5A F51 10A F18 5A
+15/1 +15/1
A30 PRINT ARU 3R7
(11) F20 5A F14 7.5A F9 10A
X21 X30/1 X18/4 +15/1 +30 +30
M
A31 2 9 8 10 X24/2 17 18 X24/2 1 6 X24/2 21 23
1 1 7 13 3R7

S60/1 9 9
13 3 (11) (11)
X30/7 A4/3 10 14 13 A4/4 X16/21 13 12 3 X6/9 E F L M H K B
CAN H
S60/2 2 16 A4 FMGR 17 1 A21 SGR

GND
CAN H CAN L

11 V
11 11 3 17 3 18 2 Supply
CAN L Supply
4 18 2
S60/3
A23 1 12 2 11 9 10 3
10 12 S4/4

0 V or 5 V
X6/3 X24/3 A4/2 LIMP HOME circuit
S60/4 3 10 8 NEUTRAL
9 4 X16/21
2 11 7 DEAD MAN GND
GSV2 10
S60/5 4 12 6 12 V
Shuttle lever 14 Select 0 V** with FORWARDS
12 5 1 2 2 12 V
8 Select 0 V** with REVERSE A23 ELECTRONICS
5 1 1 7 11 FORWARDS
**) Only if the A23 8 5 7 6
6 3 3 8 10 REVERSE
X4/59/b (A) and X4/59/c (B)

X4/59/b
X4/59/a
plug connection is linked.
A21/4 X6/1
11 4

CAN H
CAN L
X24/3 12 1
2 19 A21/5
1 21 3 3
A12 X14/15 X10/11 A13 X10/12 P8 P8 ICU P8/1 3 20 9 2
F45 5A
+15/1 12 7 6 7 4 X4/59/c
5 3 A1 ADIC S60/3 Speed button +
X4/14 X24/3 A4/2 Brake A3 EEM3 S60/4 Speed button -
3 GSV2
1 12 6 A4 FMGR S60/5 HTS button
S25 3.9 Ω
3 4 14 3 V A4/1 18-pin plug connection X4/14 4-pin plug connection
A14 X10/3 X10/14 X14/14 P8/2 3 4 A4/2 18-pin plug connection X4/59/a 3-pin plug connection
F212 5A S5 2 5 13 3 V A4/3 15-pin plug connection X4/59/b 3-pin plug connection
+30 6 7 4 (7)
A4/4 18-pin plug connection X4/59/c 3-pin plug connection
(8) A12 Central print X4/70 4-pin plug connection
X24/3 A4/2 Clutch A13 Roof print X6/1 4-pin plug connection
GSV2 A14 Engine print X6/3 6-pin plug connection
1 12 6
3.9 Ω A21 SGR transmission controller X6/9 7-pin plug connection
S46 A4/1 A21/4 12-pin plug connection X10/3 10-pin plug connection
2 24 15 3 V A21/5 12-pin plug connection X10/11 10-pin plug connection
CAN H
CAN L

A23 Electronics X10/12 10-pin plug connection

A4/4 A23 12-pin plug connection X10/14 10-pin plug connection
GND A24 Hydrostat X10/18 10-pin plug connection
1 13 4
5.6V A30 Print ARU X14/14 14-pin plug connection
B17 2 14 11 A31 Multi controller X14/15 14-pin plug connection
U 3 15 12 1.1 to 4 V B17 Angle of rotation sensor, clutch X16/21 16-pin plug connection
CN3 26-pin plug connection X18/4 18-pin plug connection
A1 ADIC CN3 P8 ICU X21 14-pin plug connection
CAN L P8 10-pin plug connection X24/2 24-pin plug connection
25 X4/70 A4/4 Accelerator pedal
CAN H GND P8/1 4-pin plug connection X24/3 24-pin plug connection
26 1 1 P8/2 4-pin plug connection X30/1 14-pin plug connection
3 6 4.4 to 0.8 V R8 Potentiometer, accelerator pedal X30/7 4-pin plug connection
X89/1 35 34 R8
5.8V S4/4 Shuttle lever X30/11 16-pin plug connection
2 10 S5 Switch for brake light X89/1 89-pin plug connection
A3 EEM3
4 3 0.8 to 4.4 V S25 Switch for steering brake (7) Ground point, roof hood, left
S46 Switch, clutch (8) Ground point, roof hood, right
S60/1 F/R button (11) Ground point, engine cable
X89/1 X10/18 X24/3 S60/2 Cruise control button carrier, rear
79 10 16

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BLANK PAGE

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FMGR 4011-623

A4 FMGR A21 SGR

A4/2 A21/2
GSV3 5V
1 p 1 4
B47 GND
S8 2 7 A21/3 Y41
X4/61 X4/61 A4/2
U 3 6 0.2 to 3.1 V 6 4V
1
GND
2 1 17 Seat contact A21/2 7
5V
S21 p 1 11 2
GND
X4/25 X4/25 A4/2 B51 2 8
2 1 16 Parking brake (open) U 3 5 0.2 to 1.2 V A21/3 Y42
4V
5 1
S20 A21/2 GND
t 8
A4/1 1 3
B32 PTC 1 kΩ to 4.4 kΩ 2
2 1 3 Engine back pressure 2 10
R
brake
X5 A21/4 A21/3 Y43
A16 GND 4V
X14/4 A4/1 1 2 9 4 1
GSV1 GND
8 18 S49/1 2 1 3 GND 9
p Opens at a difference in pressure of 2
1 2 X10/4 S2/58/1 > 5 bar
Speed ranges A21/3
0
X24/5 A4/1 12 V
1 Y44
4V
1 23 16 increase "+" 3 1
2 Y11 GND
7 5 17 decrease "-" 10
3 2
1 Sensors and 2
A4/3 solenoid valves
S2/58/2 12 V
Brake oil cooling 5 1 A21/3 Y45
Y12 4V
OFF
8 2 1
GND
ON
2 11
X24/5 A4/1 2
5 1 8 5 Manual mode A21/7
S2/59 (11) n 1 A21/3 Y46
B24 10 to 6000 Hz 4V
0
f 2 1 1
GND
1
X24/5 A4/1 12
2
Management A21/8
5 3 1 2
3 and n 1
1 4 2 all-wheel B25 10 to 6000 Hz
f 2

X3/23 X24/5 A4/4 A21/9

5.8 V
a 1 11 14 Potentiometer n 1
B26 10 to 6000 Hz
R23 b 3 12 15 0 to 5.8 V for limit load f 2 Y57
S2/61 GND
c 2 13 5 A21/5 1
A21/10 10 V
4
OFF
X24/5 A4/1 n 1 GND
ON
B27 10 to 6000 Hz 8 2
18 13 3.0 V f 2
Switch for parking X17
1 3 X24/3 A4/2 Y58
GSV2 interlock A21/6
12 6 2
n 1
B35 10 to 6000 Hz A21/5
A4 FMGR A21/10 2-pin plug connection S2/61 Switch for parking interlock f 2 10 V
5 1
A4/1 18-pin plug connection B24 Speed sensor, cartridge input S8 Seat switch
A4/2 18-pin plug connection B25 Speed sensor, planetary carrier 3/4 S20 Switch, engine back pressure brake
A4/3 15-pin plug connection B26 Speed sensor, cartridge output S21 Switch, parking brake Y12 Solenoid valve for brake oil cooling
A4/4 18-pin plug connection B27 Speed sensor, cartridge output S49/1 Switch, pressure filter Y41 Solenoid valve, clutch 1
A16 EDC print B32 Temperature sensor, transmission oil X3/23 3-pin plug connection Y42 Solenoid valve, clutch 2
A21 SGR transmission controller B35 Speed sensor, planetary carrier 1/2 X4/25 4-pin plug connection Y43 Solenoid valve, clutch 3 Y59
A21/2 12-pin plug connection B47 Pressure sensor for transmission X4/61 4-pin plug connection Y44 Solenoid valve, clutch 4 A21/5 1
A21/3 12-pin plug connection system pressure X5 2-pin plug connection Y45 Solenoid valve, clutch, forward 4V
A21/4 12-pin plug connection B51 Pressure sensor for transmission X10/4 10-pin plug connection Y46 Solenoid valve, clutch, reverse 6
A21/5 12-pin plug connection lubricating pressure X14/4 14-pin plug connection Y57 Solenoid valve, parking interlock ON GND
7 2
A21/6 2-pin plug connection R23 Potentiometer for limit load X17 Y - distributor Y58 Solenoid valve, parking interlock OFF
A21/7 2-pin plug connection S2/58/1 Switch, speed ranges X24/3 24-pin plug connection Y59 Solenoid valve, all-wheel
A21/8 2-pin plug connection S2/58/2 Switch, manual mode X24/5 24-pin plug connection (11) Ground point, engine cable carrier, rear
A21/9 2-pin plug connection S2/59 Switch, all-wheel Y11 Solenoid valve for brake oil cooling

Sva 6-52632 EN Edition 06-2006

4011-624

BLANK PAGE

Sva 6-52632 EN Edition 06-2006

FMGR 4011-625

FUNCTIONAL SCHEMATIC DIAGRAM FOR FMGR REVERSING FACILITY UP TO DBD100000

A4 FMGR
A4/2 P6
S4/4
X6/3 X24/3 A4/2 3 3
S4/4/1
3 10 8 5
2 11 7 2 1
GSV2 0

4 12 6 1
X6/15 5 6
8 A4/2
1 2 2 4
2 8 NEUTRAL A12
5 1 1 7 11 X2/4/1
7 7 DEAD MAN
6 3 3 8 10 3 GSV2 15/2
1 6 (16)

X4/59/b
X4/59/a
Shuttle lever
11 FORWARDS A21 SGR
A12 X24/3 10 REVERSE X16/21 LIMP HOME circuit
X2/4/1 X6/15 2 GND
10
19
15/2 6 12 V
1 21 14 Select 0 V** for FORWARDS
12 V
3 20 8 Select 0 V** for REVERSE
A70 X4/59/c A4/2
GSV3
1 **) Only if the
S8/1 S21 X4/59/b (A) and X4/59/c (B)
X6/58 X6/27 X6/27 X6/58 16 Parking brake (open) plug connection is linked.
X4/25 X4/25/1 X4/25/1 X4/25 A4/2
2 2 1 1
S8/2 2 2 1 1 16
6 6 5 5 A4/2
S20 S8 Seat switch
4 4 3 3 1
S8 A4/1 A4/1 Engine back pressure S8/1 Reversible seat switch
S8/2 Reversible seat switch
2 1 3 3 brake S20 Switch for engine back
4 Signal pressure brake
reversing facility S21 Switch, parking brake
A4/2 S46 Switch, clutch
17 Seat contact S46/1 Switch, clutch,
reversing facility
A4/4 X2/4/1 Plug connection
GND
X24/3 A4/4 4 Clutch X4/25 4-pin plug connection
5.6V X4/25/1 4-pin plug connection
1 13 4 11
B17
X4/59/a 3-pin plug connection
2 14 11 12 1.1 to 4 V X4/59/b 3-pin plug connection
U 3 15 12 X24/3 A4/2 A4/2 X4/59/c 3-pin plug connection
K5/60 GSV2 X4/70 4-pin plug connection
1 12 6 6
4 3.9 Ω X4/70/1 4-pin plug connection
1 3 S46 24 X6/3 6-pin plug connection
B17/1
5 X6/15 6-pin plug connection
2 2
2 1 X6/27 6-pin plug connection
U 3 A4/1 A4/1
X6/58 6-pin plug connection
1 15 15 3 V
3.9 Ω X16/21 16-pin plug connection
S46/1 X23/2 23-pin plug connection
A2 EEM2 2 X24/3 24-pin plug connection
A4 FMGR A4/4
(16) 5.8V Accelerator pedal X70 70-pin plug connection
A4/1 18-pin plug connection X4/70 A4/4 10 (16) Ground point, starter
A4/2 18-pin plug connection GND
1 1 1
A4/4 18-pin plug connection
A12 Central print R8 3 6 K5/61 3 0.8 to 4.4 V
A21 SGR transmission controller 2 10 4 6 4.4 to 0.8 V
A70 Seat switch, reversing facility 3
4 3 5
B17 Angle of rotation sensor, clutch
B17/1 Angle of rotation sensor, clutch, reversing facility 2 1
K5/60 Relay for clutch, reversing facility X4/70/1
K5/61 Relay, accelerator pedal, reversing facility 1 K5/62
K5/62 Relay, accelerator pedal, reversing facility 3
P6 Display, reversing facility R8/1 4
3
R8 Potentiometer, accelerator pedal 2 5
R8/1 Potentiometer, accelerator pedal, reversing facility 4 2 1
S4/4 Shuttle lever
S4/4/1 Forwards - reverse switch, reversing facility A2 EEM2 X70 X23/2
36 U
(16)

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 4011-626

A4 FMGR
X4/14 X24/3 A4/2 A4/2
GSV2 Brake
1 12 6 6
S25 3.9 Ω
3 4 14 14 3 V
S5 2 5 13 13 3 V

4
S5/1
3

A16 X14/4 A4/1 A4/1

GSV1
8 18 18
A4 FMGR
1 2 X10/4 S2/58/1 A4/1 18-pin plug connection
A4/2 18-pin plug connection
Speed ranges
0 A4/4 18-pin plug connection
1
X24/5 A4/1 A4/1 A16 EDC print
2

7 23 16 16 increase "+" R23 Potentiometer for limit load

3 S2/58/1 Switch, speed ranges
1 5 17 17 decrease "-" S2/58/2 Switch, manual mode
S2/58/2 S2/59 Switch, all-wheel
S2/61 Switch for parking interlock
S2/61/1 Switch for parking interlock,
OFF reversing facility
ON
S5 Switch for brake light
X24/5 A4/1 A4/1 S5/1 Switch for brake light, reversing facility
5 1 8 5 5 Manual mode S25 Switch for steering brake
X3/23 3-pin plug connection
S2/59 X4/14 4-pin plug connection
0
X10/4 10-pin plug connection
1
X24/5 A4/1 A4/1 X14/4 14-pin plug connection
2
Management X24/3 24-pin plug connection
5 3 1 1 X24/5 24-pin plug connection
3 and
1 4 2 2 all-wheel

X3/23 X24/5 A4/4 A4/4

5.8 V Potentiometer
a 1 11 14 14
for limit load
R23 b 3 12 15 15 0 to 5.8 V
GND
c 2 13 5 5

S2/61

OFF
ON
A4/1 A4/1
X24/3 13 13 3.0 V
1 3 18 A4/2 A4/2 Switch for parking
GSV2
12 6 6 interlock
S2/61/1

OFF
ON

3 1

Sva 6-52632 EN Edition 06-2006

FMGR 4011-627

FUNCTIONAL SCHEMATIC DIAGRAM FOR FMGR REVERSING FACILITY FROM DBD100001

A4 FMGR
A4/2 P6
S4/4
X6/3 X24/3 A4/2 3 3
S4/4/1
3 10 8 5
2 11 7 2 1
GSV2 0

4 12 6 1
X6/15 5 6
8 A4/2
1 2 2 4
2 8 NEUTRAL A12
5 1 1 7 11 X2/4/1
7 7 DEAD MAN
6 3 3 8 10 3 GSV2 15/2
1 6 (11)

X4/59/b
X4/59/a
Shuttle lever
11 FORWARDS A21 SGR
A12 X24/3 10 REVERSE X16/21 LIMP HOME circuit
X2/4/1 X6/15 2 GND
10
19
15/2 6 12 V
1 21 14 Select 0 V** with FORWARDS
12 V
3 20 8 Select 0 V** with REVERSE
A70 X4/59/c A4/2
GSV3
1 **) Only if the
S8/1 S21 X4/59/b (A) and X4/59/c (B)
X6/58 X6/27 X6/27 X6/58 16 Parking brake (open) plug connection is linked.
X4/25 X4/25/1 X4/25/1 X4/25 A4/2
2 2 1 1
S8/2 2 2 1 1 16
6 6 5 5 A4/2
S20 S8 Seat switch
4 4 3 3 1
S8 A4/1 A4/1 Engine back pressure S8/1 Reversible seat switch
S8/2 Reversible seat switch
2 1 3 3 brake S20 Switch, engine back
4 Signal pressure brake
reversing facility S21 Switch, parking brake
A4/2 S46 Switch, clutch
17 Seat contact S46/1 Switch, clutch,
reversing facility
A4/4 X2/4/1 Plug connection
GND
X24/3 A4/4 4 Clutch X4/25 4-pin plug connection
5.6V X4/25/1 4-pin plug connection
1 13 4 11
B17
X4/59/a 3-pin plug connection
2 14 11 12 1.1 to 4 V X4/59/b 3-pin plug connection
U 3 15 12 X24/3 A4/2 A4/2 X4/59/c 3-pin plug connection
K5/60 GSV2 X4/70 4-pin plug connection
1 12 6 6
4 3.9 Ω X4/70/1 4-pin plug connection
1 3 S46 24 X6/3 6-pin plug connection
B17/1
5 X6/15 6-pin plug connection
2 2
2 1 X6/27 6-pin plug connection
U 3 A4/1 A4/1
X6/58 6-pin plug connection
1 15 15 3 V
3.9 Ω X10/18 10-pin plug connection
S46/1 X16/21 16-pin plug connection
A3 EEM3 2 X24/3 24-pin plug connection
A4 FMGR A4/4
(11) 5.8V Accelerator pedal X89/1 89-pin plug connection
A4/1 18-pin plug connection X4/70 A4/4 10 (11) Ground point, engine
A4/2 18-pin plug connection GND cable carrier, rear
1 1 1
A4/4 18-pin plug connection
A12 Central print R8 3 6 K5/61 3 0.8 to 4.4 V
A21 SGR transmission controller 2 10 4 6 4.4 to 0.8 V
A70 Seat switch, reversing facility 3
4 3 5
B17 Angle of rotation sensor, clutch
B17/1 Angle of rotation sensor, clutch, reversing facility 2 1
K5/60 Relay for clutch, reversing facility X4/70/1
K5/61 Relay, accelerator pedal, reversing facility 1 K5/62
K5/62 Relay, accelerator pedal , reversing facility 3
P6 Display, reversing facility R8/1 4
3
R8 Potentiometer, accelerator pedal 2 5
R8/1 Potentiometer, accelerator pedal, reversing facility 4 2 1
S4/4 Shuttle lever
S4/4/1 Forwards - reverse switch, reversing facility A3 EEM3 X89/1 X10/18 X24/3
79 10 16
(11)

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 4011-628

A4 FMGR
X4/14 X24/3 A4/2 A4/2
GSV2 Brake
1 12 6 6
S25 3.9 Ω
3 4 14 14 3 V
S5 2 5 13 13 3 V

4
S5/1
3

A16 X14/4 A4/1 A4/1

GSV1
8 18 18
A4 FMGR
1 2 X10/4 S2/58/1 A4/1 18-pin plug connection
A4/2 18-pin plug connection
0 Speed ranges A4/4 18-pin plug connection
1
X24/5 A4/1 A4/1 A16 EDC print
2

7 23 16 16 increase "+" R23 Potentiometer for limit load

3 S2/58/1 Switch, speed ranges
1 5 17 17 decrease "-" S2/58/2 Switch, manual mode
S2/58/2 S2/59 Switch, all-wheel
S2/61 Switch for parking interlock
S2/61/1 Switch for parking interlock,
OFF reversing facility
ON
S5 Switch for brake light
X24/5 A4/1 A4/1 S5/1 Switch for brake light, reversing facility
5 1 8 5 5 Manual mode S25 Switch for steering brake
X3/23 3-pin plug connection
S2/59 X4/14 4-pin plug connection
0
X10/4 10-pin plug connection
1
X24/5 A4/1 A4/1 X14/4 14-pin plug connection
2
Management X24/3 24-pin plug connection
5 3 1 1 X24/5 24-pin plug connection
3 and
1 4 2 2 all-wheel

X3/23 X24/5 A4/4 A4/4

5.8 V Potentiometer
a 1 11 14 14
for limit load
R23 b 3 12 15 15 0 to 5.8 V
GND
c 2 13 5 5

S2/61

OFF
ON
A4/1 A4/1
X24/3 13 13 3.0 V
1 3 18 A4/2 A4/2 Switch for parking
GSV2
12 6 6 interlock
S2/61/1

OFF
ON

3 1

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 4011-629

FAULTCODES SGR
SGR - 1 Controller fault (Arithmetic, Push, Pop, Stack) .................................................................................... 633
SGR - 2 Controller fault (Register) .................................................................................................................... 633
SGR - 3 Controller fault (internal Watchdog) .................................................................................................... 634
SGR - 5 Controller fault (external Watchdog) ................................................................................................... 634
SGR - 7 In shipment conditions, without valid parameters ............................................................................... 634
SGR - 8 Controller memory fault (Flash checksum) at init ................................................................................ 635
SGR - 9 Controller memory fault (Flash checksum) at run ............................................................................... 635
SGR - 12 Controller memory fault (RAM addressing) internal at init ................................................................ 636
SGR - 13 Controller memory fault (RAM addressing) internal at run ................................................................ 636
SGR - 14 Controller memory fault (RAM addressing) external at init ............................................................... 637
SGR - 15 Controller memory fault (RAM addressing) external at run ............................................................... 637
SGR - 16 Controller memory fault (EEPROM checksum 0 incorrect) ............................................................... 638
SGR - 17 Controller memory fault (EEPROM checksum 1 incorrect) ............................................................... 638
SGR - 18 Controller memory fault (EEPROM checksum 2 incorrect) ............................................................... 639
SGR - 24 Controller fault (illegal external bus access) ..................................................................................... 639
SGR - 25 Controller fault (illegal instruction access) ......................................................................................... 640
SGR - 26 Controller fault (illegal word operand access, compiler fault) ............................................................ 640
SGR - 27 Controller fault (memory protection fault flag) ................................................................................... 641
SGR - 28 Program fault (no valid C167 instruction) .......................................................................................... 641
SGR - 29 Controller memory fault (stack underflow) ........................................................................................ 642
SGR - 30 Controller memory fault (stack overflow) ........................................................................................... 642
SGR - 31 Non maskable Interrupt is active (incorrect) ...................................................................................... 643
SGR - 32 Receive of local CAN Bus signal TR1 is failed (register 0) ............................................................... 643
SGR - 33 Receive of local CAN Bus signal TR5 is failed (register 1) ............................................................... 644
SGR - 35 Receive of local CAN Bus signal engine (EHS) is failed (register 3) ................................................ 645
SGR - 47 CAN Bus OFF (transmission Bus) .................................................................................................... 646
SGR - 48 Supply voltage (potential 30) too low ................................................................................................ 646
SGR - 49 Supply voltage (potential 30) too high ............................................................................................... 647
SGR - 50 Internal main switch for valves is not switchable ............................................................................... 647
SGR - 51 Internal main switch for valves is permanent on ............................................................................... 648
SGR - 52 Hydrostat, calibration data not in tolerance range ............................................................................. 648
SGR - 53 Hydrostat, transmission ratio is not reached ..................................................................................... 649
SGR - 54 Maximum hydrostat high pressure reached ...................................................................................... 649
SGR - 56 Impermissible activation of the gear clutches ................................................................................... 650
SGR - 60 Internal fault in the hydrostat ............................................................................................................. 650
SGR - 61 Hydrostat calibration data in EEPROM not plausible ........................................................................ 651
SGR - 63 FMGR-SGR check: failed .................................................................................................................. 652
SGR - 64 Cartridge input speed sensor B24 - interruption or short-circuit to ground ....................................... 652
SGR - 65 Cartridge input speed sensor B24 - sensor short-circuit ................................................................... 653
SGR - 66 Cartridge input speed too high .......................................................................................................... 653
SGR - 67 Cartridge input speed sensor B24 - signal dropout ........................................................................... 654
SGR - 68 Planet carrier 1/2 speed sensor B35 - interruption or short-circuit to ground .................................... 654
SGR - 69 Planet carrier 1/2 speed sensor B35 - sensor short-circuit ............................................................... 655
SGR - 70 Planet carrier 1/2 speed too high ...................................................................................................... 655
SGR - 71 Planet carrier 1/2 speed sensor B35 - signal dropout ....................................................................... 656
SGR - 72 Output speed 1 speed sensor B27 - interruption or short-circuit to ground ...................................... 656
SGR - 73 Output speed 1 speed sensor B27 - sensor short-circuit .................................................................. 657
SGR - 74 Output speed 1 too high .................................................................................................................... 657
SGR - 75 Output speed 1 speed sensor B27 - signal dropout .......................................................................... 657

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SGR - 76 Planet carrier 3/4 speed sensor B25 - interruption or short-circuit to ground .................................... 658
SGR - 77 Planet carrier 3/4 speed sensor B25 - sensor short-circuit ............................................................... 659
SGR - 78 Planet carrier 3/4 speed too high ...................................................................................................... 659
SGR - 79 Planet carrier 3/4 speed sensor B25 - signal dropout ....................................................................... 660
SGR - 80 Output speed 2 speed sensor B26 - interruption or short-circuit to ground ....................................... 660
SGR - 81 Output speed 2 speed sensor B26 - sensor short-circuit .................................................................. 661
SGR - 82 Output speed 2 too high .................................................................................................................... 661
SGR - 84 Cartridge input speed not plausible ................................................................................................... 662
SGR - 85 Planet carrier 1-2 speed not plausible ............................................................................................... 663
SGR - 86 Output speed not plausible ................................................................................................................ 664
SGR - 87 Planet carrier 3-4 speed not plausible ............................................................................................... 664
SGR - 88 Output speed - direction calibration incorrect value .......................................................................... 665
SGR - 96 Supply line A0 (limp home analog) - voltage out of range high ......................................................... 665
SGR - 97 Supply line A0 (limp home analog) - signal incorrect ........................................................................ 666
SGR - 99 Supply line A0 (limp home analog) - voltage out of range low .......................................................... 666
SGR - 104 Lubrication pressure sensor - voltage out of range high ................................................................. 667
SGR - 105 Lubrication pressure sensor - oil pressure missing ......................................................................... 667
SGR - 106 Lubrication pressure sensor - oil pressure out of range low ............................................................ 668
SGR - 107 Lubrication pressure sensor - voltage out of range low ................................................................... 669
SGR - 108 Lubrication pressure sensor - oil pressure out of range high .......................................................... 670
SGR - 112 System pressure sensor - voltage out of range high ....................................................................... 670
SGR - 113 System pressure sensor - system pressure too low ........................................................................ 671
SGR - 114 System pressure sensor - system pressure too low, remedy taking effect ..................................... 672
SGR - 115 System pressure sensor - voltage out of range low ........................................................................ 673
SGR - 116 System pressure sensor - oil pressure out of range high ................................................................ 673
SGR - 117 System pressure sensor - oil pressure drops during a shifting process .......................................... 674
SGR - 118 System pressure sensor - system pressure too low, remedy not taking effect ............................... 674
SGR - 120 Temperature Sensor - open circuit, short to power ......................................................................... 675
SGR - 121 Temperature Sensor - temperature gradient out of range high ....................................................... 675
SGR - 122 Temperature Sensor - temperature out of range high ..................................................................... 676
SGR - 123 Temperature Sensor - short to ground ............................................................................................ 676
SGR - 124 Temperature Sensor - temperature out of range low - restricted operation .................................... 677
SGR - 125 Temperature Sensor - temperature gradient out of range low ........................................................ 677
SGR - 126 Temperature Sensor - temperature out of range low - no operation ............................................... 678
SGR - 136 Pressure Oil Filter - Change filter .................................................................................................... 678
SGR - 144 HCU - no feedback .......................................................................................................................... 679
SGR - 145 HCU activation not correct .............................................................................................................. 679
SGR - 146 Hydrostat - index sensor does not supply a feedback signal .......................................................... 680
SGR - 147 Hydrostat electronics - starting problems ........................................................................................ 680
SGR - 148 Hydrostat - starting problems .......................................................................................................... 681
SGR - 149 Parklock - applying abborted - section 1 - travel too much ............................................................. 681
SGR - 150 Parklock - applying abborted - section 2 - travel too much ............................................................. 681
SGR - 151 Parklock - applying abborted - section 1 - no hydrostatic pressure ................................................. 682
SGR - 152 Parklock - applying abborted - section 2 - no hydrostatic pressure ................................................. 682
SGR - 153 Parklock - test abborted - section 1 - travel too high ....................................................................... 682
SGR - 154 Parklock - test abborted - section 2 - travel too high ....................................................................... 682
SGR - 155 Parklock - test abborted - section 1 - no hydrostatic high pressure ................................................ 683
SGR - 156 Parklock - test abborted - section 2 - no hydrostatic high pressure ................................................ 683
SGR - 157 Parklock - test abborted - too much hydrostatic high pressure before neutral, or travel too high ... 683
SGR - 170 Hydrostatic ECU Supply voltage - short to power ........................................................................... 684

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SGR - 171 Hydrostatic ECU Supply voltage - short circuit, or short to ground ................................................. 685
SGR - 176 Solenoid valve AWD - open circuit .................................................................................................. 686
SGR - 177 Solenoid valve AWD - PWM signal incorrect .................................................................................. 686
SGR - 178 Solenoid valve AWD - short to power ............................................................................................. 687
SGR - 179 Solenoid valve AWD - short circuit, or short to ground ................................................................... 687
SGR - 184 Solenoid valve clutch forward - open circuit .................................................................................... 688
SGR - 185 Solenoid valve clutch forward - PWM signal incorrect .................................................................... 688
SGR - 186 Solenoid valve clutch forward - short to power ............................................................................... 689
SGR - 187 Solenoid valve clutch forward - short circuit, or short to ground ..................................................... 689
SGR - 188 Forward clutch - clutch does not open ............................................................................................ 690
SGR - 189 Forward clutch - clutch does not close ............................................................................................ 690
SGR - 190 Forward clutch - clutch is slipping ................................................................................................... 691
SGR - 192 Solenoid valve clutch reverse - open circuit .................................................................................... 691
SGR - 193 Solenoid valve clutch reverse - PWM signal incorrect .................................................................... 692
SGR - 194 Solenoid valve clutch reverse - short to power ............................................................................... 692
SGR - 195 Solenoid valve clutch reverse - short circuit, or short to ground ..................................................... 693
SGR - 196 Reverse clutch - clutch does not open ............................................................................................ 693
SGR - 197 Reverse clutch - clutch does not close ............................................................................................ 694
SGR - 198 Reverse clutch - clutch is slipping ................................................................................................... 694
SGR - 200 Solenoid valve clutch 1 - open circuit .............................................................................................. 695
SGR - 201 Solenoid valve clutch 1 - PWM signal incorrect .............................................................................. 695
SGR - 202 Solenoid valve clutch 1 - short to power ......................................................................................... 696
SGR - 203 Solenoid valve clutch 1 - short circuit, short to ground .................................................................... 696
SGR - 204 Clutch K1 - clutch does not open .................................................................................................... 697
SGR - 205 Clutch K1 - clutch does not close .................................................................................................... 697
SGR - 206 Clutch K1 - clutch is slipping ........................................................................................................... 698
SGR - 208 Solenoid valve clutch 2 - open circuit .............................................................................................. 698
SGR - 209 Solenoid valve clutch 2 - PWM signal incorrect .............................................................................. 699
SGR - 210 Solenoid valve clutch 2 - short to power ......................................................................................... 699
SGR - 211 Solenoid valve clutch 2 - short circuit, or short to ground ............................................................... 700
SGR - 212 Clutch K2 - clutch does not open .................................................................................................... 700
SGR - 213 Clutch K2 - clutch does not close .................................................................................................... 701
SGR - 214 Clutch K2 - clutch is slipping ........................................................................................................... 701
SGR - 216 Solenoid valve clutch 3 - open circuit .............................................................................................. 702
SGR - 217 Solenoid valve clutch 3 - PWM signal incorrect .............................................................................. 702
SGR - 218 Solenoid valve clutch 3 - short to power ......................................................................................... 703
SGR - 219 Solenoid valve clutch 3 - short circuit, or short to ground ............................................................... 703
SGR - 220 Clutch K3 - clutch does not open .................................................................................................... 704
SGR - 221 Clutch K3 - clutch does not close .................................................................................................... 704
SGR - 222 Clutch K3 - clutch is slipping ........................................................................................................... 705
SGR - 224 Solenoid valve clutch 4 - open circuit .............................................................................................. 705
SGR - 225 Solenoid valve clutch 4 - PWM signal incorrect .............................................................................. 706
SGR - 226 Solenoid valve clutch 4 - short to power ......................................................................................... 706
SGR - 227 Solenoid valve clutch 4 - short circuit, or short to ground ............................................................... 707
SGR - 228 Clutch K4 - clutch does not open .................................................................................................... 707
SGR - 229 Clutch K4 - clutch does not close .................................................................................................... 708
SGR - 230 Clutch K4 - clutch is slipping ........................................................................................................... 708
SGR - 232 Solenoid valve parklock On - open circuit ....................................................................................... 709
SGR - 234 Solenoid valve parklock On - short to power ................................................................................... 709
SGR - 235 Solenoid valve parklock On - short circuit, or short to ground ......................................................... 710

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SGR - 236 Parking interlock - parking interlock cannot be engaged ................................................................. 710
SGR - 237 Parking interlock - parking interlock does not lock .......................................................................... 711
SGR - 240 Solenoid valve parklock Off - open circuit ....................................................................................... 711
SGR - 242 Solenoid valve parklock Off - short to power ................................................................................... 712
SGR - 243 Solenoid valve parklock Off - short circuit, or short to ground ......................................................... 712
COMPONENTS SUMMARY ............................................................................................................................. 714
FUNCTIONAL SCHEMATIC DIAGRAM FOR FMGR - SGR UP TO DBD100000 ............................................ 719
FUNCTIONAL SCHEMATIC DIAGRAM FOR FMGR - SGR FROM DBD100001 ............................................ 723

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SGR - 1 Controller fault (Arithmetic, Push, Pop, Stack)

Cause:
Controller processor error. Controller internal component defective.
Possible causes:
1. Memory defect.
2. Problem during reprogramming.
3. Intermittent voltage supply of controller.
4. EMC Problem.
Solution:
Make sure that the SGR has a good connection to the battery (potential 15 on X16/21 PIN13 to fuse F18, potential 30
on X16/21 PIN12 to fuse F9) and is properly grounded (X16/21 PIN3). If this error occurs immediatly after repro-
gramming FMGR, repeat the reprogramming because this could have been disturbed. Fault is stored, warnlamp si-
gnals and stopp tractor slowly.
1. Clear error record, switch ignition OFF and ON again.
2. If error occurs periodically again then replace SGR.
3. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC problem.

SGR - 2 Controller fault (Register)

Cause:
Controller processor error. Controller internal component defective.
Possible causes:
1. Memory defect.
2. Problem during reprogramming.
3. Intermittent voltage supply of controller.
4. EMC Problem.
Solution:
Make sure that the SGR has a good connection to the battery (potential 15 on X16/21 PIN13 to fuse F18, potential 30
on X16/21 PIN12 to fuse F9) and is properly grounded (X16/21 PIN3). If this error occurs immediatly after repro-
gramming FMGR, repeat the reprogramming because this could have been disturbed. Fault is stored, warnlamp si-
gnals and stopp tractor slowly. Main switch solen
1. Clear error record, switch ignition OFF and ON again.
2. If error occurs periodically again then replace SGR.
3. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro- Magnetic Compatibility) problem.

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SGR - 3 Controller fault (internal Watchdog)

Cause:
Controller processor error. Controller internal component defective.
Possible causes:
1. Memory defect.
2. Problem during reprogramming.
3. Intermittent voltage supply of controller.
4. EMC Problem.
Solution:
Make sure that the SGR has a good connection to the battery (potential 15 on X16/21 PIN13 to fuse F18, potential 30
on X16/21 PIN12 to fuse F9) and is properly grounded (X16/21 PIN3). If this error occurs immediatly after repro-
gramming FMGR, repeat the reprogramming because this could have been disturbed. Fault is stored, warnlamp si-
gnals and main switch solenoid valves is off.
1. Clear error record, switch ignition OFF and ON again.
2. If error occurs periodically again then replace SGR.
3. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro- Magnetic Compatibility) problem.

SGR - 5 Controller fault (external Watchdog)

Cause:
Controller processor error. Controller internal component defective.
Possible causes:
1. Memory defect.
2. Problem during reprogramming.
3. Intermittent voltage supply of controller.
4. EMC Problem.
Solution:
Make sure that the SGR has a good connection to the battery (potential 15 on X16/21 PIN13 to fuse F18, potential 30
on X16/21 PIN12 to fuse F9) and is properly grounded (X16/21 PIN3). If this error occurs immediatly after repro-
gramming FMGR, repeat the reprogramming because this could have been disturbed. Fault is stored, warnlamp si-
gnals and stopp tractor slowly. Main switch solen
1. Clear error record, switch ignition OFF and ON again.
2. If error occurs periodically again then replace SGR.
3. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro- Magnetic Compatibility) problem.

SGR - 7 In shipment conditions, without valid parameters

Cause:
The SGR as sparepart is normally shipped without valid parameters from factory. This will be indicated to the custo-
mer by setting this error.
Solution:
Fault is stored, warnlamp signals and main switch solenoid valves is off. This is a 'No Error' error. Follow the installa-
tion instructions for a controller replacement, how to setup new parameters.

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SGR - 8 Controller memory fault (Flash checksum) at init

Cause:
Controller memory error. Programm memory lost defective.
Possible causes:
1. Memory defect.
2. Problem during reprogramming.
3. Intermittent voltage supply of controller.
4. EMC Problem.
Solution:
Make sure that the SGR has a good connection to the battery (potential 15 on X16/21 PIN13 to fuse F18, potential 30
on X16/21 PIN12 to fuse F9) and is properly grounded (X16/21 PIN3). If this error occurs immediatly after repro-
gramming FMGR, repeat the reprogramming because this could have been disturbed. Fault is stored, warnlamp si-
gnals.
1. Clear error record, switch ignition OFF and ON again.
2. If error occurs periodically again then replace SGR.
3. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro- Magnetic Compatibility) problem.

SGR - 9 Controller memory fault (Flash checksum) at run

Cause:
Controller memory error. Programm memory lost defective.
Possible causes:
1. Memory defect.
2. Problem during reprogramming.
3. Intermittent voltage supply of controller.
4. EMC Problem.
Solution:
Make sure that the SGR has a good connection to the battery (potential 15 on X16/21 PIN13 to fuse F18, potential 30
on X16/21 PIN12 to fuse F9) and is properly grounded (X16/21 PIN3). If this error occurs immediatly after repro-
gramming FMGR, repeat the reprogramming because this could have been disturbed. Fault is stored, warnlamp si-
gnals and main switch solenoid valves is off.
1. Clear error record, switch ignition OFF and ON again.
2. If error occurs periodically again then replace SGR.
3. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro- Magnetic Compatibility) problem.

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SGR - 12 Controller memory fault (RAM addressing) internal at init

Cause:
Controller memory error. Controller data memory defective.
Possible causes:
1. Memory defect
2. Intermittent voltage supply of controller.
3. EMC (Electro- Magnetic Compatibility) problem.
Solution:
Make sure that the SGR has a good connection to the battery (potential 15 on X16/21 PIN13 to fuse F18, potential 30
on X16/21 PIN12 to fuse F9) and is properly grounded (X16/21 PIN3). Fault is stored, warnlamp signals and main
switch solenoid valves is off.
1. Clear error record, switch ignition OFF and ON again.
2. If error occurs periodically again then replace SGR.
3. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro- Magnetic Compatibility) problem.

SGR - 13 Controller memory fault (RAM addressing) internal at run

Cause:
Controller memory error. Controller data memory defective.
Possible causes:
1. Memory defect.
2. Intermittent voltage supply of controller.
3. EMC (Electro- Magnetic Compatibility) problem.
Solution:
Make sure that the SGR has a good connection to the battery (potential 15 on X16/21 PIN13 to fuse F18, potential 30
on X16/21 PIN12 to fuse F9) and is properly grounded (X16/21 PIN3). Fault is stored, warnlamp signals and stopp
tractor slowly. Main switch solenoid valves is off.
1. Clear error record, switch ignition OFF and ON again.
2. If error occurs periodically again then replace SGR.
3. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro- Magnetic Compatibility) problem.

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SGR - 14 Controller memory fault (RAM addressing) external at init

Cause:
Controller memory error. Controller data memory defective.
Possible causes:
1. Memory defect.
2. Intermittent voltage supply of controller.
3. EMC (Electro- Magnetic Compatibility) problem.
Solution:
Make sure that the SGR has a good connection to the battery (potential 15 on X16/21 PIN13 to fuse F18, potential 30
on X16/21 PIN12 to fuse F9) and is properly grounded (X16/21 PIN3). Fault is stored, warnlamp signals and stopp
tractor slowly. Main switch solenoid valves is off.
1. Clear error record, switch ignition OFF and ON again.
2. If error occurs periodically again then replace SGR.
3. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro- Magnetic Compatibility) problem.

SGR - 15 Controller memory fault (RAM addressing) external at run

Cause:
Controller memory error. Controller data memory defective.
Possible causes:
1. Memory defect.
2. Intermittent voltage supply of controller.
3. EMC (Electro- Magnetic Compatibility) problem.
Solution:
Make sure that the SGR has a good connection to the battery (potential 15 on X16/21 PIN13 to fuse F18, potential 30
on X16/21 PIN12 to fuse F9) and is properly grounded (X16/21 PIN3). Fault is stored, warnlamp signals and stopp
tractor slowly. Main switch solenoid valves is off.
1. Clear error record, switch ignition OFF and ON again.
2. If error occurs periodically again then replace SGR.
3. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro- Magnetic Compatibility) problem.

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SGR - 16 Controller memory fault (EEPROM checksum 0 incorrect)

Cause:
Controller memory error. Loss of controller manufacturer and diagnostic tester factory settings data. This fault doesn`t
influence driving.
Possible causes:
1. Memory defect.
2. Intermittent voltage supply of controller.
3. Incorrect terminated parameter download after software reprogramming or controller replacement.
Solution:
Make sure that the SGR has a good connection to the battery (potential 15 on X16/21 PIN13 to fuse F18, potential 30
on X16/21 PIN12 to fuse F9) and is properly grounded (X16/21 PIN3).
1. Correct checksums with configuration screen "TRANSMISSION - CLEAR NON-CRITICAL CHECKSUM
FAULTS" of the servicetool.
2. If error occurs again then replace SGR.
3. If this error occurs immediatly after replacement of SGR or reprogramming, this error can be due to missing,
wrong or obselete parameters.
Also in this case correct checksums with configuration screen "TRANSMISSION - CLEAR NON-CRITICAL
CHECKSUM FAULTS" of the servicetool.

SGR - 17 Controller memory fault (EEPROM checksum 1 incorrect)

Cause:
Controller memory error. Loss of transmission manufacturer data and vehicle manufacturer factory settings data. This
failure has no effect to vehicles with 155/170/190/195 PS. Vehicles with 135/145 PS drive slowlier than displayed,
because it will be calculated with the biggest rear axle gear ratio.
Possible causes:
1. Memory defect.
2. Intermittent voltage supply of controller.
3. Incorrect terminated parameter download after software reprogramming, or controller replacement.
Solution:
Make sure that the SGR has a good connection to the battery (potential 15 on X16/21 PIN13 to fuse F18, potential 30
on X16/21 PIN12 to fuse F9) and is properly grounded (X16/21 PIN3).
1. Check and correct if required the stored axle ratio with screen "TRANSMISSION - AXLE RATIO
CONFIGURATION" of the service tool.
2. If error occurs again then replace SGR.
3. If this error occurs imediatly after replacement of SGR or reprogramming, this error can be due to missing, wrong
or obselete parameters.
Also in this case do new download of EEPROM data with servicetool.

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SGR - 18 Controller memory fault (EEPROM checksum 2 incorrect)

Cause:
Controller memory error. Loss of service data. This fault doesn`t influence driving.
Possible causes:
1. Memory defect.
2. Intermittent voltage supply of controller.
3. Batterie main switch switched off, or battery terminal was disconnected before ignition was switched off.
4. Incorrect terminated parameter download after software reprogramming or controller replacement.
Solution:
Make sure that the SGR has a good connection to the battery (potential 15 on X16/21 PIN13 to fuse F18, potential 30
on X16/21 PIN12 to fuse F9) and is properly grounded (X16/21 PIN3).
1. Clear error, switch ignition OFF and ON again. All old service information is possibly lost, but this doesn't influence
the controller function. Correct checksums with configuration screen "TRANSMISSION - CLEAR NON-CRITICAL
CHECKSUM FAULTS" of the servicetool.
2. If error occurs again then replace SGR.

SGR - 24 Controller fault (illegal external bus access)

Cause:
Controller processor error. Programm memory lost defective.
Possible causes:
1. Memory defect.
2. Problem during reprogramming.
3. Intermittent voltage supply of controller.
4. EMC Problem.
Solution:
Make sure that the SGR has a good connection to the battery (potential 15 on X16/21 PIN13 to fuse F18, potential 30
on X16/21 PIN12 to fuse F9) and is properly grounded (X16/21 PIN3). If this error occurs immediatly after repro-
gramming FMGR, repeat the reprogramming because this could have been disturbed. Fault is stored, warnlamp
signals.
1. Clear error record, switch ignition OFF and ON again.
2. If error occurs periodically again then replace SGR.
3. If error after replacement of SGR still occurs, contact engineering department.
4. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro- Magnetic Compatibility) problem.

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SGR - 25 Controller fault (illegal instruction access)

Cause:
Controller processor error. Programm memory lost defective.
Possible causes:
1. Memory defect.
2. Problem during reprogramming.
3. Intermittent voltage supply of controller.
4. EMC Problem.
Solution:
Make sure that the SGR has a good connection to the battery (potential 15 on X16/21 PIN13 to fuse F18, potential 30
on X16/21 PIN12 to fuse F9) and is properly grounded (X16/21 PIN3). If this error occurs immediatly after repro-
gramming FMGR, repeat the reprogramming because this could have been disturbed. Fault is stored, warnlamp si-
gnals.
1. Clear error record, switch ignition OFF and ON again.
2. If error occurs periodically again then replace SGR.
3. If error after replacement of SGR still occurs, contact engineering department
4. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro- Magnetic Compatibility) problem.

SGR - 26 Controller fault (illegal word operand access,

compiler fault)
Cause:
Controller processor error. Programm memory lost defective.
Possible causes:
1. Memory defect.
2. Problem during reprogramming.
3. Intermittent voltage supply of controller.
4. EMC Problem.
Solution:
Make sure that the SGR has a good connection to the battery (potential 15 on X16/21 PIN13 to fuse F18, potential 30
on X16/21 PIN12 to fuse F9) and is properly grounded (X16/21 PIN3). If this error occurs immediatly after repro-
gramming FMGR, repeat the reprogramming because this could have been disturbed. Fault is stored, warnlamp si-
gnals.
1. Clear error record, switch ignition OFF and ON again.
2. If error occurs periodically again then replace SGR.
3. If error after replacement of SGR still occurs, contact engineering department.
4. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro- Magnetic Compatibility) problem.

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SGR - 27 Controller fault (memory protection fault flag)

Cause:
Controller processor error. Programm memory lost defective.
Possible causes:
1. Memory defect.
2. Problem during reprogramming.
3. Intermittent voltage supply of controller.
4. EMC Problem.
Solution:
Make sure that the SGR has a good connection to the battery (potential 15 on X16/21 PIN13 to fuse F18, potential 30
on X16/21 PIN12 to fuse F9) and is properly grounded (X16/21 PIN3). If this error occurs immediatly after repro-
gramming FMGR, repeat the reprogramming because this could have been disturbed. Fault is stored, warnlamp si-
gnals.
1. Clear error record, switch ignition OFF and ON again.
2. If error occurs periodically again then replace SGR.
3. If error after replacement of SGR still occurs, contact engineering department.
4. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro- Magnetic Compatibility) problem.

SGR - 28 Program fault (no valid C167 instruction)

Cause:
Controller processor error: Programm memory lost defective.
Possible causes:
1. Memory defect.
2. Problem during reprogramming.
3. Intermittent voltage supply of controller.
4. EMC Problem.
Solution:
Make sure that the SGR has a good connection to the battery (potential 15 on X16/21 PIN13 to fuse F18, potential 30
on X16/21 PIN12 to fuse F9) and is properly grounded (X16/21 PIN3). If this error occurs immediatly after repro-
gramming FMGR, repeat the reprogramming because this could have been disturbed. Fault is stored, warnlamp si-
gnals.
1. Clear error record, switch ignition OFF and ON again.
2. If error occurs periodically again then replace SGR.
3. If error after replacement of SGR still occurs, contact engineering department.
4. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC (Electro- Magnetic
compatibility) problem.

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SGR - 29 Controller memory fault (stack underflow)

Cause:
Controller processor error. Programm memory lost defective.
Possible causes:
1. Memory defect.
2. Problem during reprogramming.
3. Intermittent voltage supply of controller.
4. EMC Problem.
Solution:
Make sure that the SGR has a good connection to the battery (potential 15 on X16/21 PIN13 to fuse F18, potential 30
on X16/21 PIN12 to fuse F9) and is properly grounded (X16/21 PIN3). If this error occurs immediatly after repro-
gramming FMGR, repeat the reprogramming because this could have been disturbed. Fault is stored, warnlamp si-
gnals.
1. Clear error record, switch ignition OFF and ON again.
2. If error occurs periodically again then replace SGR.
3. If error after replacement of SGR still occurs, contact engineering department.
4. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro- Magnetic Compatibility) problem.

SGR - 30 Controller memory fault (stack overflow)

Cause:
Controller processor error. Programm memory lost defective.
Possible causes:
1. Memory defect.
2. Problem during reprogramming.
3. Intermittent voltage supply of controller.
4. EMC Problem.
Solution:
Make sure that the SGR has a good connection to the battery (potential 15 on X16/21 PIN13 to fuse F18, potential 30
on X16/21 PIN12 to fuse F9) and is properly grounded (X16/21 PIN3). If this error occurs immediatly after repro-
gramming FMGR, repeat the reprogramming because this could have been disturbed. Fault is stored, warnlamp si-
gnals.
1. Clear error record, switch ignition OFF and ON again.
2. If error occurs periodically again then replace SGR.
3. If error after replacement of SGR still occurs, contact engineering department.
4. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro- Magnetic Compatibility) problem.

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SGR - 31 Non maskable Interrupt is active (incorrect)

Cause:
Controller processor error. Programm memory lost defective.
Possible causes:
1. Memory defect.
2. Problem during reprogramming.
3. Intermittent voltage supply of controller.
4. EMC Problem.
Solution:
Make sure that the SGR has a good connection to the battery (potential 15 on X16/21 PIN13 to fuse F18, potential 30
on X16/21 PIN12 to fuse F9) and is properly grounded (X16/21 PIN3). If this error occurs immediatly after repro-
gramming FMGR, repeat the reprogramming because this could have been disturbed. Fault is stored, warnlamp si-
gnals.
1. Clear error record, switch ignition OFF and ON again.
2. If error occurs periodically again then replace SGR.
3. If error after replacement of SGR still occurs, contact engineering department.
4. If error doesn't occur again, do a longer testdrive, to make sure that it was a one time EMC
(Electro- Magnetic Compatibility) problem.

SGR - 32 Receive of local CAN Bus signal TR1 is failed (register 0)

Cause:
The controller detects a timeout of a periodical dataexchange between FMGR and SGR.
Possible causes:
1. Intermittant CAN problems between FMGR and SGR.
2. Short circuit in the CAN Bus.
3. Controller hardware failure of FMGR, or SGR.
4. Wrong, or missing Bus terminating resistor.
5. Bent, broken, or corroded pins on the Bus connectors.
6. Wrong program in the FMGR, or SGR.
Solution:
Make sure that FMGR and SGR are correctly power supplied, and are online on the Bus. For this switch Service Tool
connector to the local bus and use Service Tool for diagnose. The permanent missing of this CAN Bus signal TR1,
the SGR will not be shown as online, because the data transmission between FMGR and SGR is bad.

Fault is stored, warnlamp signals. Check for additional stored errors of the FMGR and the SGR to limit the possible
reasons. If the failure occured only one time, and the error was not recorded after deleting and a testdrive again de-
tected, there is no additional check required. The operation of the vehicle is not limited.
1. If error code SGR - 63 is permanent active, refer to description of SGR - 63.
2. If several error codes SGR - 33 and 35 are recorded and error code SGR - 47 is not active, FMGR check is nes-
sesary (check if the FMGR is at least in one position of the servicetoolbutton ONLINE). If error code SGR - 47 is
active refer to description of SGR - 47.
3. If the FMGR works correctly, check the CAN Bus connection between SGR and FMGR.
• Check CANH wire from connector X16/21 PIN1 to A4/4 PIN17.
• Check CANL wire from connector X16/21 PIN2 to A4/4 PIN18.
4. If not working check the connector of SGR for bent, broken or corroded terminals, and repair if required.
5. Do the same on the FMGR.
6. Check the program version of FMGR and the SGR for correct application.
7. Was a reprogramming of the SGR or FMGR terminated incorrectly, or was a controller unit changed to a wrong
program version. Repeat the reprogramming or replace the FMGR or SGR if required.

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SGR - 33 Receive of local CAN Bus signal TR5 is failed (register 1)

Cause:
The controller detects a timeout of a periodical dataexchange between FMGR and SGR. If this message not recieved,
the vehicle goes automatically slowly (safety).
Possible causes:
1. Intermittant CAN problems between FMGR and SGR.
2. Short circuit in the CAN Bus.
3. Controller hardware failure of FMGR, or SGR.
4. Wrong, or missing Bus terminating resistor.
5. Bent, broken, or corroded pins on the Bus connectors.
6. Wrong program in the FMGR, or SGR.
Solution:
Make sure that FMGR and SGR are correctly power supplied, and are online on the Bus. For this switch Service Tool
connector to the local bus and use Service Tool for diagnose. The permanent missing of this CAN Bus signal TR5,
the SGR will not be shown as online, because the data transmission between FMGR and SGR is bad.

Fault is stored, warnlamp signals and stopp tractor slowly. Check for additional stored errors of the FMGR and the
SGR to limit the possible reasons. If the failure occured only one time, and the error was not recorded after deleting
and a testdrive again detected, there is no additional check required. The operation of the vehicle is not limited.
1. If error code SGR - 63 is permanent active refer to description of SGR - 63.
2. If several error codes SGR - 32 and 35 are recorded and error code SGR - 47 is not active, FMGR check is nes-
sesary (check if the FMGR is at least in one position of the servicetoolbutton ONLINE). If error code SGR - 47 is
active refer to description of SGR - 47.
3. If the FMGR works correctly, check the CAN Bus connection between SGR and FMGR.
• Check CANH wire from connector X16/21 PIN1 to A4/4 PIN17.
• Check CANL wire from connector X16/21 PIN2 to A4/4 PIN18.
4. If not working check the connector of SGR for bended, broken or corroded terminals, and repair if required.
5. Do the same on the FMGR.
6. Check the program version of FMGR and the SGR for correct application.
7. Was a reprogramming of the SGR or FMGR terminated incorrectly, or was a controller unit changed to a wrong
program version. Repeat the reprogramming or replace the FMGR or SGR if required.

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SGR - 35 Receive of local CAN Bus signal engine (EHS) is failed

(register 3)
Cause:
The controller detects a timeout of a periodical dataexchange between EEM and SGR.
Possible causes:
1. The EEM is not on Bus.
2. Intermittant CAN problems between FMGR and SGR.
3. Short circuit in the CAN Bus.
4. Controller hardware failure of FMGR, or SGR.
5. Wrong, or missing Bus terminating resistor.
6. Bent, broken, or corroded pins on the Bus connectors.
7. Wrong program in the FMGR, or SGR.
Solution:
Make sure that FMGR and SGR are correctly power supplied, and check with Service Tool if SGR, FMGR and EEM
are online on Bus. Check for additional stored errors of FMGR and SGR to limit the possible reasons. If failure occured
only one time and was not recorded and detected after deletind and testdrive, is no additional check required, becau-
se function is no longer disturbed.

Fault is stored. If EEM online on the Bus, check following:

1. If error code FMGR - 240 is permanent active, refer to description of FMGR - 240.
2. If several error codes SGR - 33 and 35 are recorded and error code SGR - 47 is not active, FMGR check is nes-
sesary (check if the FMGR is at least in one position of the servicetoolbutton ONLINE). If error code FMGR - 47
is active, refer to description of FMGR - 47.
3. If the FMGR works correctly, check the CAN Bus connection between SGR and FMGR.
• Check CANH wire from connector X16/21 PIN1 to A4/4 PIN17.
• Check CANL wire from connector X16/21 PIN2 to A4/4 PIN18.
4. If not working check the connector of SGR for bended, broken or corroded terminals, and repair if required.
5. Do the same on the FMGR.
6. Check the program version of FMGR and the SGR for correct application.
7. Was a reprogramming of the SGR or FMGR terminated incorrectly, or was the controller unit changed to a wrong
one. Repeat the reprogramming, or replace the FMGR or SGR, if required.
If EEM is not online on the Bus, have a look in the EEM faulttree describtion.

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SGR - 47 CAN Bus OFF (transmission Bus)

Cause:
The controller detects the termination of data exchange between FMGR and SGR.
Possible causes:
1. Intermittant CAN problems between FMGR and SGR.
2. Short circuit in the CAN Bus.
3. Controller hardware failure of FMGR, or SGR.
4. Wrong, or missing Bus terminating resistor.
5. Bent, broken, or corroded pins on the Bus connectors.
Solution:
Make sure that FMGR and SGR are correctly power supplied. If this error is aktive, the SGR will not be shown as
online on the bus. Check for additional stored errors of the FMGR and the SGR to limit the possible reasons.
Fault is stored, warnlamp signals and stopp tractor slowly.
• Vehicle slow down to standstill
• LIMP Home possible (look at operation instructions)
1. Switch Service Tool connector to the local Bus.
2. Check all CAN Connections between FMGR and SGR.
• Check CANH wire from connector X16/21 PIN1 to A4/4 PIN17.
• Check CANL wire from connector X16/21 PIN2 to A4/4 PIN18.
3. If failure is active, disconnect FMGR A4/4 and check if failure is gone. If it is and the wire is ok, then
replace FMGR. If failure is not gone, replace SGR.

SGR - 48 Supply voltage (potential 30) too low

Cause:
The controller detects low voltage on the permanent power supply line potential 30 below 9V.
Possible causes:
1. Battery voltage low.
2. A fuse is burned.
3. Alternator regulator malfunction.
4. The controller has a bad connection to power or is not grounded properly.
Solution:
Check for fuse faults, battery voltage, alternator regulator output and the controller connection to power and ground.
Fault is stored, warnlamp signals and stopp tractor slowly. Main switch solenoid valves is off.
1. Check fuse F9.
2. Check other ECCU's for stored errors concerning under voltage.
If yes:
• Check for actual Battery voltage. Please measure directly on the batterie.
• Check alternator output voltage.
If no:
• Unplug connector X16/21 of SGR, mount adapter, measure voltage between PIN12 and PIN3 (switch igni-
tion OFF). The voltage should have Battery level. If so, switch on big electrical consumers like working-
lights, or fans. If the voltage drops, the error occured due to a low charged battery. If the voltage is
already without extra consumers below 9V, measure Voltage between PIN12 and chassis ground. If the
voltage is higher, then the failure can be found in the ground line (PIN3 of X16/21) else look in supply line
from F9 to PIN12 of X16/21.

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SGR - 49 Supply voltage (potential 30) too high

Cause:
The controller detects overvoltage of more than 15V on the supply input.
Possible causes:
1. Battery voltage over 15V.
2. Alternator regulator malfunction.
3. The battery positive wiring is accidentially connected to external higher voltage source.
Solution:
Test the alternator output and check for external power source. Check other ECU's for stored error codes. Fault is
stored, warnlamp signals and stopp tractor slowly. Main switch solenoid valves is off.
1. Check for actual batterie voltage, please measure directly on the batterie.
2. Check also alternator output voltage.
3. Unplug connector X16/21 of SGR, measure voltage between PIN12 and PIN3. The voltage should have batterie
level. Is the voltage not higher, so is the SGR defekt and has to be changed.

SGR - 50 Internal main switch for valves is not switchable

Cause:
The controller has a internal solid state relay. The controller tries to activate this relay, but cannot measure any voltage
on the output although there is supply voltage of more than 9V.
Possible causes:
1. Fuse defect.
2. Defect of the solid state relay.
3. Shortcut of another internal part that pulls the voltage down.
Solution:
If the SGR has sufficiant electrical supply. The SGR has normally to be replaced, but it has to be checked that the
defect was not due to external influences.
Fault is stored, warnlamp signals and stopp tractor slowly. Main switch solenoid valves is off.
1. Remove SGR.
2. Disconnect all connectors of SGR. Measure the SGR power supply on connector X16/21 PIN12 to PIN3 and fol-
low the procedure as describet for SGR48. Measure the resistance for posible shortcuts from all SGR pins to
ground:
There should be no direct ground connection except X16/21 PIN3. PIN12 (potential 30) and PIN13
(potential 15/1) can have low resistance. All other should be verry high.
3. If a shortcut was found, you can try whether the SGR works again. Else replace the SGR.

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SGR - 51 Internal main switch for valves is permanent on

Cause:
The controller has a internal solid state relay. The controller tests before activating this relay that it is switched off.
Possible causes:
1. Defect of the solid state relay.
2. A battery positive wiring is accidentally connected to an output.
Solution:
Before replacing the SGR it has to be checked that the error was not due to an external fault. But there is only a small
chance, because normally no other poser supply is routed byoned the transmission covers. Fault is stored, warnlamp
signals and stopp tractor slowly. Main switch solenoid valves is off.
1. If this error occurs alone: change contoller unit.
2. In combination with another error of valve outputs like short to power: SGR170, 178, 186, 194, 202, 210, 218,
226, 234, or 242 look for these errors first.

SGR - 52 Hydrostat, calibration data not in tolerance range

Cause:
Whenever the hydrostat is in the neutral position, the hydrostat is recalibrated. When the new calibration data was
checked afterwards it was found that the values are outside the permissible tolerance range. This malfunction can
only occur during a calibration process. The fault is stored.
Possible causes:
1. Hydrostat permanently defective.
2. Temporary malfunction of the hydrostat.
3. Insufficient oil supply to the hydrostat.
4. Problem during cold run.
5. Wiring defective.
6. Plug on HCU faulty.
7. Plug on stepping motor faulty.
Remedy:
1. Read out the SGR fault codes. Remedy the faults relating to the system pressure (113,114,118).
2. Temporary malfunctions can occur as a result of cold start problems or if oil supply is insufficient for a brief period.
Save the fault using the Service Tool and then delete it. Make a test drive to check the function. The transmission
temperature must exceed 20°. If the fault code does not occur again, no further action is required.
3. If the fault still occurs, the hydrostat must be recalibrated using the Service Tool. Procedure for calibrating via the
"TRANSMISSION - HYDROSTAT CALIBRATION" configuration window of the Service Tool:

The following requirements must be met:

Engine running.
• Transmission in position P or N.
• Oil temperature > 20°C.
Calibration takes approximately 2 minutes. The status of the calibration can be monitored via the Service Tool
monitor function ("SGR HYDROSTAT CALIBRATION"). If the Service Tool signals that calibration has been suc-
cessfully completed, switch off the ignition and wait 2 seconds. If the fault does not occur again, no further action
is required.
4. Should the fault still occur, remove the HCU, check the plug for bent, corroded or retracted pins and repair it if
necessary.
5. Should the fault still occur, have the hydrostat checked.

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SGR - 53 Hydrostat, transmission ratio is not reached

Cause:
The hydrostat unit cannot set the desired transmission ratio. The fault is saved and signalled on screen by a warning
triangle.
Possible causes:
1. Hydrostat permanently defective.
2. Temporary malfunction of the hydrostat.
3. Insufficient oil supply to the hydrostat.
4. Problem during cold run.
5. Wiring faulty.
6. Plug on HCU faulty.
7. Plug on stepping motor faulty.
Remedy:
1. Read out the SGR fault codes. Remedy the faults relating to the system pressure (113,114,118).
2. Temporary malfunctions can occur as a result of cold start problems or if oil supply is insufficient for a brief period.
Save the fault using the Service Tool and then delete it. Make a test drive to check the function. The transmission
temperature must exceed 20°. If the fault code does not occur again, no further action is required.
3. If the fault still occurs, the hydrostat must be recalibrated using the Service Tool. Procedure for calibrating via the
"TRANSMISSION - HYDROSTAT CALIBRATION" configuration window of the Service Tool:

The following requirements must be met:

• Engine running.
• Transmission in position P or N.
• Oil temperature > 20°C.
Calibration takes approximately 2 minutes. The status of the calibration can be monitored via the Service Tool
monitor function ("SGR HYDROSTAT CALIBRATION"). If the Service Tool signals that calibration has been suc-
cessfully completed, switch off the ignition and wait 2 seconds. If the fault does not occur again, no further action
is required.
4. Should the fault still occur, remove the HCU, check the plug for bent, corroded or retracted pins and repair it if
necessary.
5. Should the fault still occur, have the hydrostat checked.

SGR - 54 Maximum hydrostat high pressure reached

Cause:
A draft at the output shaft of the transmission causes pressure in the hydrostat. If the maximum possible draft is ap-
plied, the pressure exceeds the technically permissible value and the vehicle stops. The fault is saved and signalled
on screen by a warning triangle.
Cause: Draft limit reached.
Remedy:
This fault code is supposed to inform the driver that the maximum draft limit has been reached. This situation can
occur during heavier work (e.g. ploughing) if the technically possible draft limit has been reached. The only remedy
is to reduce the load, e.g. by lifting a plough or reducing the vehicle load.
If fault SGR 53 (SGR 52) occurs, this fault must be remedied. If these faults do not occur, no further action is required.

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SGR - 56 Impermissible activation of the gear clutches

Cause:
Only specific clutches may be closed at the same time during the operation. The fault code is generated if clutch com-
binations are used which are not permitted. The fault is stored.
Possible causes:
1. SGR defective.
2. Problems during reprogramming.
Remedy:
1. Should the fault have occurred immediately after an update of the SGR, repeat the update. Store the fault using
the Service Tool and then delete it. Make a test drive to check the function. If the fault code does not occur again,
no further action is required.
2. If the fault still occurs, replace the SGR.

SGR - 60 Internal fault in the hydrostat

Cause:
After engaging the parking brake, an automatic calibration of the hydrostats takes place. Error code SGR 146 during
the calibration, caused by a mechanical fault in the stepping motor. After the engine has been started and initial oc-
currence of error code SGR 146, no further calibration of the hydrostats is carried out. This fact is documented by the
error code SGR 60. This applies from software version SGR 1.5.0.0. on.
Possible cause:
1. Faulty stepping motor (error code SGR 146).
Remedy:
1. Start the engine and engage the parking brake. There follows an automatic calibration of the hydrostats. This lasts
approx. 2 minutes. If eerror code SGR 146 occurs, replace the stepping motor.

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SGR - 61 Hydrostat calibration data in EEPROM not plausible

Cause:
After the ignition has been switched on, it is detected that the calibration data of the hydrostat is invalid. The fault is
stored, signalled on screen by a warning triangle and driving is no longer possible.
Possible causes:
1. After replacing the SGR and using an SGR without valid calibration data.
2. SGR defective.
3. After faulty calibration using the Service Tool.
Remedy:
A calibration must be carried out. There are two ways to do so.
1. Recalibration of the hydrostat using the Service Tool. Procedure for calibrating via the "TRANSMISSION - HY-
DROSTAT CALIBRATION" configuration window of the Service Tool:

The following requirements must be met:

• Engine running.
• Transmission in position P or N.
• Temperature > 20°C.
Calibration takes approximately 2 minutes. The status of the calibration can be monitored via the Service Tool
monitor function ("SGR HYDROSTAT CALIBRATION"). If the Service Tool signals that calibration has been suc-
cessfully completed, switch off the ignition and wait 2 seconds. If the fault does not occur again, no further action
is required.
If calibration fails, call up the parameter function "Required HCU value". Restart the calibration process 2 times
in succession. This parameter function should then run as follows: Starts at approx. 17%, goes back to 10%, slow-
ly rises to 90% and drops back again to 10%. If this is the case, the hydrostat is ok. If different values are obtained
and the last value of the parameter function is approximately 50%, the hydrostat must be checked. If different
values are obtained and the last value of the parameter function is not approximately 50%, the HCU must be re-
placed.
2. Activation of the automatic calibration by engaging the parking interlock or after a permanent shift to neutral.

The following requirements must be met:

• Engine running.
• Transmission in position P or N.
• Temperature > 0°C.
This process takes approximately 3 minutes. Then switch off the ignition and wait 2 seconds.
3. If this fault still occurs after successful calibration, the SGR must be replaced.

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SGR - 63 FMGR-SGR check: failed

Cause:
The FMGR and SGR periodically check one another using an arithmetic problem. Although the SGR has responded,
the result differs from the result the FMGR has expected. If the fault only occurs temporarily, this does not affect the
driving function. The fault is stored and signalled on screen by a warning triangle.
Possible causes:
1. The SGR has the wrong program version.
2. The FMGR has the wrong program version.
3. The SGR has an internal defect.
4. The FMGR has an internal defect.
5. CAN bus problem.
6. EMC (electromagnetic compatibility) fault.
Remedy:
1. If one of the faults SGR 32, SGR 33 or SGR 35 occurs permanently, this fault must be remedied first.
2. As the function is not affected if this fault occurs for a brief period, there is only need for action if this fault stays
permanently. Store the fault using the Service Tool and then delete it. Make a test drive to check the function. If
the fault code does not occur again, no further action is required.
3. Switch on the ignition and use the Service Tool to read out the software versions of FMGR and SGR. Check whe-
ther these are identical. If they are not identical, run an update for both control units.
If the fault still occurs, replace the SGR.

SGR - 64 Cartridge input speed sensor B24 - interruption or short-

circuit to ground
Cause:
The SGR has detected an interruption or short-circuit to ground in one of the lines of the "Cartridge input" speed sen-
sor. The fault is stored and signalled on screen by a warning triangle. The vehicle can only be driven at a limited
speed.
Possible causes:
1. Temporary malfunction of the sensor.
2. The sensor cable is interrupted or chafed and is in contact with a supply line.
3. The sensor's plug-type connection to the SGR is loose or the contact is poor.
4. The sensor has an internal defect.
5. The SGR has an internal defect.
Remedy:
1. Start the engine and use the manual throttle lever to set the motor speed to 1000 rpm. Use the Service Tool's
"Cartridge input speed" monitor function to check the sensor value. If this value is approx. 1350 rpm, the fault
code was caused by a temporary malfunction. Store the fault using the Service Tool and then delete it. Make a
test drive to check the function. If the fault code does not occur again, no further measures are required. If the
sensor value strongly differs from 1350 rpm or if the fault code occurs again, go to step 2.
2. If the fault still occurs, remove the SGR and the speed sensor plug. Disconnect the input speed cartridge A21/7.
Check the plug on the cable and on the SGR for bent, loose or corroded contacts. Clean the plug. Check the
sensor resistance between PIN1 and PIN2 at the plug: this value should be approximately 1kOhm at 20°C. When
doing so, move the cable, in particular at the sensor output, so that sporadic interruptions can be detected. If the
resistance is outside the permitted range, the speed sensor must be replaced.
3. Switch on the ignition. Check the DC voltage between PIN1 of the sensor plug and the ground connection using
adapter 380000060, this should be in the range of 2 - 3 Volt. Check the DC voltage between PIN2 of the sensor
plug and the ground connection using adapter 380000060, this should be in the range of 2 - 3 Volt. If one of the
two voltages strongly differs from the expected values, replace the sensor.
4. Start the engine. Disconnect the sensor while the engine is running. If the cartridge input speed does not change
("Cartridge input speed" monitor function), replace the SGR.

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SGR - 65 Cartridge input speed sensor B24 - sensor short-circuit

Cause:
The SGR has detected a short-circuit in the lines of the "Cartridge input" speed sensor. The fault is stored and signal-
led on screen by a warning triangle. The vehicle can only be driven at a limited speed.
Possible causes:
1. Temporary malfunction of the sensor.
2. The sensor cable is interrupted or chafed and the two lines are in contact.
3. Contacts in the plug of the sensor on the SGR are bent and in contact.
4. The sensor has an internal defect.
5. The SGR has an internal defect.
Remedy:
1. Start the engine and use the manual throttle lever to set the motor speed to 1000 rpm. Use the Service Tool's
"Cartridge input speed" monitor function to check the sensor value. If this value is approx. 1350 rpm, the fault
code was caused by a temporary malfunction. Store the fault using the Service Tool and then delete it. Make a
test drive to check the function. If the fault code does not occur again, no further action is required. If the sensor
value strongly differs from 1350 rpm or if the fault code occurs again, go to step 2.
2. If the fault still occurs, remove the SGR and disconnect the plug of the "Cartridge input speed" speed sensor
A21/7. Check the plug on the cable and on the SGR for bent, loose or corroded contacts. Clean the plug. Check
the sensor resistance between PIN1 and PIN2 at the plug: this value should be approximately 1kOhm at 20°C.
When doing so, move the cable, in particular at the sensor output, so that sporadic interruptions can be detected.
If the resistance is outside the permitted range, the speed sensor must be replaced.
3. Start the engine. Disconnect the sensor while the engine is running. If the cartridge input speed does not change
("Cartridge input speed" monitor function), replace the SGR.

SGR - 66 Cartridge input speed too high

Cause:
The SGR checks whether the cartridge input speed exceeds 3500 rpm (engine speed > 2600 rmp). When this speed
is exceeded, the fault is stored, signalled on screen by a warning triangle and the buzzer is activated. Driving is only
possible at a limited speed (< 8 km/h).
Cause: The engine overspeeds in an overrun condition.
Remedy:
This fault code is supposed to inform the driver that the maximum motor speed has been reached. This is a warning
to the vehicle owner to avoid these driving conditions, since subsequent damage to the motor and transmission could
be caused.

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SGR - 67 Cartridge input speed sensor B24 - signal dropout

Cause:
The SGR checks the speed pulses from the speed sensor for continuity. The fault is stored. There is no response to
the fault.
Possible causes:
1. Temporary malfunction of the sensor or the plug.
2. Temporary malfunction of the SGR.
3. The sensor has an internal defect.
4. The SGR has an internal defect.
Remedy:
1. If fault SGR 64 or SGR 65 occurs at the same time, remedy this fault first.
2. Apply the parking brake. Start the engine and use the manual throttle lever to set the motor speed to 1000 rpm.
Use the Service Tool's "Cartridge input speed" monitor function to check the sensor value. If this value is approx.
1350 rpm, the fault code was caused by a brief malfunction. Store the fault using the Service Tool and then delete
it. Make a test drive to check the function. If the fault code does not occur again, no further action is required. If
the sensor value strongly differs from 1350 rpm, there is a permanent defect and the sensor must be replaced.
3. If the fault occurs again after another test drive, replace the SGR.

SGR - 68 Planet carrier 1/2 speed sensor B35 - interruption or short-

circuit to ground
Cause:
The SGR has detected an interruption or short-circuit to ground in one of the lines of the
"Planet carrier 1/2" speed sensor. The fault is stored and signalled on screen by a warning triangle. The vehicle can
only be driven at a limited speed.
Possible causes:
1. Temporary malfunction of the sensor.
2. The sensor cable is interrupted or chafed and is in contact with a supply line.
3. The sensor's plug-type connection to the SGR is loose or the contact is poor.
4. The sensor has an internal defect.
5. The SGR has an internal defect.
Remedy:
1. Apply the parking brake. Start the engine and use the manual throttle lever to set the motor speed to 1000 rpm.
Preselect a driving direction; the vehicle must be stationary. Use the Service Tool's "Planet carrier 1/2 speed" mo-
nitor function to check the sensor value. If this value is approx. 1350 rpm, the fault code was caused by a brief
malfunction. Store the fault using the Service Tool and then delete it. Make a test drive to check the function. If
the fault code does not occur again, no further action is required. If the sensor value strongly differs from 1350 rpm
or if the fault code occurs again, go to step 2.
2. If the fault still occurs, remove the SGR and disconnect the plug of the planet carrier 1/2 speed sensor A21/6.
Check the plug on the cable and on the SGR for bent, loose or corroded contacts. Clean the plug. Check the
sensor resistance between PIN1 and PIN2 at the plug: this value should be approximately 1kOhm at 20°C. When
doing so, move the cable, in particular at the sensor output, so that sporadic interruptions can be detected. If the
resistance is outside the permitted range, the speed sensor must be replaced.
3. Switch on the ignition. Check the DC voltage between PIN1 of the sensor plug and ground connection using ad-
apter 380000060, this should be in the range of 2 - 3 Volt. Check the DC voltage between PIN2 of the sensor plug
and the ground connection using adapter 380000060, this should be in the range of 2 - 3 Volt. If one of the two
voltages strongly differs from the expected values, replace the sensor.
4. Start the engine. Disconnect the sensor while the engine is running. If the cartridge input speed does not change
("Planet carrier 1/2" monitor function), replace the SGR.

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SGR - 69 Planet carrier 1/2 speed sensor B35 - sensor short-circuit

Cause:
The SGR has detected a short-circuit in the lines of the "Planet carrier 1/2" speed sensor. The fault is stored and si-
gnalled on screen by a warning triangle. The vehicle can only be driven at a limited speed.
Possible causes:
1. Temporary malfunction of the sensor.
2. The sensor cable is interrupted or chafed and the two lines are in contact.
3. Contacts in the plug of the sensor on the SGR are bent and in contact.
4. The sensor has an internal defect.
5. The SGR has an internal defect.
Remedy:
1. Apply the parking brake. Start the engine and use the manual throttle lever to set the motor speed to 1000 rpm.
Preselect a driving direction; the vehicle must be stationary. Use the Service Tool's "Planet carrier 1/2 speed" mo-
nitor function to check the sensor value. If this value is approx. 1350 rpm, the fault code was caused by a tem-
porary malfunction. Store the fault using the Service Tool and then delete it. Make a test drive to check the
function. If the fault code does not occur again, no further action is required. If the sensor value strongly differs
from 1350 rpm or if the fault code occurs again, go to step 2.
2. If the fault still occurs, remove the SGR and disconnect the plug of the "Cartridge input speed" speed sensor
A21/6. Check the plug on the cable and on the SGR for bent, loose or corroded contacts. Clean the plug. Check
the sensor resistance between PIN1 and PIN2 at the plug: this value should be approximately 1kOhm at 20°C.
When doing so, move the cable, in particular at the sensor output, so that sporadic interruptions can be detected.
If the resistance is outside the permitted range, the speed sensor must be replaced.
3. Start the engine. Disconnect the sensor while the engine is running. If the cartridge input speed does not change
("Planet carrier 1/2 speed" monitor function), replace the SGR.

SGR - 70 Planet carrier 1/2 speed too high

Cause:
The SGR checks whether the speed of planet carrier 1/2 exceeds 3500 rpm. When this speed is exceeded, the fault
is stored, signalled on screen by a warning triangle and the buzzer is activated. Driving is only possible at a limited
speed (< 8 km/h).
Cause: The engine overspeeds in an overrun condition at lower speeds (approx. 8 km/h or approx. 20 km/h).
Remedy:
This is a warning to the vehicle owner to avoid these driving conditions, since subsequent damage to the motor and
transmission could be caused.

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SGR - 71 Planet carrier 1/2 speed sensor B35 - signal dropout

Cause:
The SGR checks the speed pulses from the speed sensor for continuity. The fault is stored. There is no response to
the fault.
Possible causes:
1. Temporary malfunction of the sensor or the plug.
2. Temporary malfunction of the SGR.
3. The sensor has an internal defect.
4. The SGR has an internal defect.
Remedy:
1. If fault SGR 68 or SGR 69 occurs at the same time, remedy this fault first.
2. Apply the parking brake. Start the engine and use the manual throttle lever to set the motor speed to 1000 rpm.
Preselect a driving direction; the vehicle must be stationary. Use the Service Tool's "Planet carrier 1/2 speed" mo-
nitor function to check the sensor value. If this value is approx. 1350 rpm, the fault code was caused by a tem-
porary malfunction. Store the fault using the Service Tool and then delete it. Make a test drive to check the
function. If the fault code does not occur again, no further action is required.
If the sensor value strongly differs from 1350 rpm, there is a permanent defect and the sensor must be replaced.
3. If the fault occurs again after another test drive, replace the SGR.

SGR - 72 Output speed 1 speed sensor B27 - interruption or short-

circuit to ground
Cause:
The SGR has detected an interruption or short-circuit to ground in one of the lines of the "Output speed 1" speed
sensor. The fault is stored and signalled on screen by a warning triangle. The vehicle can only be driven at a limited
speed.
Possible causes:
1. Temporary malfunction of the sensor.
2. The sensor cable is interrupted or chafed and is in contact with a supply line.
3. The sensor's plug-type connection to the SGR is loose or the contact is poor.
4. The sensor has an internal defect.
5. The SGR has an internal defect.
Remedy:
1. Store the fault using the Service Tool and then delete it. Carry out a test drive at approximately 5 km/h. Use the
Service Tool's "Output speed 1" monitor function to check the sensor value. If this value is approx. 500 rpm, the
fault code was caused by a temporary malfunction. If the fault code does not occur again during the test drive, no
further action is required. If the sensor value strongly differs from 500 rpm or if the fault code occurs again, go to
step 2.
2. If the fault still occurs, remove the SGR and disconnect the plug of the planet carrier 1/2 speed sensor A21/10.
Check the plug on the cable and on the SGR for bent, loose or corroded contacts. Clean the plug. Check the
sensor resistance between PIN1 and PIN2 at the plug: this value should be approximately 1kOhm at 20°C. When
doing so, move the cable, in particular at the sensor output, so that sporadic interruptions can be detected. If the
resistance is outside the permitted range, the speed sensor must be replaced.
3. Switch on the ignition. Check the DC voltage between PIN1 of the sensor plug and the ground connection using
adapter 380000060, this should be in the range of 2 - 3 Volt. Check the DC voltage between PIN2 of the sensor
plug and the ground connection using adapter 380000060, this should be in the range of 2 - 3 Volt. If one of the
two voltages strongly differs from the expected values, replace the sensor.
4. Carry out a test drive at approximately 5 km/h. Check the AC voltage between sensor and ground connection
using adapter 380000060, this should be in the range of 1 - 1.5 Volt. If this voltage strongly differs from the ex-
pected value, replace the sensor.
5. If the fault still occurs, replace the SGR.

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SGR - 73 Output speed 1 speed sensor B27 - sensor short-circuit

Cause:
The SGR has detected a short-circuit in the lines of the "Output speed 1" speed sensor. The fault is stored and si-
gnalled on screen by a warning triangle. The vehicle can only be driven at a limited speed.
Possible causes:
1. Temporary malfunction of the sensor.
2. The sensor cable is interrupted or chafed and the two lines are in contact.
3. Contacts in the plug of the sensor on the SGR are bent and in contact.
4. The sensor has an internal defect.
Remedy:
1. Store the fault using the Service Tool and then delete it. Carry out a test drive at approximately 5 km/h. Use the
Service Tool's "Output speed 1" monitor function to check the sensor value. If this value is approx. 500 rpm, the
fault code was caused by a temporary malfunction. If the fault code does not occur again during the test drive, no
further action is required. If the sensor value strongly differs from 500 rpm or if the fault code occurs again during
the test drive, go to step 2.
2. If the fault still occurs, remove the SGR and disconnect the plug of the planet carrier 1/2 speed sensor A21/10.
Check the plug on the cable and on the SGR for bent, loose or corroded contacts. Clean the plug. Check the
sensor resistance between PIN1 and PIN2 at the plug: this value should be approximately 1kOhm at 20°C. When
doing so, move the cable, in particular at the sensor output, so that sporadic interruptions can be detected. If the
resistance is outside the permitted range, the speed sensor must be replaced.

SGR - 74 Output speed 1 too high

Cause:
The SGR checks whether the output speed exceeds 5700 rpm (vehicle speed approx. 57 km/h. When this speed is
exceeded, the fault is stored, signalled on screen by a warning triangle and the buzzer is activated.
Cause: Overrun condition with the vehicle speed being too high.
Remedy:
This is a warning to the vehicle owner to avoid these driving conditions, since subsequent damage to the motor and
transmission could be caused.

SGR - 75 Output speed 1 speed sensor B27 - signal dropout

Cause:
The SGR checks the speed pulses from the speed sensor for continuity. The fault is stored. There is no response to
the fault.
Possible causes:
1. Temporary malfunction of the sensor or the plug.
2. Temporary malfunction of the SGR.
3. The sensor has an internal defect.
4. The SGR has an internal defect.
Remedy:
1. If fault SGR 72 or SGR 73 occurs at the same time, remedy this fault first.
2. Store the fault using the Service Tool and then delete it. Carry out a test drive at approximately 5 km/h. Use the
Service Tool's "Output speed 1" monitor function to check the sensor value. If this value is approx. 500 rpm, the
fault code was caused by a temporary malfunction. If the fault code does not occur again during the test drive, no
further action is required. If the sensor value strongly differs from 500 rpm, there is a permanent defect and the
sensor must be replaced.
3. If the fault occurs again after another test drive, replace the SGR.

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SGR - 76 Planet carrier 3/4 speed sensor B25 - interruption or short-

circuit to ground
Cause:
The SGR has detected an interruption or short-circuit to ground in one of the lines of the "Planet carrier 3/4" speed
sensor. The fault is stored and signalled on screen by a warning triangle. The vehicle can only be driven at a limited
speed.
Possible causes:
1. Temporary malfunction of the sensor.
2. The sensor cable is interrupted or chafed and is in contact with a supply line.
3. The sensor's plug-type connection to the SGR is loose or the contact is poor.
4. The sensor has an internal defect.
5. The SGR has an internal defect.
Remedy:
1. Store the fault using the Service Tool and then delete it. Carry out a test drive in forward direction at approximately
5 km/h. Use the Service Tool's "Planet carrier 3/4 speed" monitor function to check the sensor value. If this value
is approx. 500 rpm, the fault code was caused by a temporary malfunction. If the fault code does not occur again
during the test drive, no further action is required. If the sensor value strongly differs from 500 rpm or if the fault
code occurs again during the test drive, go to step 2.
2. If the fault still occurs, remove the SGR and disconnect the plug of the planet carrier speed sensor A21/8. Check
the plug on the cable and on the SGR for bent, loose or corroded contacts. Clean the plug. Check the sensor
resistance between PIN1 and PIN2 at the plug: this value should be approximately 1kOhm at 20°C. When doing
so, move the cable, in particular at the sensor output, so that sporadic interruptions can be detected. If the resi-
stance is outside the permitted range, the speed sensor must be replaced.
3. Switch on the ignition. Check the DC voltage between PIN1 of the sensor plug and the ground connection using
adapter 380000060, this should be in the range of 2 - 3 Volt. Check the DC voltage between PIN2 of the sensor
plug and the ground connection using adapter 380000060, this should be in the range of 2 - 3 Volt. If one of the
two voltages strongly differs from the expected values, replace the sensor.
4. Carry out a test drive at approximately 5 km/h. Check the AC voltage between sensor and ground connection
using adapter 380000060, this should be in the range of 1 - 1.5 Volt. If this voltage strongly differs from the ex-
pected value, replace the sensor.
5. If the fault code still occurs, carry out a test drive in forward direction at approximately 5 km/h. Use the Service
Tool's "Planet carrier 3/4 speed" monitor function to check the sensor value. If this value is zero, replace the SGR.

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SGR - 77 Planet carrier 3/4 speed sensor B25 - sensor short-circuit

Cause:
The SGR has detected a short-circuit in the lines of the "Planet carrier 3/4" speed sensor. The fault is stored and si-
gnalled on screen by a warning triangle. The vehicle can only be driven at a limited speed.
Possible causes:
1. Temporary malfunction of the sensor.
2. The sensor cable is interrupted or chafed and the two lines are in contact.
3. Contacts in the plug of the sensor on the SGR are bent and in contact.
4. The sensor has an internal defect.
5. The SGR has an internal defect.
Remedy:
1. Store the fault using the Service Tool and then delete it. Carry out a test drive at approximately 5 km/h in forward
direction. Use the Service Tool's "Planet carrier 3/4 speed" monitor function to check the sensor value. If this value
is approx. 500 rpm, the fault code was caused by a temporary malfunction. If the fault code does not occur again
during the test drive, no further action is required. If the sensor value strongly differs from 500 rpm, there is a
permanent defect. Go to step 2.
2. If the fault still occurs, remove the SGR and disconnect the plug of the planet carrier 3/4 speed sensor A21/8.
Check the plug on the cable and on the SGR for bent, loose or corroded contacts. Clean the plug. Check the
sensor resistance between PIN1 and PIN2 at the plug: this value should be approximately 1kOhm at 20°C. When
doing so, move the cable, in particular at the sensor output, so that sporadic interruptions can be detected. If the
resistance is outside the permitted range, the speed sensor must be replaced.
3. If the fault code still occurs, carry out a test drive in forward direction at approximately 5 km/h. Use the Service
Tool's "Planet carrier 3/4 speed" monitor function to check the sensor value. If this value is zero, replace the SGR.

SGR - 78 Planet carrier 3/4 speed too high

Cause:
The SGR checks whether the speed at planet carrier 3/4 exceeds 5700 rpm. When this speed is exceeded, the fault
is stored, signalled on screen by a warning triangle and the buzzer is activated.
Cause: Overrun condition with the vehicle speed being too high.
Remedy:
This is a warning to the vehicle owner to avoid these driving conditions, since subsequent damage to the motor and
transmission could be caused.

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SGR - 79 Planet carrier 3/4 speed sensor B25 - signal dropout

Cause:
The SGR checks the speed pulses from the speed sensor for continuity. The fault is stored. There is no response to
the fault.
Possible causes:
1. Temporary malfunction of the sensor or the plug.
2. Temporary malfunction of the SGR.
3. The sensor has an internal defect.
4. The SGR has an internal defect.
Remedy:
1. If fault SGR 76 or SGR 77 occurs at the same time, remedy this fault first.
2. Store the fault using the Service Tool and then delete it. Carry out a test drive at approximately 5 km/h in forward
direction. Use the Service Tool's "Planet carrier 3/4 speed" monitor function to check the sensor value. If this value
is approx. 500 rpm, the fault code was caused by a temporary malfunction. If the fault code does not occur again
during the test drive, no further action is required. If the sensor value strongly differs from 500 rpm, there is a
permanent defect and the sensor must be replaced.
3. If the fault occurs again after another test drive, replace the SGR.

SGR - 80 Output speed 2 speed sensor B26 - interruption or short-

circuit to ground
Cause:
The SGR has detected an interruption or short-circuit to ground in one of the lines of the "Output speed 2" speed
sensor. The fault is stored and signalled on screen by a warning triangle. The vehicle can only be driven at a limited
speed.
Possible causes:
1. Temporary malfunction of the sensor.
2. The sensor cable is interrupted or chafed and is in contact with a supply line.
3. The sensor's plug-type connection to the SGR is loose or the contact is poor.
4. The sensor has an internal defect.
5. The SGR has an internal defect.
Remedy:
1. Store the fault using the Service Tool and then delete it. Carry out a test drive at approximately 5 km/h. Use the
Service Tool's "Output speed 2" monitor function to check the sensor value. If this value is approx. 500 rpm, the
fault code was caused by a temporary malfunction. If the fault code does not occur again during the test drive, no
further action is required. If the sensor value strongly differs from 500 rpm or if the fault code occurs again, go to
step 2.
2. If the fault still occurs, remove the SGR and disconnect the plug of the planet carrier 1/2 speed sensor A21/9.
Check the plug on the cable and on the SGR for bent, loose or corroded contacts. Clean the plug. Check the
sensor resistance between PIN1 and PIN2 at the plug: this value should be approximately 1kOhm at 20°C. When
doing so, move the cable, in particular at the sensor output, so that sporadic interruptions can be detected. If the
resistance is outside the permitted range, the speed sensor must be replaced.
3. Switch on the ignition. Check the DC voltage between PIN1 of the sensor plug and the ground connection using
adapter 380000060, this should be in the range of 2 - 3 Volt. Check the DC voltage between PIN2 of the sensor
plug and the ground connection using adapter 380000060, this should be in the range of 2 - 3 Volt. If one of the
two voltages strongly differs from the expected values, replace the sensor.
4. Carry out a test drive at approximately 5 km/h. Check the AC voltage between sensor and ground connection
using adapter 380000060, this should be in the range of 1 - 1.5 Volt. If this voltage strongly differs from the ex-
pected value, replace the sensor.
5. If the fault still occurs, replace the SGR.

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SGR - 81 Output speed 2 speed sensor B26 - sensor short-circuit

Cause:
The SGR has detected a short-circuit in the lines of the "Output speed 2" speed sensor. The fault is stored and si-
gnalled on screen by a warning triangle. The vehicle can only be driven at a limited speed.
Possible causes:
1. Temporary malfunction of the sensor.
2. The sensor cable is interrupted or chafed and the two lines are in contact.
3. Contacts in the plug of the sensor on the SGR are bent and in contact.
4. The sensor has an internal defect.
5. The SGR has an internal defect.
Remedy:
1. Store the fault using the Service Tool and then delete it. Carry out a test drive at approximately 5 km/h. Use the
Service Tool's "Output speed 2" monitor function to check the sensor value. If this value is approx. 500 rpm, the
fault code was caused by a temporary malfunction. If the fault code does not occur again during the test drive, no
further action is required. If the sensor value strongly differs from 500 rpm or if the fault code occurs again during
the test drive, go to step 2.
2. If the fault still occurs, remove the SGR and disconnect the plug of the speed sensor for the output speed A21/9.
Check the plug on the cable and on the SGR for bent, loose or corroded contacts. Clean the plug. Check the
sensor resistance between PIN1 and PIN2 at the plug: this value should be approximately 1kOhm at 20°C. When
doing so, move the cable, in particular at the sensor output, so that sporadic interruptions can be detected. If the
resistance is outside the permitted range, the speed sensor must be replaced.

SGR - 82 Output speed 2 too high

Cause:
The SGR checks whether the output speed exceeds 5700 rpm (vehicle speed approx. 57 km/h. When this speed is
exceeded, the fault is stored, signalled on screen by a warning triangle and the buzzer is activated.
Cause: Overrun condition with the vehicle speed being too high.
Remedy:
This is a warning to the vehicle owner to avoid these driving conditions, since subsequent damage to the motor and
transmission could be caused.

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SGR - 84 Cartridge input speed not plausible

Cause:
The SGR checks whether the speeds measured are plausible. This check is made on the basis of the adjustment of
the hydrostat and the clutches that are engaged. The fault is stored, signalled on screen by a warning triangle and
driving is only possible at a limited speed (< 8 km/h).
Possible causes:
1. Hydrostat defective.
2. Temporary malfunction of the hydrostat.
3. Temporary electrical malfunction when measuring the speeds.
4. Malfunction of the HCU.
Remedy:
If fault codes SGR 64 or SGR 65 or SGR 67 do not occur at the same time, the cartridge input speed (sensor B24) is
ok.
1. If the hydrostat is permanently defective, fault code SGR 53 or fault code SGR 52 or fault code SGR 61 will also
occur. The causes for these fault codes must be remedied first.
2. In the case of a temporary malfunction of the hydrostat, fault code SGR 85 will also occur in most cases. Tem-
porary malfunctions can occur as a result of cold start problems or if oil supply is insufficient for a brief period.
Store the fault using the Service Tool and then delete it. Make a test drive to check the function. The transmission
temperature must exceed 20°. If the fault code does not occur again, no further measures are required.
3. The software of the SGR includes measures to remedy temporary electrical malfunctions occurring when the
speeds are measured. In this case run an update with the most recent software version. Store the fault using the
Service Tool and then delete it. Make a test drive to check the function. If the fault code does not occur again, no
further action is required.
4. Malfunctions of the HCU can be caused by electrical faults. Store the fault using the Service Tool and then delete
it. Make a test drive to check the function. If the fault code does not occur again, no further action is required. If
fault code SGR 84 still occurs and if fault codes SGR 144 or SGR 145 or SGR 146 occur at the same time, these
faults must be remedied first.

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SGR - 85 Planet carrier 1-2 speed not plausible

Cause:
The SGR checks whether the speeds measured are plausible. This check is made on the basis of the adjustment of
the hydrostat and the clutches that are engaged. The fault is stored, signalled on screen by a warning triangle and
driving is only possible at a limited speed (< 8 km/h).
Possible causes:
1. Hydrostat defective.
2. Temporary malfunction of the hydrostat.
3. Temporary electrical malfunction when measuring the speeds.
4. Malfunction of the HCU.
5. Malfunctions of the ratio clutches.
Remedy:
If fault codes SGR 68 or SGR 69 or SGR 71 do not occur at the same time, the speed of planet carrier 1-2 (sensor
B35) is ok.
1. If the hydrostat is permanently defective, fault code SGR 53 or fault code SGR 52 or fault code SGR 61 will also
occur. The causes for these fault codes must be remedied first.
2. In the case of a temporary malfunction of the hydrostat, fault code SGR 84 will also occur in most cases. Tem-
porary malfunctions can occur as a result of cold start problems or if oil supply is insufficient for a brief period.
Store the fault using the Service Tool and then delete it. Make a test drive to check the function. The transmission
temperature must exceed 20°. If the fault code does not occur again, no further action is required.
3. The software of the SGR includes measures to remedy temporary electrical malfunctions occurring when the
speeds are measured. In this case run an update with the most recent software version. Store the fault using the
Service Tool and then delete it. Make a test drive to check the function. If the fault code does not occur again, no
further action is required.
4. Malfunctions of the HCU can be caused by electrical faults. Store the fault using the Service Tool and then delete
it. Make a test drive to check the function. If the fault code does not occur again, no further action is required. If
fault code 84 still occurs and if fault codes 144 or 145 or 146 occur at the same time, these faults must be reme-
died first.
5. If fault code SGR 85 occurs in combination with fault code SGR 87, this is in most cases caused by a malfunction
of a ratio clutch. Observe the fault codes SGR 200, SGR 201, SGR 202, SGR 203, SGR 204, SGR 205 for ratio
clutch K1 or SGR 208, SGR 209, SGR 210, SGR 211, SGR 212, SGR 213 for ratio clutch K2 or SGR 216, SGR
217, SGR 218, SGR 219, SGR 220, SGR 221 for ratio clutch K3 or SGR 224, SGR 225, SGR 226, SGR 227,
SGR 228, SGR 229 for ratio clutch K4 and remedy these faults first.

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SGR - 86 Output speed not plausible

Cause:
The SGR checks whether the speeds measured are plausible. This check is made on the basis of the adjustment of
the hydrostat and the clutches that are engaged.
The fault is stored, signalled on screen by a warning triangle and driving is only possible at a limited speed (< 8 km/h).
Possible causes:
1. Temporary electrical malfunction when measuring the speeds.
2. Malfunctions when operating the directional clutches. (Forward clutch, reverse clutch)
Remedy:
If fault codes SGR 72 or SGR 73 or SGR 75 or 80 or 81 or 82 do not occur at the same time, the output speed (sensor
B26, sensor B27) is ok.
In most cases, fault code 86 occurs in combination with fault code 87.
1. The software of the SGR includes measures to remedy temporary electrical malfunctions occurring when the
speeds are measured. In this case run an update with the most recent software version. Store the fault using the
Service Tool and then delete it. Make a test drive to check the function. If the fault code does not occur again, no
further action is required.
2. Faults occurring when operating directional clutches will cause fault codes SGR 188, SGR 189 for directional
clutch KV or SGR 196, SGR 197 for directional clutch KR. These faults must be remedied first.
3. If fault code SGR 88 occurs at the same time, one of the speed sensors (B26, B27) is defective.

SGR - 87 Planet carrier 3-4 speed not plausible

Cause:
The SGR checks whether the speeds measured are plausible. This check is made on the basis of the adjustment of
the hydrostat and the clutches that are engaged. The fault is stored, signalled on screen by a warning triangle and
driving is only possible at a limited speed (< 8 km/h).
Possible causes:
1. Temporary electrical malfunction when measuring the speeds.
2. Malfunctions of the ratio clutches.
3. Malfunctions when operating the directional clutches. (Forward clutch, reverse clutch)
Remedy:
If fault codes SGR 77 or SGR 78 or SGR 79 do not occur at the same time, the speed of planet carrier 3-4
(sensor B25) is ok.
1. The software of the SGR includes measures to remedy temporary electrical malfunctions occurring when the
speeds are measured. In this case run an update with the most recent software version. Store the fault using the
Service Tool and then delete it. Make a test drive to check the function. If the fault code does not occur again, no
further action is required.
2. If fault code SGR 87 occurs in combination with fault code SGR 85, this is in most cases caused by a malfunction
of a ratio clutch. Observe the fault codes SGR 200, SGR 201, SGR 202, SGR 203, SGR 204, SGR 205 for ratio
clutch K1 or SGR 208, SGR 209, SGR 210, SGR 211, SGR 212, SGR 213 for ratio clutch K2 or SGR 216,
SGR 217, SGR 218, SGR 219, SGR 220, SGR 221 for ratio clutch K3 or SGR 224, SGR 225, SGR 226,
SGR 227, SGR 228, SGR 229 for ratio clutch K4 and remedy these faults first.
3. If fault code SGR 87 occurs in combination with fault code SGR 86, this is in most cases caused by a malfunction
of directional clutches. Observe fault codes SGR 188, SGR 189 for directional clutch KV or 196,197 for directional
clutch KR and remedy these faults.

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SGR - 88 Output speed - direction calibration incorrect value

Cause:
The SGR checks the two measured speedsignals of the outputspeed for their correct phase, to check the correct di-
rection movement of the vehicle.
Possible causes:
1. A speedsensor was replaced and was a new calibrated.
2. Sensor B26 was exchanged with sensor B27 at other repairwork.
3. SGR was replaced.
4. New software or parameterdownload was done and was new calibrated.
Solution:
Failure will be stored. Tractor stops slowly. The only reason for this error is to make sure, that after sensor replace-
ment, SGR replacement, Software or parameter download the direction indication of the outputspeed is done correctly
to prevent accidents.

The calibration is already done automatically, clear error code, switch ignition OFF (at min 10 sec.) and ON again.
The new calibration values are stored automatically in the EEPROM.

SGR - 96 Supply line A0 (limp home analog) - voltage out of

range high
Cause:
Check of voltage with errors.
Possible causes:
1. Touches the connector while fault searching.
2. Humidity at connector.
Solution:
Failure will be stored. Because this connection is not used, this fault can only be stored by touching the connector
X16/21 PIN6 during fault searching or humidtiy at connector X16/21.
1. If fault was stored while searching, delete fault and no further action required.
2. If fault occures at running, disconnect connector X16/21 at SGR and check connection wether there is humidity
or not. If there is one, restore the waterproofness of the connector, clean probably corroded contacts. Also clean
away the humidity at SGR connector.
3. If there is no humidity at connector and fault is still acitve, the SGR has an internal defect and has to be changed,
because of the humidity there will occure other faults.

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SGR - 97 Supply line A0 (limp home analog) - signal incorrect

Cause:
Check of signal with error.
Possible causes:
1. Touches the connector while fault searching.
2. Humidity at connector.
Solution:
Failure will be stored. Because this connection is not used, this fault can only be stored by touching the connector
X16/21 PIN6 at fault searching or humidity at connector X16/21.
1. If fault was stored while searching, delete fault and not further action required.
2. If fault occures at running, disconnect connector X16/21 at SGR and check connection wether there is humidity
or not. If there is humidity, restore the waterproofness of the connector, clean probably corroded contacts. Also
clean away the humidity at SGR connector.
3. If there is no humidity at connector and fault is still acitve, the SGR has an internal defect and has to be changed,
because of the humidity there will occure other faults too.

SGR - 99 Supply line A0 (limp home analog) - voltage out of

range low
Cause:
Check of voltage with error.
Possible causes:
1. Touches the connector by fault searching.
2. Humidity at connector.
Solution:
Failure will be stored. Because this connection is not used, this fault can only be stored by touching the connector
X16/21 PIN6 at fault searching or humidity at connector X16/21.
1. If fault was stored while searching, delete fault and no further action required.
2. If fault occures at running, disconnect connector X16/21 at SGR and check connection wether there is humidity
or not. If there is one, restore the waterproofness of the connector, clean probably corroded contacts. Also clean
away the humidity at SGR connector.
3. If there is no humidity at connector and fault is still acitve, the SGR has an internal defect and has to be changed,
because of the humidity there will occure other faults too.

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SGR - 104 Lubrication pressure sensor - voltage out of range high

Cause:
The voltage on this input exceeds 4.5V.
Possible causes:
1. Wire to the sensor has short to a power supply line, or sensor supply line.
2. Connector on the sensor is loose and touches a supply line.
3. Sensor has an internal defect (short to supply).
4. SGR controller failure.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. Lubrication pressure
sensor is mounted on the hydraulic block of the transmission cartridge and wired to the SGR.
1. Unplug connector B51 of the lubrication pressure sensor. Check with voltmeter the voltage between PIN3 and
PIN2 (Ignition ON). In case of no measurable voltage, the lubrication pressure sensor is corrupted and has to be
replaced.
2. If the voltage exceeds 4.5V, remove the SGR and unplug connector A21/2. If there is still voltage on connector
B51 measurable, the complete harness has to be replaced, or to be repaired if the defect is obvious.
3. If there is not anymore a measurable voltage, check the resistance on connector A21/2 PIN8 and the other occu-
pied connector pins
(Iginition OFF and B51 disconnected). If there is a conductance to any other PIN, the harness has to be replaced,
or if damage visible, repaired.
4. If tests 1 to 3 are not successful, the SGR is corrupted and has to be replaced.

SGR - 105 Lubrication pressure sensor - oil pressure missing

Cause:
The measured lubrication pressure sensor is below 0.5 bar.
Possible causes:
1. Pressure sensor is defective.
2. Pressure limiting valve opens too early.
3. The lubrication pressure is due to leakages below 0.5 bar.
4. The lubrication oil pump is defective.
5. No oil.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. The fault reaction will be that only the first
section will be allowed. If the pressure drops during the operation the fault SGR 106 will be stored.

The pressure sensor is defective. The oil pressure cannot be reached because of a leakage in the lubrication circuit.
Because of a broken spring the pressure limiting valve can open too early. The oil level in the engine is too low or the
lubrication oil pump is defective.
1. Install a pressure gauge on the desired connection and start the engine (see chapter 6002).
2. In case of sufficient pressure indicated on the gauge, while the servicetool indicates poor pressure, replace the
lubrication pressure sensor.
3. If the measured pressure is too low, check the lubrication pressure limiting valve. (see chapter 6002)
4. If the lubrication pressure limiting valve is OK, check the transmission, wether there is a leakage in the lubrication
circuit or a defect lubrication pump. (see chapter 6002)

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SGR - 106 Lubrication pressure sensor - oil pressure out of

range low
Cause:
If fault106 is active the max. vehicle speed is limitted to 15 km/h. The sensor measured lubrication pressure is bet-
ween 0.5 and 1 bar.
Possible causes:
1. The lubrication pressure is below 1 bar, due to leakages.
2. Pressure limiting valve opens too early.
3. No oil.
4. The pressure sensor is defective.
5. The lubrication oil pump is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. The fault reaction will be that the max. speed
will be limited (to approx. 15 km/h). If the lubric.pressure drops below 1 bar, the engine speed is increased to
max.1400 rpm, to reach this pressure. If the pressure is below 0.5 bar, error SGR105 is set.

Because of a broken spring the pressure limiting valve can open too early. If the lubrication pressure is too low the
reason could be a leakage in the whole lubrication circuit. The pressure sensor is sending an incorrect value. The oil
pump could be defective or the oil level is too low.
1. Install a pressure gauge on the provided connection and start the engine (see chapter 6002).
2. If the pressure is correct and the pressure which is displayed at service tool is low, the lubrication oil pressure
sensor has to be changed.
3. Check all lubrication pipes out of the transmission, wether they are OK or not.
4. Check if the fault occurres in special uses (PTO switch => leakage at PTO clutch).
5. Check the lubrication pressure - pressure limiting valve.
6. If the measured pressure is too low, check the lubrication pressure limiting valve.
7. If the lubrication pressure limiting valve is OK, check the transmission wether there is a leakage in the lubrication
or a defective lubrication pump.
8. Insufficient oil level causes sizzling suction noise.

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SGR - 107 Lubrication pressure sensor - voltage out of range low

Cause:
The voltage on this input is below 0.5V.
Possible causes:
1. Wire to the sensor has short circuit to a power ground line, or a sensor ground line.
2. Connector on the sensor is loose and touches chassis ground.
3. Supplyvoltage of sensor is interrupted.
4. Sensor has an internal defect (short to ground).
5. SGR controller failure.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor.
The fault will be that the max. speed will be limited (to approx. 15 km/h). The lubrication pressure sensor is mounted
on the hydraulic block of the transmission cartridge and wired to the SGR.

If it is a problem with the sensor supply voltage, also error SGR115 will be active.
1. Unplug connector B51 of the lubrication pressure sensor and install an measure adapter in between. Check the
voltage between PIN1 and PIN2 (Ignition ON). Is the voltage exceeds 5V, continue with pt.2. Else disconnect sen-
sor connector B51. If the voltage remains below 5V, disconnect also system pressure sensor B47. If the voltage
exceeds now 5V, the system pressure sensor is defective and has to be replaced. If the voltage still remains below
5V, check the supply voltage.
2. Measure voltage between PIN3 and PIN1. The voltage must be app. 0.5V (Ignition ON and engine NOT running).
Is the voltage ok,
continue with pt.3. Else take a new pressure sensor and connect that one. If the voltage is OK now, the first lub-
rication sensor is defective and has to be replaced by the new one.
3. Remove the SGR and unplug connector A21/2. Switch ignition off, and check with ohmmeter the following con-
nections:
• A21/2 PIN11 and B51 PIN1,
• A21/2 PIN5 and B51 PIN3,
• A21/2 PIN8 and B51 PIN2.
If any of these has no conductance, the harness has to be replaced, or repaired. In case of no interruption, check
the conductance on the connector A21/2 PIN5 and the remaining pins of this connector (Ignition OFF and B51
disconnected). If there is a conductance to one of the other pins, the harness has to be replaced, or repaired.
4. If tests 1 to 3 do not discover any malfunctions, the SGR has to be replaced.

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SGR - 108 Lubrication pressure sensor - oil pressure out of

range high
Cause:
The measured lubrication pressure sensor is above 10 bar.
Possible causes:
1. Pressure limiting valve doesn't open.
2. Pressure in lubricant return pipes too high.
3. The lubrication pressure sensor is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. If the lubrication pres-
sure is above 10 bar, the engine speed is limitted to max.1700 rpm. In the most cases the pressure limiting valve
doesn't open (sticks).
Eventually the pressure in the lubricant return pipes is too high. In some cases also the lubrication pressure sensor
can be defective.
1. Install a pressure gauge on the desired connection and start the engine (see chapter 6002).
2. If there is normal pressure, while the servicetool indicates overpressure, replace the lubrication pressure sensor.
3. Ceck the lubrication pressure limiting valve (see chapter 6002).
4. Check the lubricant return pipes to rear axle (e.g. pipe squeezed).

SGR - 112 System pressure sensor - voltage out of range high

Cause:
The voltage on this input exceeds 4.5V.
Possible causes:
1. Wire to the sensor has short circuit to a power supply line, or sensor supply line.
2. Connector on the sensor is loose and touches a power supply line.
3. Sensor has an internal defect (short to supply).
4. SGR controller failure.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. The system pressure
sensor is mounted on the hydraulic block of the transmission cartridge and wired to the SGR.
1. Unplug connector B47 of the system pressure sensor. Check the voltage between PIN3 and PIN2 (Ignition ON).
Is there no voltage measurable, the system pressure sensor has to be replaced.
2. If the voltage is higher than 4.5V, remove the SGR and unplug connector A21/2. If there is still voltage on con-
nector B47 measured, the complete harness has to be replaced, or repaired if the defect is obviously visible.
3. In case of no measurable voltage, check the resistance on connector A21/2 PIN6 and the remaining connector
pins with an ohmmeter
(Ignition OFF and B47 disconnected). If there is a conductance to any other PIN, the harness has to be replaced,
or repaired.
4. If tests 1 to 3 do not discover any malfunction, the SGR has to be replaced.

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SGR - 113 System pressure sensor - system pressure too low

Cause:
The measured system oil pressure is under 20 bar.
Possible causes:
1. The system oil pressure is under 20 bar due to leaks.
2. The system pump controller setting is too low.
3. The system pump is faulty.
4. Hydrostat leaky,
5. No oil.
6. Faulty pressure sensor.
Remedy:
The fault is stored and signalled on the display by a warning triangle. In addition the buzzer is turned on. If the system
pressure remains under this limit for longer than 20 seconds the transmission is switched to neutral. The time delay
between buzzer and switching to neutral allows the vehicle to be stopped safely.
Setting the controller spring can reduce the system pressure. A leak can occur at the hydrostat, the couplings or con-
nection points in the system oil circuit. (i.e. pump flow rate is no longer sufficient => pressure drops). The required
flow rate is no longer delivered because of damage to the system pump. Too low an oil level can also lead to a pres-
sure drop. It can also be a faulty pressure sensor. Check whether error SGR114, or 118 is applied. In this way fault
locating can be limited. In the case of active error SGR113 drivng is no longer possible.
1. Oil level check, check filter.
2. Mount the manometer at the scheduled measuring connection and start the engine (see chapter 6002).
3. If there is sufficient pressure, and the pressure read off on the service tool is small, change the lubricating oil pres-
sure sensor.
4. Reset the system pressure at the regulating screw (see chapter 6002).
5. If none of the measures take effect, a check of the drum controller must be carried out (see chapter 6006).
6. Replace transmission pump (see chapter 6002).

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SGR - 114 System pressure sensor - system pressure too low,

remedy taking effect
Cause:
The measured system pressure falls below 27 bar.
Possible causes:
1. The system oil pressure is below 27 bar due to leaks.
2. The system pump is faulty.
3. Hydrostat leaky.
4. Faulty pressure sensor.
Remedy:
The fault is stored and signalled on the display by a warning triangle. Controlled error reaction. If the system pressure
sinks below 27 bar, the engine speed is increased to max. 75% of the rated speed. This should cause the system
pressure to rise.
Probably sufficient pressure will not be generated because of leaks. Leaks can occur at the hydrostat, the couplings
or connecting points in the system oil circuit. The required flow rate is no longer delivered because of damage to the
system pump.
1. Oil level check, check filter.
2. Check whether error SGR113, or 118 is applied. Error location may possibly be limited in this way.
3. Mount manometer at the planned measuring connection and start the engine (see chapter 6002).
4. If sufficient pressure is available, and the pressure read off at the service tool is mall, change the system oil pres-
sure sensor.
5. If the sensor is OK, try to increase pressure at the system pressure DBV(spring could be weak).
6. If higher pressure is not achieved by increasing the spring tension of the system pressure DBV, then carry out
leak testing (see chapter 6002).

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SGR - 115 System pressure sensor - voltage out of range low

Cause:
The voltage on this input is below 0.5V.
Possible causes are:
1. Wire to the sensor has short circuit to a power ground line, or a sensor ground line.
2. Connector on the sensor is loose and touches chassis ground.
3. Voltage supply of sensor is interrupted
4. Sensor has an internal defect (short to ground).
5. SGR controller failure.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. The system pressure
sensor is mounted on the hydraulic block of the transmission cartridge and wired to the SGR.

If there is a problem with the sensor supply voltage, also error SGR107 will be active.
1. Unplug connector B47 of the system pressure sensor and install a measuring adapter in between. Check voltage
between PIN1 and PIN2 with voltmeter (Ignition ON). If the voltage is more than 5V, continue with pt.2. Else dis-
connect sensor connector B47. If the voltage is still below 5V, disconnect also lubrication pressure sensor con-
nector B51. If the voltage is now more than 5V, the lubrication pressure sensor is defective and has to be
replaced. In case of a voltage now below 5V, the supply voltage has to be checked.
2. Measure voltage between PIN3 and PIN1. The voltage must be app.0.5V (Ignition ON and engine not running).
If the voltage is OK, continue with pt.3. Else, connect a new pressure sensor. If now the voltage is correct, the
first system pressure is defective and has to be replaced by the new one.
3. Remove SGR and unplug connector A21/2. Switch ignition off, and check the following connections with an ohm-
meter.
• A21/2 PIN4 and B47 PIN1,
• A21/2 PIN6 and B47 PIN3,
• A21/2 PIN7 and B47 PIN2.
If any of these has no conductance, the harness has to be replaced or repaired. If there is no interruption, check
the conductance on the connector A21/2 PIN6 and the remaining pins of the connector (Ignition OFF and B51
disconnected). If there is a conductance to one of the other pins, the harness has to be replaced, or repaired.
4. If tests 1 to 3 are not successful, the SGR has to be replaced.

SGR - 116 System pressure sensor - oil pressure out of range high
Cause:
The measured system pressure sensor is above 45 bar.
Possible causes are:
1. System pressure adjustment too high.
2. System pump is defective.
3. The pressure sensor is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. If the system pressure
is above 45 bar, the engine speed is limited to max.1700 rpm. The pressure can become too high because of a defect
in the pump regulation. Also the pressure sensor can be defective.
1. Install a pressure gauge on the desired connection and start the engine (see chapter 6002).
2. If there is normal pressure, but the servicetool reading is too high, replace the lubrication pressure sensor.
3. If there is a pump problem you have to change the transmission pump (see chapter 6002).

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SGR - 117 System pressure sensor - oil pressure drops during a

shifting process
Cause:
During a shifting process the system pressure drops under a determined value, respectively system pressure rege-
neration time exxeds determined value.
Possible reasons:
1. Preload pressure of the pressure accumulator.
2. System oil pump regulates too slow.
3. Leakage in the system oil circuit =>pump delivery rate too low.
4. System oil pump is defective.
Solution:
Failure will be stored and signaled with a warning triangel on the monitor. Tractor stops slowly. If the pre load pressure
at the pressure accu. drops, the needed oil volume cannot be deliverd and the system pressure drops. At system oil
circuit can occurre a leakage at the hydrostate, the clutches or connection points, or because of a def. system pump
the needed delivery rate cannot be supply.
1. Check system pressure (see chapter 6002).
2. Check pre load pressure of the pressure accumulator.
3. Delete fault. If fault doesn´t occurre again, it is no problem any more. The reason why the fault occurres only one
time could be the using of more valves at the same time.
4. If the fault occures again after deleting, the pressure accumulator and the system pressure are OK, then check
the system pump or the shifting drum.

SGR - 118 System pressure sensor - system pressure too low,

remedy not taking effect
Cause:
The measured system pressure is below 25 bar and the engine speed increase (FC 114) brings no improvement.
Possible causes:
1. The system pressure is under 25 bar because of leaks.
2. The system pump is faulty.
3. Leaky hydrostats.
4. No oil.
5. The pressure sensor is faulty.
Remedy:
The fault is stored and signalled on the display by a warning triangle. Only the 1st range (maximum 8 km/h) is per-
mitted as error reaction. Changes of direction are only carried out with the vehicle at a standstill.
1. Oil level check, check filter.
2. Mount manometer at the planned measuring connection and start the engine (see chapter 6002).
3. Should sufficient pressure be available. and the pressure read off from the service tool is small, replace the sy-
stem pressure sensor.
4. Reset the system pressure at the regulating screw (see chapter 6002).
5. If none of the measures take effect, a leak test must be carried out (see chapter 6002).
6. Replace transmission pump (see chapter 6002).
7. If the pressure is not sufficient, a check of the drum controller must be carried out. (see chapter 6006).

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SGR - 120 Temperature Sensor - open circuit, short to power

Cause:
The voltage value on this input is higher than technical possible.
Possible causes are:
1. Wire to the sensor has short circuit to a power supply line, or sensor supply line.
2. Connector on the sensor is loose and touches a supply line.
3. Connector on the sensor is interrupted.
4. Wire to the sensor is interrupted.
5. Sensor has an internal defect (interruption).
6. SGR controller failure.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. The temperature sen-
sor is mounted on the hydraulic block of the transmission cartridge and wired to the SGR.
1. Unplug connector B32 of the temperature sensor. Check the resistance between PIN1 and PIN2 of the tempera-
ture sensor with ohmmeter. (Ignition OFF). The resistance must be appr. 2000 Ohm at 20°C. For other values see
Tecnical Data. If the resistance is outside the specified range, the temperature sensor has to be replaced.
2. Remove the SGR, unplug connector A21/2. Check the resistance between:
• A21/2 PIN10 and B32 PIN2 and A21/2 PIN3 and B32 PIN1.
In case of a detectable interruption, examine also the crossed version:
• A21/2 PIN10 and B32 PIN1 and A21/2 PIN3 and B32 PIN2.
If an interruption can be detected, so the harness has to be replaced, or repaired.
3. Check the resistance on connector A21/2 PIN3 and the remaining connector pins with an ohmmeter (Iginition
OFF and B32 disconnected). If there is a conductance to any other PIN, the harness has to be replaced, or re-
paired, if the damage is obviously visible.
4. If tests 1 to 3 are not successful, the SGR has to be replaced.

SGR - 121 Temperature Sensor - temperature gradient out of

range high
Cause:
The temperature increase of the last 4 seconds is higher than permitted.
Possible causes:
1. Oil cooler is dirty.
2. Coolant DDBV opens too early (leakage or brooken spring).
3. High friction heat due to an transmission internal defect.
4. High brake power has been necessary.
5. Temperature sensor is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. The main reason for the occurence of this
error are cooling problems. Further possibilities include extreme long brake operations, problems inside the transmis-
sion or a defect of the temperature sensor.
1. Check oilcooler: It must be clean, and the coolant air flow must not be hindered.
2. Check oil cooler pipes (possibly squeezed).
3. If the acoustical performance of the transmission sound´s good, it is possible that fault occurres because of a
special driving situation. If the fault doesn´t occures again after deleting and a longer test drive with heavy load,
everything should be OK.
4. Check cooler DDBV (see chapter 6002).
5. Check the temperature sensor B32 as described in error manual SGR120 and SGR123. It is possible, that the
error is intermittent and occurs only under certain circumstances.

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SGR - 122 Temperature Sensor - temperature out of range high

Cause:
The temperature was higher than 100°C for a longer time.
Possible causes:
1. Oil cooler is dirty.
2. Coolant DDBV opens too early (leakage or brooken spring).
3. High friction heat due to an transmission internal defect.
4. High brake power was necessary.
5. Temperature sensor defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. In reaction to this error the maximum vehicle
speed is reduced to approx. 40 km/h. The main reason for the occurance of this error are cooling problems. Further
possibilities include extreme long brake operations, problems inside the transmission or a defect of the temperature
sensor.
1. Check oil cooler: It must be clean, and the coolant air flow must not be hindered.
2. Check oil cooler pipes (possible squeezed).
3. If the acoustical performance of the transmission sound´s good, it is possible that fault occurres because of a
special driving situation. If the fault doesn´t occures again after deleting and a longer test drive with heavy load,
everything should be OK.
4. Check cooler DDBV (see chapter 6002).
5. Check the temperature sensor B32 as described in error manual SGR120 and SGR123. It is possible, that the
error is intermittent and occurs only under certain circumstances.

SGR - 123 Temperature Sensor - short to ground

Cause:
The measured voltage value on this input is lower than technical possible.
Possible causes:
1. Wire to the sensor has short circuit to a ground line.
2. Connector on the sensor is loose and touches ground.
3. Connector on the sensor is shortcutted.
4. Temperature sensor has an internal defect (shortcut).
5. SGR controller failure.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. The temperature sen-
sor is mounted on the hydraulic block of the transmission cartridge and wired to the SGR.
1. Unplug connector B32 of the temperature sensor. Check the resistance between PIN1 and PIN2 of the tempera-
ture sensor with ohmmeter (Ignition OFF). The resistance must be appr. 2000 Ohm at 20°C. For other values see
Technical data. If the resistance is outside the specified range, the temperaturesensor has to be replaced.
2. Remove the SGR, unplug connector A21/2. Check the resistance between:
• A21/2 PIN10 and A21/2 PIN3.
In case of a measurable shortcut, the harness has to be replaced, or repaired.
3. Check the resistance on connector A21/2 PIN3 and the remaining connector pins with ohmmeter (Iginition OFF
and B32 disconnected). If there is a conductance to any other PIN, the harness has to be replaced, or repaired,
if the damage is obviously visible.
4. If tests 1 to 3 are not successful, the SGR has to be replaced.

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SGR - 124 Temperature Sensor - temperature out of range low -

restricted operation
Cause:
The transmission oil temperature is for all propper vehicle operations too low.
Possible causes:
1. Too cold.
2. Temperature sensor defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. Solenoid valves main
switch off. This error is a "no error". It is used to inform the driver, that the transmission oil temp. is too low for proper
operation. This fault is also shown visible on the display as "**" to the driver.

In case of an error appearance while the vehicle has already been operating properly at normal temperatures, the
temperature sensor is probably defective.
1. If this error occurs under vehicle cold conditions (below - 5°C), the appearance is normal, and the driving instruc-
tions for cold conditions has to be followed.
2. If this error occurs under normal driving temperatures, check the temperature sensor B32 as described in error
manual SGR120 and 123. It is possible, that the error is intermittent and occurs only under certain circumstances.

SGR - 125 Temperature Sensor - temperature gradient out of

range low
Cause:
Under certain circumstances it is required, that the transmission oil temperature changes.
Possible causes:
1. Cooler DDBV is defective and does not open.
2. Temperature sensor is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. The main reason for the occurance of this
error are cooling problems or the temperature sensor is defective. If the cooler pressure limiting valve doesn´t open,
the whole lubrication oil has to pass through the oil cooler and that means that oil heating takes longer time.
1. Check cooler DDBV: measuring of the difference pressure "before cooler - after cooler". Compare measured va-
lue with the value in the repair manual. Is the pressure too high, check pressure limiting valve.
2. Check the temperature sensor B32 as describet in error manual SGR120 and SGR123. It is possible, that the
error is intermittant and occurs only under certain circumstances.

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SGR - 126 Temperature Sensor - temperature out of range low - no

operation
Cause:
The transmission oil temperature is for a safe transmission operation too low.
Possible causes are:
1. Transmission oil temperature is too low.
2. Temperature sensor is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. This error is a "no error". It is used to inform
the driver, that the transmission oil temperature is too lowfor proper operation. Under this condition, all transmission
shiftings are electronically blocked.

In case of an error apperance while the vehicle has already been operating properly at normal temperatures, the tem-
perature sensor is probably defective.
1. If this error occurs under vehicle extreme cold conditions (below -30°C) the appearance is normal, and the driving
instructions for cold conditions has to be followed.
2. If this error occurs under normal driving temperatures, check the temperature sensor B32 as described in error
SGR120 and 123. It is possible, that the error is intermittent and occurs only under certain circumstances.

SGR - 136 Pressure Oil Filter - Change filter

Cause:
The oil filter in the pressure circuit is checked for this operation with an indicator switch. If the differential pressure
becomes too high, the filter has to be replaced.
Possible causes are:
1. Usage of filter exceeds service interval
2. Transmission oil is excessively contaminated with particles or blended with another fluid.
3. The filter head bypass valve is defective.
4. The filter indicator switch is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor.
The error is active, if the pressure filter is contaminated to such an extent, so that the generated pressure difference
between filter in- and outlet effects the activation of the filter indication switch. If the error appears within the specified
service interval, the oil is largely contaminated by particles, or a blending of oils of different types or other fluids may
reduce filter lifetime drastically. Also, the filter head bypass valve or pressure filter indication switch can be defective.
1. Remove the oilfilter. If the oilfilter has been in use longer than specified in the maintenance instructions, replace
the suction filter (see chapter 6002).
2. If the service interval has not been exceeded, check the removed pressure filter for excessive contamination. If
the pressure filter is visibly dirty, replace the filter and also check also the transmission oil for visible contamination
and if an exchange is necessary. In case of the filter containing visible, unusually large metal particles, examine
the transmission internal gears for damages, to prevent any further damage.
3. If the oil has accidentally blended with another incompatible fluid, exchange the oil, suction and pressure oil filter
of the transmission.
4. If the pressure filter is not visibly dirty, and the oil obviously not excessively contaminated or blended, replace the
service indicator switch S49/1.
5. In case of a soon reappearance of the error after indicatior switch exchange, the entire filter head has to be re-
placed.

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SGR - 144 HCU - no feedback

Cause:
The SGR does not receive a valid signal from the HCU. The fault is stored, signalled on screen by a warning triangle
and driving is no longer possible.
Possible causes:
1. Temporary malfunction of the HCU.
2. Permanent defect of the HCU.
3. Wiring defective.
4. SGR defective.
5. Plug on HCU faulty.
6. Plug on SGR faulty.
7. Plug X6/1 faulty.
Remedy:
Temporary malfunctions of the HCU sometimes occur after the engine has been started, but this will not affect the
driving functions. Store the fault using the Service Tool and then delete it. Make a test drive to check the function. If
the fault code does not occur again, no further action is required.
If the driving function is affected (vehicle stops), proceed as follows:
1. Remove the HCU, disconnect the plug and check it for bent, corroded or retracted contacts. If the plug turns out
to be defective, remedy the defect.
2. Remove the SGR. Disconnect plug A21/4 and check the plug for bent, corroded or retracted contacts. If the plug
turns out to be defective, remedy the defect.
3. Check the resistance between the line of plug A21/4 PIN11 and plug A23 PIN8. If there is no continuity here, ex-
amine plug X6/1. If the plug is not defective, check the line and repair or replace it if required.
4. Check whether the power supply to the HCU is ok. Connect the SGR and use a multimeter to measure the voltage
of the hydrostat electronics at plug A23 between PIN7 and PIN6. These should be approximately 0.5 V below the
battery voltage. If the voltage measured is lower, examine the line between the SGR and the hydrostat electro-
nics; also examine connector X6/1.
5. Start the engine. Use the Service Tool to check the parameter function HCU status. If the HCU status is zero,
replace the HCU.
6. Start the engine. Use the Service Tool to check the parameter function HCU - required value. Select the forward
direction, if the function is correct, the parameter function "HCU required value" should be approximately 17%. If
the value deviates by more than 5%, replace the SGR. Afterwards, recalibrate the unit using the Service Tool.

SGR - 145 HCU activation not correct

Cause:
The HCU receives a faulty signal from the SGR. The fault is stored, signalled on screen by a warning triangle and
driving is no longer possible.
Possible causes:
1. Wiring or plug to HCU defective.
2. SGR defective.
Remedy:
1. Start the engine. Use the Service Tool to check the parameter function HCU status. If the HCU status is between
73% and 77%, there is a permanent defect. Go to step 2. If the HCU status is approximately 50%, the fault code
was caused by a temporary malfunction. Store the fault using the Service Tool and then delete it. Make a test
drive to check the function. If the fault code does not occur again, no further action is required.
2. Remove the HCU, disconnect the plug and check it for bent, corroded or retracted contacts. If the plug turns out
to be defective, remedy the defect.
3. Remove the SGR. Disconnect plug A21/4 and check the plug for bent, corroded or retracted contacts. If the plug
turns out to be defective, remedy the defect.
4. Check the resistance between the line of plug A21/4 PIN12 and plug A23 PIN5. If there is no continuity here, ex-
amine plug X6/1. If the plug is not defective, check the line and repair or replace it if required.
5. Start the engine. If the fault still occurs, replace the SGR. Afterwards, recalibrate the unit using the Service Tool.

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SGR - 146 Hydrostat - index sensor does not supply a feedback

signal
Cause:
The index sensor of the hydrostat supplies a faulty signal. The fault is stored, signalled on screen by a warning triangle
and driving is only possible at a limited speed (< 8km/h).
Possible causes:
1. Temporary malfunction of the index sensor.
2. Permanent defect of the index sensor.
3. Stepping motor variable unit defective.
Remedy:
If faults 144 or 145 occur at the same time, remedy these faults first.
1. Start the engine. Use the Service Tool to check the parameter function HCU status. If the HCU status is between
23% and 27%, there is a permanent defect. Go to step 2. If the HCU status is approximately 50%, the fault code
was caused by a temporary malfunction. Store the fault using the Service Tool and then delete it. Make a test
drive to check the function. If the fault code does not occur again, no further action is required.
2. Check the index sensor in accordance with the diagram. If a fault is detected, replace the stepping motor.
Index sensor resistances, measured at plug A23:
PIN9 against PIN3 = approx. 5.8 MOhm
PIN3 against PIN9 = infinite
PIN3 against PIN10 = approx. 4.4 MOhm
PIN10 against PIN3 = infinite
PIN9 against PIN10 = approx. 18.4 MOhm
PIN10 against PIN9 = infinite

SGR - 147 Hydrostat electronics - starting problems

Cause:
The hydrostat electronics is checked when the engine starts up. During this test phase, temporary malfunctions will
occur. The fault is stored and will reduce the acceleration if oil temperatures are below -5°C.
Possible causes:
1. Low temperatures.
2. Temporarily insufficient lubrication of the hydrostat's variable unit.
Remedy:
Fault SGR147 informs the driver about the operating status of the transmission and is not to be regarded as a mal-
function. No action is required.

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SGR - 148 Hydrostat - starting problems

Cause:
The hydrostat is checked when the engine starts up. During this test phase, malfunctions will occur. The fault code is
only generated when the engine is started. The fault is stored, signalled on screen by a warning triangle and driving
is no longer possible.
Possible causes:
1. Cold start problems.
2. Battery voltage too low.
3. Stepping motor defective or hydrostat defective.
Remedy:
1. In the case of a cold start problem, the stepping motor sometimes fails to move the hydrostat swivel plate to the
correct position. If this fault does not occur again after the engine has warmed up (oil temperature higher than
20°) and the engine has been restarted, no further action is required.
2. If the fault still occurs, check the battery voltage. If this is below 11 V, recharge the battery. If the fault code does
not occur again after the engine has been restarted, no further action is required.
3. If the fault still occurs, the hydrostat must be recalibrated using the Service Tool. Procedure for calibrating via the
"TRANSMISSION - HYDROSTAT CALIBRATION" configuration window of the Service Tool:

The following requirements must be met:

• Engine running.
• Transmission in position P or N.
• Oil temperature > 20°C.
Calibration takes approximately 2 minutes. The status of the calibration can be monitored via the Service Tool
monitor function ("SGR HYDROSTAT CALIBRATION"). If the Service Tool signals that calibration has been suc-
cessfully completed, switch off the ignition and wait 2 seconds. If the fault does not occur again, no further action
is required.
4. If the calibration process was not completed successfully, fault code 61 is generated. Proceed according to the
instructions given for fault code SGR 61.

SGR - 149 Parklock - applying abborted - section 1 - travel too

much
Cause:
The complete process of applying the parklock is watched in every phase.
During the first hydrostatic movement, the max. value of travel was exceeded.

This errorcode is only an additional information for development purposes for error SGR236.

SGR - 150 Parklock - applying abborted - section 2 - travel too

much
Cause:
The complete process of applying the parklock is watched in every phase.

During the second hydrostatic movement, the max. value of travel was exceeded.

This errorcode is only an additional information for development purposes for error SGR236.

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4011-682

SGR - 151 Parklock - applying abborted - section 1 - no hydrostatic

pressure
Cause:
The complete process of applying the parklock is watched in every phase.

During the first hydrostatic movement, the max. value of the calculated high pressure was exceeded.

This errorcode is only an additional information for development purposes for error SGR236.

SGR - 152 Parklock - applying abborted - section 2 - no hydrostatic

pressure
Cause:
The complete process of applying the parklock is watched in every phase.

During the second hydrostatic movement, the max. value of the calculated high pressure was exceeded.

This errorcode is only an additional information for development purposes for error SGR236.

SGR - 153 Parklock - test abborted - section 1 - travel too high

Cause:
The complete process of applying the parklock is watched in every phase.

During the first hydrostatic verification movement, the max. value of travel was exceeded.

This errorcode is only an additional information for development purposes for error SGR236.

SGR - 154 Parklock - test abborted - section 2 - travel too high

Cause:
The complete process of applying the parklock is watched in every phase.

During the second hydrostatic verification movement, the max. value of travel was exceeded.

This errorcode is only an additional information for development purposes for error SGR236.

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 4011-683

SGR - 155 Parklock - test abborted - section 1 - no hydrostatic high

pressure
Cause:
The complete process of applying the parklock is watched in every phase.

During the first hydrostatic verification movement, the max. value of the calculated high pressure was exceeded.

This errorcode is only an additional information for development purposes for error SGR236.

SGR - 156 Parklock - test abborted - section 2 - no hydrostatic high

pressure
Cause:
The complete process of applying the parklock is watched in every phase.

During the second hydrostatic verification movement, the max. value of the calculated high pressure was exceeded.

This errorcode is only an additional information for development purposes for error SGR236.

SGR - 157 Parklock - test abborted - too much hydrostatic high

pressure before neutral, or travel too high
Cause:
The complete process of applying the parklock is watched in every phase.

Before shifting neutral, there was still too much hydrostatic high pressure calculated, or the travel was again too high.

This errorcode is only an additional information for development purposes for error SGR236.

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4011-684

SGR - 170 Hydrostatic ECU Supply voltage - short to power

Cause:
SGR attempts to switch off a solenoid valve, but it is indicated that it is still supplied with voltage.
Possible causes:
1. SGR is defective.
2. Connector X6/1 is loose and touches another solenoid valve connector.
3. Connector on hydrostatic control unit is loose or unplugged and touches another solenoid valve connector.
4. Wire isolation to solenoid valve is fretted and touches another solenoid valve wire.
Solution:
Failure will be stored. The main occurences of this error is a defective SGR, when one or more internal highside swit-
ches have been shortcutted. In this case, another error has to be searched, causing an obvious overload condition
(shorcut in wire harness, or solenoid valve).
1. Remove SGR. Unplug connector A21/3 and A21/5, check connector for bent, corroded or loose pins. If a defect
is visible, repair it.
2. Switch ignition "ON" and clear errors. If the error still occurs, replace the SGR, but check also the next steps.
3. Switch ignition "OFF". Check on connector A21/5 the resistance between PIN3 and 9. The resistance should ex-
ceed 100 kOhm. If there is no shortcut visible, and the SGR was defective, no further checks have to be made.
4. Check the resistance of PIN3 and the other occupied pins of connector A21/5 and A21/3 for a connection. In case
of a measurable conductance continue with step 5. Else the error has to be observed until its next occurence.
5. Check connector X6/1 for improper connection and for eventually touching a second vicinal connector.
6. Check connector of hydrostatic control unit for improper connection and for eventually touching a second vicinal
connector.
7. Disconnect solenoid valve connector and check for bendt, corroded or loose terminals. If there is a defect visible,
repair it.
8. Check the wire harness between SGR and hydrostatic contol untit. Check the wire harness and replace or repair
it, if the defect is obviously visible.

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SGR - 171 Hydrostatic ECU Supply voltage - short circuit, or short

to ground
Cause:
SGR detects a short circuit on the supply output to the hydrostatic contr. unit (HCU).
Possible causes:
1. HCU has a short circuit
2. Connector on HCU is unplugged and touches ground
3. Steppermotor on HCU has short circuit
4. Connector of steppermotor is loose and causes short circuit
5. Isolation of wires to HCU is fretted and causes short circuit
6. Isolation of wire to stepper motor is broken and connected to a ground
7. Connector X6/1 is loose and short circuit
8. SGR defect
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. The most probable
occurences of this error is a defective HCU or a defective stepper motor.
1. Remove HCU. Unplug connector and check for bent, corroded or loose pins. If a defect is visible, repair it.
2. Clear errors, switch ignition "OFF" and "ON" again.
3. If the error doesn't occur again continue with step 7 (probably error SGR 144 is now active).
4. Remove SGR and unplug connector A21/5.
5. Clear errors, switch ignition "OFF" and "ON" again.
6. If error occures again, replace the SGR (probably errors SGR144, 176, 232 and 240 are now active, here without
any importance).
7. Reconnect SGR and check the supply voltage of hydrostatic control unit with a multimeter on connector A23 bet-
ween PIN7 and 6. The voltage should be appr.0.5V below vehicle onboard voltage. If the voltage is significantly
lower, check the wire harness between SGR and the HCU. Check also connector X6/1. There must be a defect
in the wire harness. Replace or repair the harness.
8. Check on connector A23 the connection to the stepper motor. In case of a failure, and the brief cable line between
HCU is without damage, the transmission cartridge has to be removed.
9. Check the connection line between transmission entrance and stepper motor on the hydrostatic unit. If the step-
per motor is not properly connected, repair the connection. Else, the transmission cartridge has to be replaced or
repaired in the specified way, as agreed with the service organisation.

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SGR - 176 Solenoid valve AWD - open circuit

Cause:
The connection between SGR and solenoid valve is interrupted.
Possible causes:
1. Solenoid valve is defective.
2. Wire is interrupted.
3. Connector on SGR is unplugged or defective.
4. Connector on solenoid valve is unplugged or defective.
5. SGR is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. The most frequent occurences of this error
will be a defective solenoid valve, or if the valve is not reconnected after repair work. If errors SGR168, 232 or 240
occur at the same time, probably SGR connector is unplugged. In this case start with step 3.
1. Disconnect connector of solenoid valve and check connector for bent, corroded or loose pins. If a defect is visible,
repair it.
2. Check resistance of the solenoid valve coil with an ohmmeter. The value should be appr. 2.5 Ohm. If the coil is
interrupted, replace the solenoid valve.
3. Else connect solenoid valve again and remove SGR. Unplug connector A21/5 and check connector for bent, cor-
roded or loose pins. If a defect is visible, repair it.
4. Check resistance between PIN7 and PIN6 on connector. If the line is interrupted the harness has to be replaced,
or the wire can be repaired, if the damage is obviously visible.
5. Else replace SGR.

SGR - 177 Solenoid valve AWD - PWM signal incorrect

Cause:
The SGR internal diagnosis has indicated that the current PWM sampling value is different to the desired value.
Possible causes:
1. External short circuit to power or short circuit to ground.
2. SGR defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. As long as no external faults like short to
ground or short to power disable a PWM mode, the only reason can be a defective SGR.
1. Check for other error codes in the SGR and repair them first.
2. Else replace SGR.

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SGR - 178 Solenoid valve AWD - short to power

Cause:
SGR attempts to switch off a solenoid valve, but it is indicated that the solenoid valve is still supplied with voltage.
Possible causes:
1. SGR defective.
2. Connector on solenoid valve is unplugged and touches another solenoid valve connector.
3. Isolation of wire to solenoid valve is fretted, and the wire is connected to another solenoid valve wire.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Solenoid valves main switch off. The most
occurences of this error will be a defective SGR when one or more internal highside switches have been shortcutted.
In this case, another error, causing an obvious overload condition, has to be searched (shortcut in wire harness, or
solenoid valve).
1. Remove SGR. Unplug connector A21/3 and and A21/5, check connector for bent, corroded or loose pins. If a
defect is visible, repair it.
2. Switch ignition "ON" and clear errors. If the error still occurs, replace the SGR, but check also the next steps.
3. Switch ignition "OFF". Check on connector A21/5 the resistance between PIN6 and7. The restistance should be
appr. 2.5 Ohm. If there is no shortcut visible, and the SGR has been defective, no other check have to be made.
4. Check the resistance of PIN6 and the other occupied pins of connector A21/5 and A21/3 for a connection. In case
of a measurable conductance measureable, continue with step 5. Else, the error has to be observed until its next
occurrence.
5. Check connector of solenoid valve for improper connection and for eventually touching a second vicinal connec-
tor.
6. Disconnect solenoid valve connector and check for bent, corroded or loose terminals. In case of a visible defect,
repair it.
7. Check the resistance of the solenoid valve with multimeter. The resistance should be appr. 2.5 Ohm. In case of
a detectable shortcut, replace the solenoid valve.
8. Replug connector A21/3 and A21/5 and switch ignition "ON". Measure the voltage on connector Y59.The voltage
should be below 1V. If the Voltage corresponds appr. to "Vehicle onboard" voltage, replace the wire harness or
repair the wire, if the damage is obviously visible.

SGR - 179 Solenoid valve AWD - short circuit, or short to ground

Cause:
The SGR detects a short circuit on a solenenoid output.
Possible causes:
1. Solenoid valve has a short circuit.
2. Connector on solenoid valve is unplugged and touches ground.
3. Isolation of wire to solenoid valve is fretted, and the wire is connected to a ground wire.
4. SGR is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. The most frequent occurences of this error
will be a defective solenoid valve.
1. Disconnect connector of solenoid valve and check connector for bent, corroded or loose pins. If a defect is visible,
repair it.
2. Check the resistance of the solenoid valve coil with an ohmmeter. The value should be appr. 2.5 Ohm. If the coil
has a short circuit, replace the solenoid valve.
3. Else connect solenoid valve again and remove SGR. Unplug connector A21/5 and check connector for bent, cor-
roded or loose pins. If a defect is visible, repair it.
4. Check resistance between PIN6 and PIN7 on connector. If the line has a short circuit the harness has to be re-
placed, or the wire can be repaired, if the damage is obviously visible.
5. Else replace SGR.

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SGR - 184 Solenoid valve clutch forward - open circuit

Cause:
The connection between SGR and solenoid valve is interrupted.
Possible causes:
1. Solenoid valve is defective.
2. Wire is interrupted.
3. Connector on SGR is unplugged or defective.
4. Connector on solenoid valve is unplugged or defective.
5. SGR is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. The most frequent
occurences of this error will be a defective solenoid valve, or the valve is not connected after repair work. If errors
SGR192, 200, 208, 216 or 224 occur at the same time, probably the SGR connector is unplugged. In this case start
with step 3.
1. Disconnect connector of solenoid valve and check connector for bent, corroded or loose pins. If a defect is visible,
repair it.
2. Check the resistance of the solenoid valve coil with an ohmmeter. The value should be appr. 2.5 Ohm. If the coil
is interrupted, replace the solenoid valve.
3. Else connect solenoid valve again and remove SGR. Unplug connector A21/3 and check connector for bent, cor-
roded or loose pins. If a defect is visible, repair this.
4. Check resistance between PIN2 and 11 on connector. If the line is interrupted the harness has to be replaced,or
the wire can be repaired, if the damage is obviously visible.
5. Else replace SGR.

SGR - 185 Solenoid valve clutch forward - PWM signal incorrect

Cause:
The SGR internal diagnosis has indicated that the current PWM sampling value is different to the desiredl value.
Possible causes:
1. External short circuit to power or short circuit to ground.
2. SGR defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. As long as no external
faults, like short to ground or short to power disable a PWM mode, the only reason can be a defective SGR.
1. Check for other error codes in the SGR, and repair them first.
2. Else replace SGR.

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SGR - 186 Solenoid valve clutch forward - short to power

Cause:
SGR attempts to switch off a solenoid valve, but it is indicated that the solenoid valve is still supplied with voltage.
Possible causes:
1. SGR defective.
2. Connector on solenoid valve is unplugged and touches another solenoid valve connector.
3. Isolation of wire to solenoid valve is broken and connected to another solenoid valve wire.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. Solenoid valve main
switch off. The most frequent occurences of this error will be a defective SGR, when one or more internal highside
switches have been shortcutted. In this case, another error, causing an obvious overload condition, has to be sear-
ched (shortcut in wire harness, or solenoid valve).
1. Remove SGR. Unplug connector A21/3 and A21/5, check connector for bent, corroded or loose pins. If a defect
is visible, repair it.
2. Switch ignition "ON" and clear errors. If the error still occurs, replace the SGR, but check also the next steps.
3. Switch ignition "OFF". Check on connector A21/3 the resistance between PIN2 and 11. The restistance should
be appr. 2.5 Ohm. If there is no shortcut visible, and the SGR was defective, no further check has to be made.
4. Check the resistance of PIN2 and the other occupied pins of connector A21/5 and A21/3 for a connection. In case
of a measurable conductance measurable, continue with step 5. Else, the error has to be observed until its next
occurs.
5. Check connector of solenoid valve for improper connection and for eventually touching a second vicinal
connector.
6. Disconnect solenoid valve connector and check for bent, corroded or loose terminals. If there is a defect visible,
repair it.
7. Check the resistance of the solenoid valve with ohmmeter. The resistance should be appr. 2.5 Ohm. If this is
shortcutted, replace the solenoid valve.
8. Replug connector A21/3 and A21/5 and switch ignition "ON". Measure the voltage on connector Y45.The voltage
should be below 1V. If the Voltage corresponds appr. to "Vehicle onboard" voltage, replace the wire harness or
repair the wire, if the damage is obviously visible.

SGR - 187 Solenoid valve clutch forward - short circuit, or short to

ground
Cause:
SGR detects a short circuit on a solenoid output.
Possible causes:
1. Solenoid valve has a short circuit.
2. Connector on solenoid valve is unplugged and touches ground.
3. Isolation of wire to solenoid valve is fretted, and the wire is connected to a ground wire.
4. SGR is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. The most frequent
occurences of this error will be a defective solenoid valve.
1. Disconnect connector of solenoid valve and check connector for bent, corroded or loose pins. If a defect is visible,
repair it.
2. Check the resistance of the solenoid valve coil with ohmmeter. The value should be appr. 2.5 Ohm. If the coil has
a short circuit, replace the solenoid valve.
3. Else connect Solenoid valve again and remove SGR. Unplug connector A21/3 and check connector for bent, cor-
roded or loose pins. If a defect is visible, repair it.
4. Check resistance between PIN2 and 11 on connector. If the line has a short circuit the harness has to be replaced,
or the wire can be repaired, if the damage is obviously visible.
5. Else replace SGR.

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SGR - 188 Forward clutch - clutch does not open

Cause:
The forward clutch should be open, but the SGR diagnoses that the forward clutch is closed. The diagnosis is based
on the speeds supplied by the speed sensors. The fault is stored and signalled on screen by a warning triangle. The
vehicle can only be driven at a limited speed.
Possible causes:
1. Temporary malfunction of the clutch.
2. Solenoid valve on hydraulic side defective.
3. Clutch defective.
Remedy:
1. If fault code SGR 184, SGR 185, SGR 186 or SGR 187 occurs at the same time, remedy this fault first.
2. If this malfunction of the forward clutch occurs and you do not hear a loud noise, this could be a false diagnosis.
Store the fault using the Service Tool and then delete it. Then carry out a test drive. If the fault code does not occur
again, no further action is required.
3. If this malfunction of the forward clutch occurs and you hear a loud noise, there could be mechanical damage.
Store the fault using the Service Tool and then delete it. Then carry out a test drive. If the fault code does not occur
again, check the forward claw coupling for mechanical damage (see chapter 6006).
4. If the fault stays permanently, start the engine and apply the parking interlock. Check the system pressure at
measuring point KV (see chapter 6002). If a system pressure of approximately 30 bar is applied at this point, dis-
connect the plug of solenoid valve KV. If the system pressure does not change, replace solenoid valve KV. If no
system pressure is present at this point, this is caused by a mechanical defect of the forward clutch (see chapter
6006).

SGR - 189 Forward clutch - clutch does not close

Cause:
The forward clutch should be closed, but the SGR diagnoses that the forward clutch is open. The diagnosis is based
on the speeds supplied by the speed sensors. The fault is stored and signalled on screen by a warning triangle. There
is a specific response to this fault.
Possible causes:
1. Temporary false diagnosis as a result of load fluctuations in the drive train.
2. Solenoid valve on hydraulic side defective.
3. Clutch defective.
Remedy:
1. If fault code SGR 184, SGR 185, SGR 186 or SGR 187 occurs at the same time, remedy this fault first.
2. Temporary false diagnoses can occur as a result of high load fluctuations in the drive train. Store the fault using
the Service Tool and then delete it. Make a test drive to check the function. If the fault code does not occur again,
no further action is required.
3. If the fault stays permanently, first check solenoid valve KV. Check the shift pressure at measuring point KV (see
chapter 6002). Start the engine, apply the parking brake and select the forward driving direction. If the shift pres-
sure at measuring point KV is considerably lower than the system pressure (approx. 30 bar), check solenoid valve
KV and replace it if the valve is defective. If shift pressure and system pressure are identical, the fault is caused
by a mechanical defect of the forward clutch (see chapter 6006).

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SGR - 190 Forward clutch - clutch is slipping

Cause:
The forward clutch should be closed, but the SGR diagnoses that the forward clutch is slipping. The diagnosis is ba-
sed on the speed supplied by the speed sensors. The fault is stored. There is no specific response to this fault.
Possible causes:
Temporary false diagnosis as a result of load fluctuations in the drive train.
Remedy:
1. If fault code SGR 184, SGR 185, SGR 186, SGR 187 or SGR 189 occurs at the same time, remedy this fault first.
2. Temporary false diagnoses can occur as a result of high load fluctuations in the drive train. Store the fault using
the Service Tool and then delete it. Make a test drive to check the function. If the fault code does not occur again,
no further action is required.

SGR - 192 Solenoid valve clutch reverse - open circuit

Cause:
The connection between SGR and solenoid valve is interrupted.
Possible causes:
1. Solenoid valve is defective.
2. Wire is interrupted.
3. Connector on SGR unplugged or defective.
4. Connector on solenoid valve unplugged or defective.
5. SGR is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. The most frequent
occurences of this error will be a defective solenoid valve, or if the valve is not reconnected after repair work. If errors
SGR184, 200, 208, 216 or 224 occur at the same time, probably the SGR connector is unplugged. In this case start
with step 3.
1. Disconnect connector of solenoid valve and check connector for bent, corroded or loose pins. If a defect is visible,
repair it.
2. Check the resistance of the solenoid valve coil with ohmmeter. The value should be appr. 2.5 Ohm. If the coil is
interrupted, replace the solenoid valve.
3. Else connect Solenoid valve again and remove SGR. Unplug connector A21/3 and check connector for bent, cor-
roded or loose pins. If a defect is visible, repair it.
4. Check resistance between PIN1 and 12 on connector. If the line is interrupted the harness has to be replaced, or
the wire can be repaired, if the damage is obviously visible.
5. Else replace SGR.

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SGR - 193 Solenoid valve clutch reverse - PWM signal incorrect

Cause:
The SGR internal diagnosis has indicated that the desired PWM sampling value is different to the desired value.
Possible causes:
1. External short circuit to power or short circuit to ground.
2. SGR is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. As long as no external
faults like short to ground or short to power disable a PWM mode, the only reason can be a defective SGR.
1. Check for other error codes in the SGR and repair them first.
2. Else replace SGR.

SGR - 194 Solenoid valve clutch reverse - short to power

Cause:
SGR attempts to switch off a solenoid valve, but it is indicated that the solenoid valve is still supplied with voltage.
Possible causes:
1. SGR is defective
2. Connector on solenoid valve is unplugged and touches another solenoid valve connector.
3. Isolation of wire to solenoid valve is fretted, and the wire is connected to another solenoid valve wire.
Solution:
4. Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. Solenoid valve main
switch off. The most frequent occurences of this error will be a defective SGR, when one or more internal highside
switches have been shortcutted. In this case, another error, causing an obvious overload condition, has to be se-
arched (shortcut in wire harness, or solenoid valve).
1. Remove SGR. Unplug connector A21/3 and A21/5, check connector for bent, corroded or loose pins. If a defect
is visible, repair this.
2. Switch ignition "ON" and clear errors. If the error still occurs, replace the SGR, but check also the next steps.
3. Switch ignition "OFF". Check on connector A21/3 the resistance between PIN1 and 12. The restistance should
be appr. 2.5 Ohm. If there is no shortcut visible, and the SGR has been defective, no further check has to be
made.
4. Check the resistance of PIN1 and the used pins of connector A21/5 and A21/3 for a connection. Is there a con-
ductance measurable, continue with step 5. Else, the error has to be observed until it occurs again.
5. Check connector of solenoid valve for improper connection. If the connector was loose this could be the reason
for the error.
6. Disconnect solenoid valve connector and check for bent, corroded or loose terminals. If there is a defect visible,
repair it.
7. Check the resistance of the solenoid valve with an ohmmeter. The resistance should be appr. 2.5 Ohm. If this is
shortcutted, replace the solenoid valve.
8. Replug connector A21/3 and A21/5 and switch ignition "ON". Measure the voltage on connector Y46.The voltage
should be below 1V. If the Voltage is appr. "Vehicle onboard" voltage, replace the wire harness or repair the wire,
if the damage is obviously visible.

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SGR - 195 Solenoid valve clutch reverse - short circuit, or short to

ground
Cause:
SGR detects a short circuit on a solenoid output.
Possible causes:
1. Solenoid valve has a short circuit.
2. Connector on solenoid valve is unplugged and touches ground.
3. Isolation of wire to solenoid valve is fretted, and the wire is connected to a ground wire.
4. SGR is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. The most frequent
occurences of this error will be a defective solenoid valve.
1. Disconnect connector of solenoid valve and check connector for bent, corroded or loose pins. If a defect is visible,
repair it.
2. Check the resistance of the solenoid valve coil with ohmmeter. The value should be appr. 2.5 Ohm. If the coil has
a short circuit, replace the solenoid valve.
3. Else connect Solenoid valve again and remove SGR. Unplug connector A21/3 and check connector for bent, cor-
roded or loose pins. If a defect is visible, repair it.
4. Check resistance between PIN1 and 12 on connector A21/3. If the line has a short circuit the harness has to be
replaced, or the wire can be repaired, if the damage is obviously visible.
5. Else replace SGR.

SGR - 196 Reverse clutch - clutch does not open

Cause:
The reverse clutch should be open, but the SGR diagnoses that the forward clutch is closed. The diagnosis is based
on the speeds supplied by the speed sensors. The fault is stored and signalled on screen by a warning triangle. The
vehicle can only be driven at a limited speed.
Possible causes:
1. Temporary malfunction of the clutch.
2. Solenoid valve on hydraulic side defective.
3. Clutch defective.
Remedy:
1. If fault code SGR 192, SGR 193, SGR 194 or SGR 195 occurs at the same time, remedy this fault first.
2. If this malfunction of the reverse clutch occurs and you do not hear a loud noise, this could be a false diagnosis.
Store the fault using the Service Tool and then delete it. Then carry out a test drive. If the fault code does not occur
again, no further action is required.
3. If this malfunction of the reverse clutch occurs and you hear a loud noise, there could be mechanical damage.
Store the fault using the Service Tool and then delete it. Then carry out a test drive. If the fault code does not occur
again, check the reverse claw coupling for mechanical damage (see chapter 6006).
4. If the fault stays permanently, start the engine and apply the parking interlock. Check the system pressure at
measuring point KR (see chapter 6002). If a system pressure of approximately 30 bar is applied at this point, dis-
connect the plug of solenoid valve KR. If the system pressure does not change, replace solenoid valve KR. If no
system pressure is present at this point, this is caused by a mechanical defect of the reverse clutch (see chapter
6006).

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SGR - 197 Reverse clutch - clutch does not close

Cause:
The reverse clutch should be closed, but the SGR diagnoses that the reverse clutch is open. The diagnosis is based
on the speeds supplied by the speed sensors. The fault is stored and signalled on screen by a warning triangle. There
is a specific response to this fault.
Possible causes:
1. Temporary false diagnosis as a result of load fluctuations in the drive train.
2. Solenoid valve on hydraulic side defective.
3. Clutch defective.
Remedy:
1. If fault code SGR 192, SGR 193, SGR 194 or SGR 195 occurs at the same time, remedy this fault first.
2. Temporary false diagnoses can occur as a result of high load fluctuations in the drive train. Store the fault using
the Service Tool and then delete it. Make a test drive to check the function. If the fault code does not occur again,
no further action is required.
3. If the fault stays permanently, first check solenoid valve KR. Check the shift pressure at measuring point KR (see
chapter 6002). Start the engine, apply the parking brake and select the reverse driving direction. If the shift pres-
sure at measuring point KR is considerably lower than the system pressure (approx. 30 bar), check solenoid valve
KR and replace it if the valve is defective. If shift pressure and system pressure are identical, the fault is caused
by a mechanical defect of the reverse clutch (see chapter 6006).

SGR - 198 Reverse clutch - clutch is slipping

Cause:
The reverse clutch should be closed, but the SGR diagnoses that the reverse clutch is slipping. The diagnosis is ba-
sed on the speed supplied by the speed sensors. The fault is stored. There is no specific response to this fault.
Possible causes:
Temporary false diagnosis as a result of load fluctuations in the drive train.
Remedy:
1. If fault code SGR 192, SGR 193, SGR 194, SGR 195 or SGR 197 occurs at the same time, remedy this fault first.
2. Temporary false diagnoses can occur as a result of high load fluctuations in the drive train. Store the fault using
the Service Tool and then delete it. Make a test drive to check the function. If the fault code does not occur again,
no further action is required.

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SGR - 200 Solenoid valve clutch 1 - open circuit

Cause:
The connection between SGR and solenoid valve is interrupted.
Possible causes:
1. Solenoid valve is defective.
2. Wire is interrupted.
3. Connector on SGR is unplugged or defective.
4. Connector on solenoid valve is unplugged or defective.
5. SGR is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. The most frequent
occurences of this error will be a defective solenoid valve, or the valve is not connected after repair work. If errors
SGR184, 192, 208, 216 or 224 occur at the same time, probably the SGR connector is unplugged.

In this case start with step 3.

1. Disconnect connector of solenoid valve and check connector for bent, corroded or loose pins. If a defect is visible,
repair it.
2. Check the resistance of the solenoid valve coil with ohmmeter. The value should be appr. 2.5 Ohm. If the coil is
interrupted, replace the solenoid valve.
3. Else connect Solenoid valve again and remove SGR. Unplug connector A21/3 and check connector for bent, cor-
roded or loose pins. If a defect is visible, repair it.
4. Check resistance between PIN6 and 7 on connector. If the line is interrupted the harness has to be replaced, or
the wire can be repaired, if the damage is obviously visible.
5. Else replace SGR.

SGR - 201 Solenoid valve clutch 1 - PWM signal incorrect

Cause:
SGR internal diagnosis has indicated that the current PWM sampling value is different to the desired value.
Possible causes:
1. External short circuit to power or short circuit to ground.
2. SGR is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. As long as no external
faults like short to ground or short to power disable a PWM mode, the only reason can be a defective SGR.
1. Check for other error codes in the SGR and repair them first.
2. Else replace SGR.

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SGR - 202 Solenoid valve clutch 1 - short to power

Cause:
SGR attempts to switch off a solenoid valve, but it is indicated that the solenoid valve is still supplied with voltage.
Possible causes:
1. SGR is defective.
2. Connector on solenoid valve is unplugged and touches another solenoid valve connector.
3. Isolation of wire to solenoid valve is fretted and the wire is connected to another solenoid valve wire.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. Solenoid valve main
switch off. The most frequent occurences of this error will be a defective SGR when can be one or more internal high-
side switches have been shortcutted. In this case, another error, causing an obvious overload, has to be searched
(shortcut in wire harness, or solenoid valve)
1. Remove SGR. Unplug connector A21/3 and A21/5, check connector for bent, corroded or loose pins. If a defect
is visible, repair it.
2. Switch ignition "ON" and clear errors. If the error still occurs, replace the SGR, but check also the next steps.
3. Switch ignition "OFF". Check on connector A21/3 the resistance between PIN6 and 7. The restistance should be
appr. 2.5 Ohm. If there is no shortcut visible, and the SGR has been defective, no further check has to be made.
4. Check the resistance of PIN6 and the used pins of connector A21/5 and A21/3 for a connection. Is there a con-
ductance measurable, continue with step 5. Else the error has to be observed until it occurs again.
5. Check connector of solenoid valve for improper connection. If the connector was loose this could be the reason
for the error.
6. Disconnect solenoid valve connector and check for bent, corroded or loose terminals. If there is a defect visible,
repair it.
7. Check the resistance of the solenoid valve with ohmmeter. The resistance should be appr. 2.5 Ohm. If this is
shortcutted, replace the solenoid valve
8. Replug connector A21/3 and A21/5 and switch ignition "ON". Measure the voltage on connector Y41. The voltage
should be below 1 V. If the Voltage is appr. "Vehicle onboard" voltage, replace the wire harness or repair the wire,
if the damage is obviously visible.

SGR - 203 Solenoid valve clutch 1 - short circuit, short to ground

Cause:
SGR detects a short circuit on a solenoid output.
Possible causes:
1. Solenoid valve has a short circuit.
2. Connector on solenoid valve is unplugged and touches ground.
3. Isolation of wire to solenoid valve is fretted and the wire is connected to a ground wire.SGR is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. The most frequent
occurences of this error will be a defective solenoid valve.
1. Disconnect connector of solenoid valve and check connector for bent, corroded or loose pins. If a defect is visible,
repair it.
2. Check the resistance of the solenoid valve coil with ohmmeter. The value should be appr. 2.5 Ohm. If the coil has
a short circuit, replace the solenoid valve.
3. Else connect Solenoid valve again and remove SGR. Unplug connector A21/3 and check connector for bent, cor-
roded or loose pins. If a defect is visible, repair it.
4. Check resistance between PIN6 and 7 on connector. If the line has a short circuit the harness has to be replaced,
or the wire can be repaired, if the damage is obviously visible.
5. Else replace SGR.

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SGR - 204 Clutch K1 - clutch does not open

Cause:
Clutch K1 should be open, but the SGR diagnoses that clutch K1 is closed. The diagnosis is based on the speeds
supplied by the speed sensors. The fault is stored and signalled on screen by a warning triangle. The vehicle can only
be driven at a limited speed.
Possible causes:
1. Temporary malfunction of the clutch.
2. Solenoid valve on hydraulic side defective.
3. Clutch defective.
Remedy:
1. If fault code SGR 200, SGR 201, SGR 202 or SGR 203 occurs at the same time, remedy this fault first.
2. If this malfunction of clutch K1 occurs and you do not hear a loud noise, this could be a false diagnosis. Store the
fault using the Service Tool and then delete it. Then carry out a test drive. If the fault code does not occur again,
no further action is required.
3. If this malfunction of clutch K1 occurs and you hear a loud noise, there could be mechanical damage. Store the
fault using the Service Tool and then delete it. Then carry out a test drive. If the fault code does not occur again,
check claw coupling K1 for mechanical damage (see chapter 6006).
4. If the fault stays permanently, start the engine and apply the parking interlock. Check the system pressure at
measuring point K1 (see chapter 6002). If a system pressure of approximately 30 bar is applied at this point, dis-
connect the plug of solenoid valve K1. If the system pressure does not change, replace solenoid valve K1. If no
system pressure is present at this point, this is caused by a mechanical defect of the forward clutch (see chapter
6006).

SGR - 205 Clutch K1 - clutch does not close

Cause:
Clutch K1 should be closed, but the SGR diagnoses that clutch K1 is open. The diagnosis is based on the speeds
supplied by the speed sensors. The fault is stored and signalled on screen by a warning triangle. There is a specific
response to this fault.
Possible causes:
1. Temporary false diagnosis as a result of load fluctuations in the drive train.
2. Solenoid valve on hydraulic side defective.
3. Clutch defective.
Remedy:
1. If fault code SGR 200, SGR 201, SGR 202 or SGR 203 occurs at the same time, remedy this fault first.
2. Temporary false diagnoses can occur as a result of high load fluctuations in the drive train. Store the fault using
the Service Tool and then delete it. Make a test drive to check the function. If the fault code does not occur again,
no further action is required.
3. If the fault stays permanently, first check solenoid valve K1. Check the shift pressure at measuring point K1 (see
chapter 6002). Start the engine, apply the parking brake and select the forward driving direction. If the shift pres-
sure at measuring point K1 is considerably lower than the system pressure (approx. 30 bar), check solenoid valve
K1 and replace it if the valve is defective. If shift pressure and system pressure are identical, the fault is caused
by a mechanical defect of clutch K1 (see chapter 6006).

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SGR - 206 Clutch K1 - clutch is slipping

Cause:
Clutch K1 should be closed, but the SGR diagnoses that clutch K1 is slipping. The diagnosis is based on the speed
supplied by the speed sensors. The fault is stored. There is no specific response to this fault.
Possible causes:
Temporary false diagnosis as a result of load fluctuations in the drive train.
Remedy:
1. If fault code SGR 200, SGR 201, SGR 202, SGR 203 or SGR 205 occurs at the same time, remedy this fault first.
2. Temporary false diagnoses can occur as a result of high load fluctuations in the drive train. Store the fault using
the Service Tool and then delete it. Make a test drive to check the function. If the fault code does not occur again,
no further action is required.

SGR - 208 Solenoid valve clutch 2 - open circuit

Cause:
The connection between SGR and solenoid valve is interrupted.
Possible causes:
1. Solenoid valve is defective.
2. Wire is interrupted.
3. Connector on SGR is unplugged or defective.
4. Connector on solenoid valve is unplugged or defective.
5. SGR is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. The most frequent
occurences of this error will be a defective solenoid valve, or the valve is not connected after repair work. If errors
SGR 184, 192, 200, 216 or 224 occur at the same time, probably the SGR connector is unplugged. In this case start
with step 3.
1. Disconnect connector of solenoid valve and check connector for bent, corroded or loose pins. If a defect is visible,
repair it.
2. Check the resistance of the solenoid valve coil with ohmmeter. The value should be appr. 2.5 Ohm. If the coil is
interrupted, replace the solenoid valve.
3. Else connect Solenoid valve again and remove SGR. Unplug connector A21/3 and check connector for bent, cor-
roded or loose pins.
If a defect is visible, repair it.
4. Check resistance between PIN5 and 8 on connector. If the line is interrupted the harness has to be replaced, or
the wire can be repaired, if the damage is obviously visible.
5. Else replace SGR.

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SGR - 209 Solenoid valve clutch 2 - PWM signal incorrect

Cause:
SGR internal diagnostic has indicated that the current PWM sampling value is different to the actual value.
Possible causes:
1. External short circuit to power or short circuit to ground.
2. SGR is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. As long as no external
faults like short to ground or short to power disable a PWM mode, the only reason can be a defective SGR.
1. Check for other error codes in the SGR and repair them first.
2. Else replace SGR.

SGR - 210 Solenoid valve clutch 2 - short to power

Cause:
The SGR tries to switch off a solenoid valve, but it is indicated that it is still supplied with voltage.
Possible causes:
1. SGR defective.
2. Connector on solenoid valve is unplugged and touches another solenoid valve connector.
3. Isolation of wire to solenoid valve is broken and connected to another solenoid valve wire.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. Solenoid valve main
switch off. The most frequent occurences of this error will be a defective SGR when one or more internal highside
switches have been shortcutted. In this case, another error, causing an obvious overload condition, has to be sear-
ched (shortcut in wire harness, or solenoid valve)
1. Remove SGR. Unplug connector A21/3 and A21/5, check connector for bent, corroded or loose pins. If a defect
is visible, repair it.
2. Switch ignition "ON" and clear errors. If the error still occurs, replace the SGR, but check also the next steps.
3. Switch ignition "OFF". Check on connector A21/3 the resistance between PIN5 and 8. The restistance should be
appr. 2.5 Ohm. If there is no shortcut visible, and the SGR has been defective, no further check has to be made.
4. Check the resistance of PIN5 and the used pins of connector A21/5 and A21/3 for a connection. Is there a con-
ductance measurable continue with step 5. Else the error has to be observed until it occurs again.
5. Check connector of solenoid valve for improper connection and for eventually touching a second vicinal
connector.
6. Disconnect solenoid valve connector and check for bent, corroded or loose terminals. If there is a defect visible,
repair it.
7. Check the resistance of the solenoid valve with ohmmeter. The resistance should be appr. 2.5 Ohm. If this is
shortcutted, replace the solenoid valve.
8. Replug connector A21/3 and A21/5 and switch ignition "ON". Measure the voltage on connector Y42.The voltage
should be below 1 V. If the Voltage is appr. "Vehicle onboard" voltage, replace the wire harness or repair the wire,
if the damage is obviously visible.

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SGR - 211 Solenoid valve clutch 2 - short circuit, or short to ground

Cause:
SGR detects a short circuit on a solenoid output.
Possible causes:
1. Solenoid valve has a short circuit.
2. Connector on solenoid valve is unplugged and touches ground.
3. Isolation of wire to solenoid valve is fretted and connected to a ground wire.
4. SGR is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. The most frequent
occurences of this error will be a defective solenoid valve.
1. Disconnect connector of solenoid valve and check connector for bent, corroded or loose pins. If a defect is visible,
repair it.
2. Check the resistance of the solenoid valve coil with ohmmeter. The value should be appr. 2.5 Ohm. If the coil has
a short circuit, replace the solenoid valve.
3. Else connect Solenoid valve again and remove SGR. Unplug connector A21/3 and check connector for bent, cor-
roded or loose pins. If a defect is visible, repair it.
4. Check resistance between PIN5 and 8 on connector. If the line has a short circuit the harness has to be replaced,
or the wire can be repaired, if the damage is obviously visible.
5. Else replace SGR.

SGR - 212 Clutch K2 - clutch does not open

Cause:
Clutch K2 should be open, but the SGR diagnoses that clutch K2 is closed. The diagnosis is based on the speeds
supplied by the speed sensors. The fault is stored and signalled on screen by a warning triangle. The vehicle can only
be driven at a limited speed.
Possible causes:
1. Temporary malfunction of the clutch.
2. Solenoid valve on hydraulic side defective.
3. Clutch defective.
Remedy:
1. If fault code SGR 208, SGR 209, SGR 210 or SGR 211 occurs at the same time, remedy this fault first.
2. If this malfunction of clutch K2 occurs and you do not hear a loud noise, this could be a false diagnosis. Store the
fault using the Service Tool and then delete it. Then carry out a test drive. If the fault code does not occur again,
no further action is required.
3. If this malfunction of clutch K2 occurs and you hear a loud noise, there could be mechanical damage. Store the
fault using the Service Tool and then delete it. Then carry out a test drive. If the fault code does not occur again,
check claw coupling K2 for mechanical damage (see chapter 6006).
4. If the fault stays permanently, start the engine and apply the parking interlock. Check the system pressure at
measuring point K2 (see chapter 6002). If a system pressure of approximately 30 bar is applied at this point, dis-
connect the plug of solenoid valve K2. If the system pressure does not change, replace solenoid valve K2. If no
system pressure is present at this point, this is caused by a mechanical defect of clutch K2 (see chapter 6006).

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SGR - 213 Clutch K2 - clutch does not close

Remedy:
Clutch K2 should be closed, but the SGR diagnoses that clutch K2 is open. The diagnosis is based on the speeds
supplied by the speed sensors. The fault is stored and signalled on screen by a warning triangle. There is a specific
response to this fault.
Possible causes:
1. Temporary false diagnosis as a result of load fluctuations in the drive train.
2. Solenoid valve on hydraulic side defective.
3. Clutch defective.
Remedy:
1. If fault code SGR 208, SGR 209, SGR 210 or SGR 211 occurs at the same time, remedy this fault first.
2. Temporary false diagnoses can occur as a result of high load fluctuations in the drive train. Store the fault using
the Service Tool and then delete it. Make a test drive to check the function. If the fault code does not occur again,
no further action is required.
3. If the fault stays permanently, first check solenoid valve K2. Replace it if a fault is detected. If you cannot detect
a malfunction of the solenoid valve, this is caused by a mechanical defect of clutch K2 (see chapter 6006).

SGR - 214 Clutch K2 - clutch is slipping

Cause:
Clutch K2 should be closed, but the SGR diagnoses that clutch K2 is slipping. The diagnosis is based on the speed
supplied by the speed sensors. The fault is stored. There is no specific response to this fault.
Possible causes:
Temporary false diagnosis as a result of load fluctuations in the drive train.
Remedy:
1. If fault code SGR 208, SGR 209, SGR 210, SGR 211 or SGR 213 occurs at the same time, remedy this fault first.
2. Temporary false diagnoses can occur as a result of high load fluctuations in the drive train. Store the fault using
the Service Tool and then delete it. Make a test drive to check the function. If the fault code does not occur again,
no further action is required.

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SGR - 216 Solenoid valve clutch 3 - open circuit

Cause:
The connection between SGR and solenoid valve is interrupted.
Possible causes:
1. Solenoid valve is defective.
2. Wire is interrupted.
3. Connector on SGR is unplugged or defective.
4. Connector on solenoid valve is unplugged or defective.
5. SGR is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. The most frequent
occurences of this error will be a defective solenoid valve, or the valve is not connected after repair work. If errors
SGR 184, 192, 200, 208 or 224 occur at the same time, probably the SGR connector is unplugged. In this case start
with step 3.
1. Disconnect connector of solenoid valve and check connector for bent, corroded or loose pins. If a defect is visible,
repair it.
2. Check the resistance of the solenoid valve coil with ohmmeter. The value should be appr. 2.5 Ohm. If the coil is
interrupted, replace the solenoid valve.
3. Else connect Solenoid valve again and remove SGR. Unplug connector A21/3 and check connector for bent, cor-
roded or loose pins. If a defect is visible, repair it.
4. Check resistance between PIN4 and 9 on connector. If the line is interrupted the harness has to be replaced, or
the wire can be repaired, if the damage is obviously visible.
5. Else replace the SGR.

SGR - 217 Solenoid valve clutch 3 - PWM signal incorrect

Cause:
SGR internal diagnosis has indicated that the current PWM sampling value is different to the desired value.
Possible causes:
1. External short circuit to power or short circuit to ground.
2. SGR is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. As long as no external
faults like short to ground or short to power disable a PWM mode, the only reason can be a defective SGR.
1. Check for other error codes in the SGR and repair them first.
2. Else replace SGR.

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SGR - 218 Solenoid valve clutch 3 - short to power

Cause:
SGR attempts to switch off a solenoid valve, but it is indicated that the solenoid valve is still supplied with voltage.
Possible causes:
1. SGR is defective.
2. Connector on solenoid valve is unplugged and touches another solenoid valve connector.
3. Isolation of wire to solenoid valve is fretted and connected to another solenoid valve wire.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. Solenoid valve main
switch off. The most frequent occurences of this error will be a defective SGR. There can be one or more internal
highside switches be shortcutted. In this case, another error, causing an obvious overload condition, has to be sear-
ched (shortcut in wire harness, or solenoid valve).
1. Remove SGR. Unplug connector A21/3 and A21/5, check connector for bent, corroded or loose pins. In case of
a visible defect, repair it.
2. Switch ignition "ON" and clear errors. If the error still occurs, replace the SGR, but check also the next steps.
3. Switch ignition "OFF". Check on connector A21/3 the resistance between PIN4 and 9. The restistance should be
appr. 2.5 Ohm. If there is no shortcut visible, and the SGR has been defective, no further check has to be made.
4. Check the resistance of PIN4 and the used pins of connector A21/5 and A21/3 for a connection. Is there a con-
ductance measurable continue with step 5. Else the error has to be observed until it occurs again.
5. Check connector of solenoid valve for improper connection and for eventually touching a second vicinal
connector.
6. Disconnect solenoid valve connector and check for bent, corroded or loose terminals. If there is a defect visible,
repair it.
7. Check the resistance of the solenoid valve with ohmmeter. The resistance should be appr. 2.5 Ohm. If this is
shortcutted, replace the solenoid valve.
8. Replug connector A21/3 and A21/5 and switch ignition "ON". Measure the voltage on connector Y43.The voltage
should be below 1 V. If the Voltage is appr. "Vehicle onboard" voltage, replace the wire harness or repair the wire,
if the damage is obviously visible.

SGR - 219 Solenoid valve clutch 3 - short circuit, or short to ground

Cause:
SGR detects a short circuit on a solenenoid output.
Possible causes:
1. Solenoid valve has a short circuit.
2. Connector on solenoid valve is unplugged and touches ground.
3. Isolation of wire to solenoid valve is fretted and connected to a ground wire.
4. SGR is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. The most frequent
occurences of this error will be a defective solenoid valve.
1. Disconnect connector of solenoid valve and check connector for bent, corroded or loose pins. If a defect is visible,
repair it.
2. Check the resistance of the solenoid valve coil with ohmmeter. The value should be appr. 2.5 Ohm. If the coil has
a short circuit, replace the solenoid valve.
3. Else connect Solenoid valve again and remove SGR. Unplug connector A21/3 and check connector for bent, cor-
roded or loose pins. If a defect is visible, repair it.
4. Check resistance between PIN4 and 9 on connector. If the line has a short circuit the harness has to be replaced,
or the wire can be repaired, if the damage is obviously visible.
5. Else replace SGR.

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SGR - 220 Clutch K3 - clutch does not open

Cause:
Clutch K3 should be open, but the SGR diagnoses that clutch K3 is closed. The diagnosis is based on the speeds
supplied by the speed sensors. The fault is stored and signalled on screen by a warning triangle. The vehicle can only
be driven at a limited speed.
Possible causes:
1. Temporary malfunction of the clutch.
2. Solenoid valve on hydraulic side defective.
3. Clutch defective.
Remedy:
1. If fault code SGR 216, SGR 217, SGR 218 or SGR 219 occurs at the same time, remedy this fault first.
2. If this malfunction of clutch K3 occurs and you do not hear a loud noise, this could be a false diagnosis. Store the
fault using the Service Tool and then delete it. Then carry out a test drive. If the fault code does not occur again,
no further action is required.
3. If this malfunction of clutch K3 occurs and you hear a loud noise, there could be mechanical damage. Store the
fault using the Service Tool and then delete it. Then carry out a test drive. If the fault code does not occur again,
check claw coupling K3 for mechanical damage (see chapter 6006).
4. If the fault stays permanently, start the engine and apply the parking interlock. Check the system pressure at
measuring point K3 (see chapter 6002). If a system pressure of approximately 30 bar is applied at this point, dis-
connect the plug of solenoid valve K3. If the system pressure does not change, replace solenoid valve K3. If no
system pressure is present at this point, this is caused by a mechanical defect of clutch K3 (see chapter 6006).

SGR - 221 Clutch K3 - clutch does not close

Cause:
Clutch K3 should be closed, but the SGR diagnoses that clutch K3 is open. The diagnosis is based on the speeds
supplied by the speed sensors. The fault is stored and signalled on screen by a warning triangle. There is a specific
response to this fault.
Possible causes:
1. Temporary false diagnosis as a result of load fluctuations in the drive train.
2. Solenoid valve on hydraulic side defective.
3. Clutch defective.
Remedy:
1. If fault code SGR 216, SGR 217, SGR 218 or SGR 219 occurs at the same time, remedy this fault first.
2. Temporary false diagnoses can occur as a result of high load fluctuations in the drive train. Store the fault using
the Service Tool and then delete it. Make a test drive to check the function. If the fault code does not occur again,
no further action is required.
3. If the fault stays permanently, first check solenoid valve K3. Replace it if a fault is detected. If you cannot detect
a malfunction of the solenoid valve, this is caused by a mechanical defect of clutch K3 (see chapter 6006).

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SGR - 222 Clutch K3 - clutch is slipping

Cause:
Clutch K3 should be closed, but the SGR diagnoses that clutch K3 is slipping. The diagnosis is based on the speed
supplied by the speed sensors. The fault is stored. There is no specific response to this fault.
Possible causes:
Temporary false diagnosis as a result of load fluctuations in the drive train.
Remedy:
1. If fault code SGR 216, SGR 217, SGR 218, SGR 219 or SGR 221 occurs at the same time, remedy this fault first.
2. Temporary false diagnoses can occur as a result of high load fluctuations in the drive train. Store the fault using
the Service Tool and then delete it. Make a test drive to check the function. If the fault code does not occur again,
no further action is required.

SGR - 224 Solenoid valve clutch 4 - open circuit

Cause:
The connection between SGR and solenoid valve is interrupted.
Possible causes:
1. Solenoid valve defective.
2. Wire interrupted.
3. Connector on SGR unplugged or defective.
4. Connector on solenoid valve unplugged or defective.
5. SGR is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. The most frequent
occurences of this error will be a defective solenoid valve, or the valve is not connected after repair work. If errors
SGR 184, 192, 200, 208 or 216 occur at the same time, probably the SGR connector is unplugged. In this case start
with step 3.
1. Disconnect connector of solenoid valve and check connector for bent, corroded or loose pins. If a defect is visible,
repair it.
2. Check the resistance of the solenoid valve coil with ohmmeter. The value should be appr. 2.5 Ohm. If the coil is
interrupted, replace the solenoid valve.
3. Else connect Solenoid valve again and remove SGR. Unplug connector A21/3 and check connector for bent, cor-
roded or loose pins. If a defect is visible, repair it.
4. Check resistance between PIN3 and 10 on connector. If the line is interrupted . The harness has to be replaced,
or if the damage is visible, the wire can be repaired.
5. Else replace SGR.

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SGR - 225 Solenoid valve clutch 4 - PWM signal incorrect

Cause:
SGR internal diagnosis has indicated that the current PWM sampling value is different to the desired value.
Possible causes:
1. External short circuit to power or short circuit to ground.
2. SGR is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. As long as no external
faults like short to ground or short to power disable a PWM mode, the only reason can be a defective SGR.
1. Check for other error codes in the SGR and repair them first.
2. Else replace SGR.

SGR - 226 Solenoid valve clutch 4 - short to power

Cause:
SGR attempts to switch off a solenoid valve, but it is indicated that the solenoid valve is still supplied with voltage.
Possible causes:
1. SGR is defective.
2. Connector on solenoid valve is unplugged and touches another solenoid valve connector.
3. Isolation of wire to solenoid valve is fretted and connected to another solenoid valve wire.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. Solenoid valve main
switch off. The most frequent occurences of this error will be a defective SGR. There can be one or more internal
highside switches be shortcutted. In this case, another error, causing an obvious overload condition, has to be sear-
ched (shortcut in wire harness, or solenoid valve).
1. Remove SGR. Unplug connector A21/3 and and A21/5, check connector for bent, corroded or loose pins. If a
defect is visible, repair it.
2. Switch ignition "ON" and clear errors. If the error still occurs, replace the SGR, but check also the next steps.
3. Switch ignition "OFF". Check on connector A21/5 the resistance between PIN3 and 10. The resistance should be
appr. 2.5 Ohm. If there is no shortcut visible, and the SGR has been defective, no further check has to be made.
4. Check the resistance of PIN3 and the used pins of connector A21/5 and A21/3 for a connection. Is there a con-
ductance measurable continue with step 5. Else the error has to be observed until it occurs again.
5. Check connector of solenoid valve for improper connection and for eventually touching a second vicinal
connector.
6. Disconnect solenoid valve connector and check for bent, corroded or loose terminals. If there is a defect visible,
repair it.
7. Check the resistance of the solenoid valve with ohmmeter. The resistance should be appr. 2.5 Ohm. If this is
shortcutted, replace the solenoid valve.
8. Replug connector A21/3 and A21/5 and switch ignition "ON". Measure the voltage on connector Y44. The voltage
should be below 1 V. If the Voltage is appr. "Vehicle onboard" voltage, replace the wire harness or repair the wire,
if the damage is obviously visible.

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SGR - 227 Solenoid valve clutch 4 - short circuit, or short to ground

Cause:
SGR detects a short circuit on a solenoid output.
Possible causes:
1. Solenoid valve has a short circuit.
2. Connector on solenoid valve is unplugged and touches ground.
3. Isolation of wire to solenoid valve is broken and connected to a ground wire.
4. SGR is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Tractor stops slowly. The most frequent
occurences of this error will be a defective solenoid valve.
1. Disconnect connector of solenoid valve and check connector for bent, corroded or loose pins. If a defect is visible,
repair it.
2. Check the resistance of the solenoid valve coil with ohmmeter. The value should be appr. 2.5 Ohm. If the coil has
a short circuit, replace the solenoid valve.
3. Else connect Solenoid valve again and remove SGR. Unplug connector A21/3 and check connector for bent, cor-
roded or loose pins. If a defect is visible, repair it.
4. Check resistance between PIN3 and 10 on connector. If the line has a short circuit the harness has to be repla-
ced,or the wire can be repaired, if the damage is obviously visible.
5. Else replace SGR.

SGR - 228 Clutch K4 - clutch does not open

Cause:
Clutch K4 should be open, but the SGR diagnoses that clutch K4 is closed. The diagnosis is based on the speeds
supplied by the speed sensors. The fault is stored and signalled on screen by a warning triangle. The vehicle can only
be driven at a limited speed.
Possible causes:
1. Temporary malfunction of the clutch.
2. Solenoid valve on hydraulic side defective.
3. Clutch defective.
Remedy:
1. If fault code SGR 224, SGR 225, SGR 226 or SGR 227 occurs at the same time, remedy this fault first.
2. If this malfunction of clutch K4 occurs and you do not hear a loud noise, this could be a false diagnosis. Store the
fault using the Service Tool and then delete it. Then carry out a test drive. If the fault code does not occur again,
no further action is required.
3. If this malfunction of clutch K4 occurs and you hear a loud noise, there could be mechanical damage. Store the
fault using the Service Tool and then delete it. Then carry out a test drive. If the fault code does not occur again,
check claw coupling K4 for mechanical damage (see chapter 6006).
4. If the fault stays permanently, start the engine and apply the parking interlock. Check the system pressure at
measuring point K4 (see chapter 6002). If a system pressure of approximately 30 bar is applied at this point, dis-
connect the plug of solenoid valve K4. If the system pressure does not change, replace solenoid valve K4. If no
system pressure is present at this point, this is caused by a mechanical defect of clutch K4 (see chapter 6006).

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SGR - 229 Clutch K4 - clutch does not close

Cause:
Clutch K4 should be closed, but the SGR diagnoses that clutch K4 is open. The diagnosis is based on the speeds
supplied by the speed sensors. The fault is stored and signalled on screen by a warning triangle. There is a specific
response to this fault.
Possible causes:
1. Temporary false diagnosis as a result of load fluctuations in the drive train.
2. Solenoid valve on hydraulic side defective.
3. Clutch defective.
Remedy:
1. If fault code SGR 224, SGR 225, SGR 226 or SGR 227 occurs at the same time, remedy this fault first.
2. Temporary false diagnoses can occur as a result of high load fluctuations in the drive train. Store the fault using
the Service Tool and then delete it. Make a test drive to check the function. If the fault code does not occur again,
no further action is required.
3. If the fault stays permanently, first check solenoid valve K4. Replace it if a fault is detected. If you cannot detect
a malfunction of the solenoid valve, this is caused by a mechanical defect of clutch K4 (see chapter 6006).

SGR - 230 Clutch K4 - clutch is slipping

Cause:
Clutch K4 should be closed, but the SGR diagnoses that clutch K4 is slipping. The diagnosis is based on the speed
supplied by the speed sensors. The fault is stored. There is no specific response to this fault.
Possible causes:
Temporary false diagnosis as a result of load fluctuations in the drive train.
Remedy:
1. If fault code SGR 224, SGR 225, SGR 226, SGR 227 or SGR 229 occurs at the same time, remedy this fault first.
2. Temporary false diagnoses can occur as a result of high load fluctuations in the drive train. Store the fault using
the Service Tool and then delete it. Make a test drive to check the function. If the fault code does not occur again,
no further action is required.

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SGR - 232 Solenoid valve parklock On - open circuit

Cause:
The connection between SGR and solenoid valve is interrupted.
Possible causes:
1. Solenoid valve is defective.
2. Wire is interrupted.
3. Connector on SGR is unplugged or defective.
4. Connector on solenoid valve is unplugged or defective.
5. SGR is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. The most frequent occurences of this error
will be a defective solenoid valve, or the valve is not connected after repair work. If errors SGR 168, 176 or 240 occur
at the same time, probably the SGR connector is unplugged. In this case start with step 3.
1. Disconnect connector of solenoid valve and check connector for bent, corroded or loose pins. If a defect is visible,
repair it.
2. Check the resistance of the solenoid valve coil with ohmmeter. The value should be appr. 7 Ohm. If the coil is
interrupted, replace the solenoid valve.
3. Else connect Solenoid valve again and remove SGR. Unplug connector A21/5 and check connector for bent, cor-
roded or loose pins. If a defect is visible, repair it.
4. Check resistance between PIN4 and 8 on connector. If the line is interrupted the harness has to be replaced, or
the wire can be repaired, if the damage is obviously visible.
5. Else replace SGR.

SGR - 234 Solenoid valve parklock On - short to power

Cause:
SGR attempts to switch off a solenoid valve, but it is indicated that te solenoid valve is still supplied with voltage.
Possible causes:
1. SGR is defective.
2. Connector on solenoid valve is unplugged and touches another solenoid valve connector.
3. Isolation of wire to solenoid valve is fretted and connected to another solenoid valve wire.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Solenoid valve main switch off. The most
frequent occurences of this error will be a defective SGR. There can be one or more internal highside switches have
been shortcutted. In this case, another error, causing an obvious overload condition, has to be searched (shortcut in
wire harness, or solenoid valve).
1. Remove SGR. Unplug connector A21/3 and A21/5, check connector for bent, corroded or loose pins. If a defect
is visible, repair it.
2. Switch ignition "ON" and clear errors. If the error still occurs, replace the SGR, but check also the next steps.
3. Switch ignition "OFF". Check on connector A21/5 the resistance between PIN4 and 8. The restistance should be
app. 7 Ohm. If there is no shortcut visible, and the SGR has been defective, no further check has to be made.
4. Check the resistance of PIN4 and the used pins of connector A21/5 and A21/3 for a connection. Is there a con-
ductance measurable continue with step 5. Else the error has to be observed until it occurs again.
5. Check connector of solenoid valve for improper connection and for eventually touching a second vicinal
connector.
6. Disconnect solenoid valve connector and check for bent, corroded or loose terminals. If there is a defect visible,
repair it.
7. Check the resistance of the solenoid valve with ohmmeter. The resistance should be appr. 2.5 Ohm. If this is
shortcutted, replace the solenoid valve.
8. Replug connector A21/3 and A21/5 and switch ignition "ON". Measure the voltage on connector Y57. The voltage
should be below 1 V. If the Voltage is appr. "Vehicle onboard" voltage, replace the wire harness or repair the wire,
if the damage is obviously visible.

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SGR - 235 Solenoid valve parklock On - short circuit, or short to

ground
Cause:
SGR detects a short circuit on a solenenoid output.
Possible causes:
1. Solenoid valve has a short circuit.
2. Connector on solenoid valve is unplugged and touches ground.
3. Isolation of wire to solenoid valve is broken and connected to a ground wire.
4. SGR is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. The most frequent occurences of this error
will be a defective solenoid valve.
1. Disconnect connector of solenoid valve and check connector for bent, corroded or loose pins. If a defect is visible,
repair it.
2. Check the resistance of the solenoid valve coil with ohmmeter. The value should be appr. 7 Ohm. If the coil has
a short circuit, replace the solenoid valve.
3. Else connect Solenoid valve again and remove SGR. Unplug connector A21/5 and check connector for bent, cor-
roded or loose pins. If a defect is visible, repair it.
4. Check resistance between PIN4 and 8 on connector. If the line has a short circuit the harness has to be replaced,
or the wire can be repaired, if the damage is obviously visible.
5. Else replace SGR.

SGR - 236 Parking interlock - parking interlock cannot be engaged

Cause:
When the parking interlock has been activated, the SGR checks whether it has really been engaged. This check was
not completely successfully as a fault was detected. The fault is stored and signalled on screen by a warning triangle.
Possible causes:
1. Parking interlock unlocked by emergency unlocking device
2. Temporary malfunction of the solenoid valve.
3. Solenoid valve defective.
4. Mechanical defect of the parking interlock.
Remedy:
1. If fault code SGR 232, SGR 234, SGR 235 or SGR 240 occurs at the same time, remedy this fault first.
2. Check whether the emergency unlocking device is completely released.
3. Store the fault using the Service Tool and then delete it. Make a test drive to check the function. If the fault code
does not occur again, this is a temporary fault. In this case no further action is required.
4. If the fault code stays permanently, check the solenoid valve of the parking interlock. Check the shift pressure at
measuring point "Parking interlock ON" (see chapter 6002). Engage the parking interlock using the parking inter-
lock button. While the parking interlock is being engaged, the shift pressure briefly (1-3 seconds) rises to system
pressure and then drops again to zero.
a) If this temporary rise in pressure cannot be measured, check the solenoid valve of the parking interlock and
replace it if a fault is detected.
b) If this temporary rise in pressure can be measured, go to step 6.
5. If the fault still occurs, check the shift pressure at measuring point "Parking interlock OFF" (see chapter 6002).
Engage the parking interlock using the parking interlock button. While the parking interlock is being engaged, the
OFF shift pressure must be zero.
a) If a pressure can be measured at the measuring point "Parking interlock OFF" when the parking interlock is
being engaged, check the solenoid valve of the parking interlock and replace it if a fault is detected.
b) If a pressure cannot be measured at the measuring point "Parking interlock OFF" when the parking interlock
is being engaged, go to step 6.
6. If the fault still occurs, check the parking interlock for hydraulic or mechanical damage (see chapter 6009).

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SGR - 237 Parking interlock - parking interlock does not lock

Cause:
When the parking interlock is engaged, the SGR checks the output speed. If an output speed is detected, the fault is
stored and the warning triangle is activated. The vehicle's standstill control is then activated.
Possible causes:
1. Emergency unlocking
2. Temporary false diagnosis as a result of load fluctuations in the drive train or PTO shaft train.
3. Mechanical defect of the parking interlock.
Remedy:
1. If fault code SGR 232, SGR 234, SGR 235, SGR 236 or SGR 240 occurs at the same time, remedy this fault first.
2. Check whether the emergency unlocking device is completely released.

SGR - 240 Solenoid valve parklock Off - open circuit

Cause:
The connection between SGR and solenoid valve is interrupted.
Possible causes:
1. Solenoid valve is defective.
2. Wire is interrupted.
3. Connector on SGR is unplugged or defective.
4. Connector on solenoid valve is unplugged or defective.
5. SGR is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. The most frequent occurences of this error
will be a defective solenoid valve, or the valve is not connected after repair work. If errors SGR 168, 176 or 232 occur
at the same time, probably the SGR connector is unplugged. In this case start with step 3.
1. Disconnect connector of solenoid valve and check connector for bent, corroded or loose pins. If a defect is visible,
repair it.
2. Check the resistance of the solenoid valve coil with ohmmeter. The value should be appr. 7 Ohm. If the coil is
interrupted, replace the solenoid valve.
3. Else connect Solenoid valve again and remove SGR. Unplug connector A21/5 and check connector for bent, cor-
roded or loose pins. If a defect is visible, repair it.
4. Check resistance between PIN5 and 8 on connector. If the line is interrupted the harness has to be replaced, or
the wire can be repaired, if the damage is obviously visible.
5. Else replace SGR.

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SGR - 242 Solenoid valve parklock Off - short to power

Cause:
SGR attempts to switch off a solenoid valve, but it is indicated that the solenoid valve is still supplied with voltage.
Possible causes:
1. SGR is defective.
2. Connector on solenoid valve is unplugged and touches another solenoid valve connector.
3. Isolation of wire to solenoid valve is fretted and connected to another solenoid valve wire.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. Solenoid valve main switch off. The most
frequent occurences of this error will be a defective SGR when one or more internal highside switches be shortcutted.
In this case, another error, causing an obvious overload condition, has to be searched (shortcut in wire harness, or
solenoid valve).
1. Remove SGR. Unplug connector A21/3 and A21/5, check connector for bent, corroded or loose pins. If a defect
is visible, repair it.
2. Switch ignition "ON" and clear errors. If the error still occurs, replace the SGR, but check also the next steps.
3. Switch ignition "OFF". Check on connector A21/5 the resistance between PIN5 and 8. The restistance should be
appr. 7 Ohm. If there is no shortcut visible, and the SGR has been defective, no further check has to be made.
4. Check the resistance of PIN5 and the used pins of connector A21/5 and A21/3 for a connection. Is there a con-
ductance measurable continue with step 5. Else the error has to be observed until it occurs again.
5. Check connector of solenoid valve for improper connection and for eventually touching a second vicinal connetor.
6. Disconnect solenoid valve connector and check for bent, corroded or loose terminals. If there is a defect visible,
repair it.
7. Check the resistance of the solenoid valve with ohmmeter. The resistance should be appr. 7 Ohm. If this is short-
cutted, replace the solenoid valve.
8. Replug connector A21/3 and A21/5 and switch ignition "ON". Measure the voltage on connector Y58. The voltage
should be below 1 V. If the Voltage is appr. "Vehicle onboard" voltage, replace the wire harness or repair the wire,
if the damage is obviously visible.

SGR - 243 Solenoid valve parklock Off - short circuit, or short to

ground
Cause:
SGR detects a short circuit on a solenenoid output.
Possible causes:
1. Solenoid valve has a short circuit.
2. Connector on solenoid valve is unplugged and toughes ground.
3. Isolation of wire to solenoid valve is fretted and connected to a ground wire.
4. SGR is defective.
Solution:
Failure will be stored and signaled with a warning triangle on the monitor. The most frequent occurences of this error
will be a defective solenoid valve.
1. Disconnect connector of solenoid valve and check connector for bent, corroded or loose pins. If a defect is visible,
repair it.
2. Check the resistance of the solenoid valve coil with ohmmeter. The value should be appr. 7 Ohm. If the coil has
a short circuit, replace the solenoid valve.
3. Else connect Solenoid valve again and remove SGR. Unplug connector A21/5 and check connector for bent, cor-
roded or loose pins. If a defect is visible, repair it.
4. Check resistance between PIN5 and 8 on connector. If the line has a short circuit the harness has to be replaced,
or the wire repaired, if the damage is obviously visible.
5. Else replace SGR.

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 4011-713

BLANK PAGE

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4011-714

COMPONENTS SUMMARY
A2 EEM2 control unit up to DBD100000 ................................................................................................ Fig. 1
A3 EEM3 control unit from DBD100001................................................................................................. Fig. 2
A4 FMGR ............................................................................................................................................... Fig. 3
A4/4 FMGR plug connection - grey [4] ...................................................................................................... Fig. 4
A21 SGR transmission controller ............................................................................................................ Fig. 5
A21/2 Plug connection, SGR grey .............................................................................................................. Fig. 6
A21/3 Plug connection, SGR black ............................................................................................................ Fig. 6
A21/4 Plug connection, SGR green ............................................................................................................ Fig. 6
A21/5 Plug connection, SGR brown............................................................................................................ Fig. 6
A21/6 Plug connection, speed sensor, black planetary carrier 1/2, B35 ..................................................... Fig. 7
A21/7 Plug connection, speed sensor, grey cartridge input B24................................................................. Fig. 7
A21/8 Plug connection, speed sensor, brown planetary carrier 3/4, B25.................................................... Fig. 7
A21/9 Plug connection, speed sensor, green cartridge output B26 ........................................................... Fig. 7
A21/10 Plug connection, speed sensor, orange cartridge output B27 .......................................................... Fig. 7
A23 Plug connection, Linde electronics ................................................................................................... Fig. 8
B24 Speed sensor, cartridge input .......................................................................................................... Fig. 9
B25 Speed sensor, planetary carrier 3/4 ................................................................................................. Fig. 9
B26 Speed sensor, cartridge output ......................................................................................................... Fig. 9
B27 Speed sensor, cartridge output ......................................................................................................... Fig. 9
B32 Speed sensor, temperature sensor, transmission oil ..................................................................... Fig. 10
B35 Speed sensor, planetary carrier 1/2 .................................................................................................. Fig. 9
B47 Pressure sensor for transmission system pressure .........................................................................Fig. 11
B51 Pressure sensor for transmission lubricating pressure ....................................................................Fig. 11
S49/1 Switch, pressure filter, 5bar ............................................................................................................ Fig. 12
X6/1 Plug connection, Linde electronics ................................................................................................ Fig. 13
X16/21 SGR plug connection ...................................................................................................................... Fig. 14
Y41 Solenoid valve, coupling 1 ..............................................................................................................Fig. 11
Y42 Solenoid valve, coupling 2 ..............................................................................................................Fig. 11
Y43 Solenoid valve, coupling 3 ..............................................................................................................Fig. 11
Y44 Solenoid valve, coupling 4 ..............................................................................................................Fig. 11
Y45 Solenoid valve, coupling, forward ....................................................................................................Fig. 11
Y46 Solenoid valve, coupling, reverse ................................................................................................... Fig. 15
Y57 Solenoid valve, parking interlock On............................................................................................... Fig. 15
Y58 Solenoid valve, parking interlock Off .............................................................................................. Fig. 15
Y59 All-wheel solenoid valve ................................................................................................................. Fig. 15

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SGR 4011-715

Fig. 1 up to DBD100000

Fig. 4 up to DBD100000

Fig. 2 from DBD100001

Fig. 3

Fig. 4 from DBD100001

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 4011-716

Fig. 5 Fig. 7

Fig. 6

Fig. 8

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SGR 4011-717

Fig. 9 Fig. 11

Fig. 10

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 4011-718

Fig. 12 Fig. 14 from DBD100001

Fig. 13 Fig. 15

Fig. 14 up to DBD100000

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SGR 4011-719

*) see Note page 8

FUNCTIONAL SCHEMATIC DIAGRAM FOR FMGR - SGR UP TO DBD100000
X24/2
ARMREST (16) F19 5A
17 +15/1 F51 10A F18 5A
F20 5A +15/1 +15/1
*A28 PLUG MODULE 18 F14 7.5A A12 F9 10A
F16 5A GND +30 +30 A24 HYDROSTAT
X21 X11 *A30 PRINT ARU X1 X18/4 2 +15/2
3R7
A31 2 9 8 10
X5/1 X24/2 1 6 X24/2 21 23 M
1 1 7 13
S60/1 9 9
13 3 (16) (16) 3R7
X7 15 A4/3 10 14 13 A4/4 X16/21 13 12 3
CAN - CAN H
S60/2 2 16 1 A4 FMGR 17 1 A21 SGR
CAN H CAN L X6/9 E F L M H K B
11 11 3 17 3 18 2
CAN L Supply Supply
4 18 2

GND
11 V
S60/3
10 12 S4/4
X6/3 X24/3 A4/2 1 12 2 11 9 10 3
S60/4

0 V or 5 V
3 10 8 NEUTRAL LIMP HOME circuit
9 4 X16/21
2 11 7 DEAD MAN GND
GSV2 10
S60/5 4 12 6 12 V
Shuttle lever 14 Select 0 V** for FORWARDS
12 5 1 2 2 12 V
8 Select 0 V** for REVERSE
5 1 1 7 11 FORWARDS
*YA1 21 17 15 13 11 8 6 4 2 3 1 33 5 7 A23 ELECTRONICS
6 3 3 8 10 REVERSE **) Only if the
X4/59/b (A) and X4/59/c (B) A23 8 5 7 6

X4/59/b
X4/59/a
*YB1 21 17 15 13 11 8 6 4 2 3 1 33 5 7 plug connection is linked.
A21/4
* A27 CAN MODULE 11 X6/1

CAN H

CAN +
CAN L
12 4

CAN -
X24/3
2 19 A21/5 1
A12 X14/15 X10/11 A13 X10/12 P8 P8 ICU P8/1 1 21 3 3
F45 5A
+15/1 12 7 6 7 4 3 20 9 2
5 3 X4/59/c
3 2 A24 Hydrostat X5/1 Plug connection
Brake
X14/14 4 1 A27 CAN module ---> DBD..... X6/1 4-pin plug connection
X4/14 X24/3 A4/2 A28 Plug module ---> DBD..... X6/3 6-pin plug connection
P8/2 3 4 1 GSV2
6 A30 Print ARU DBD..... ---> X6/9 7-pin plug connection
A14 X20/1 X23/1 X10/14 12
F93 5A (7) S25 3.9 Ω A31 Multi controller X7 4-pin plug connection
+30 8 Q 7 (8) 3 4 14 3 V B17 Angle of rotation sensor, clutch X10/11 10-pin plug connection
S5 2 5 13 3 V CN3 26-pin plug connection X10/12 10-pin plug connection
P8 ICU X10/14 10-pin plug connection
P8 10-pin plug connection X11 16-pin plug connection
CN3 X24/3 A4/2 Clutch P8/1 4-pin plug connection X14/14 14-pin plug connection
A1 ADIC CAN L GSV2 P8/2 4-pin plug connection X14/15 14-pin plug connection
25 1 12 6
3.9 Ω R8 Potentiometer, accelerator pedal X16/21 16-pin plug connection
CAN H S46
26 A4/1 S4/4 Shuttle lever X18/4 18-pin plug connection
2 24 15 3 V S5 Switch for brake light X20/1 20-pin plug connection
S25 Switch for steering brake X21 14-pin plug connection
A4/4 S46 Switch, clutch X23/1 23-pin plug connection
A1 ADIC GND
1 13 4 S60/1 F/R button X23/2 23-pin plug connection
CAN H

A2 EEM2
CAN L

B17 5.6V S60/2 Cruise control button X24/2 24-pin plug connection
A4 FMGR 2 14 11
S60/3 Speed button + X24/3 24-pin plug connection
A4/1 18-pin plug connection U 3 15 12 1.1 to 4 V S60/4 Speed button - X70 70-pin plug connection
A4/2 18-pin plug connection S60/5 HTS button YA1 44-pin plug connection
A4/3 15-pin plug connection X1 14-pin plug connection ---> DBD.....
A4/4 18-pin plug connection X4/70 A4/4 Accelerator pedal X4/14 4-pin plug connection YB1 44-pin plug connection
A12 Central print GND X4/59/a 3-pin plug connection ---> DBD.....
1 1
A13 Roof print
X70 18 42 3 X4/59/b 3-pin plug connection (7) Ground point, roof hood, left
A14 Engine print R8 6 4.4 to 0.8 V X4/59/c 3-pin plug connection (8) Ground point, roof hood, right
A21 SGR transmission controller
A2 EEM2 5.8V
2 10 X4/70 4-pin plug connection (16) Ground point, starter
A21/4 12-pin plug connection
A21/5 12-pin plug connection 4 3 0.8 to 4.4 V
A23 Electronics X70 X23/2
A23 12-pin plug connection 36 U

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4011-720

BLANK PAGE

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SGR 4011-721

A4 FMGR
A4/2 A21/2 A21 SGR
GSV3 5V
1 p 1 4
B47 GND
S8 2 7 A21/3 Y41
U 4V
X4/61 X4/61 A4/2 3 6 0.2 to 3.1 V 6 1
GND
2 1 17 Seat contact A21/2 7
5V
S21 p 1 11 2
GND
X4/25 X4/25 A4/2 B51 2 8
2 1 16 Parking brake (open) U 3 5 0.2 to 1.2 V A21/3 Y42
4V
5 1
S20 A21/2 GND
t 8
A4/1 Engine back pressure 1 3
B32 PTC 1 kΩ to 4.4 kΩ 2
2 1 3 brake R 2 10
X5 A21/4 A21/3 Y43
GND 4V
1 2 9 4 1
A16 X14/4 A4/1 GND
GSV1 S49/1 2 1 3 GND 9
8 18 p Opens at a difference in pressure of 2
> 5 bar
1 2 X10/4 S2/58/1
Speed ranges 12 V
1 A21/3 Y44
0
X24/5 A4/1 3 4V
1
1 23 16 increase "+" Y11 GND
2 10
7 5 17 decrease "-" 2
3 Sensors and 2
1 A4/3 solenoid valves
12 V
S2/58/2 5 1 A21/3 Y45
Brake oil cooling Y12 4V
8 2 1
GND
OFF
ON
2 11
X24/5 A4/1 2
A21/7
5 1 8 5 Manual mode
(16) n 1 A21/3 Y46
S2/59 B24 10 to 6000 Hz 4V
f 2 1 1
GND
0 12
1
X24/5 A4/1 A21/8
2
Management 2
5 3 1 n 1
3 and B25 10 to 6000 Hz
1 4 2 all-wheel f 2

A21/9
X3/23 X24/5 A4/4 1
5.8 V n
a 1 11 14 Potentiometer B26 10 to 6000 Hz
f 2 Y57
R23 b 3 12 15 0 to 5.8 V for limit load
S2/61 GND A21/5 1
c 2 13 5 A21/10 10 V
4
n 1 GND
OFF
A4/1 B27 10 to 6000 Hz 8 2
ON
f 2
X24/3 13 3.0 V X17
Switch for parking Y58
1 3 18 A4/2 A21/6
GSV2 interlock 2
12 6 n 1
B35 10 to 6000 Hz A21/5
f 2 10 V
A4 FMGR A21/9 2-pin plug connection S2/58/2 Switch, manual mode 5 1
A4/1 18-pin plug connection A21/10 2-pin plug connection S2/59 Switch, all-wheel X24/5 24-pin plug connection
A4/2 18-pin plug connection B24 Speed sensor, cartridge input S2/61 Switch for parking interlock X17 Y - distributor
A4/3 15-pin plug connection B25 Speed sensor, planetary carrier 3/4 S8 Seat switch Y11 Solenoid valve for brake oil cooling
A4/4 18-pin plug connection B26 Speed sensor, cartridge output S20 Switch, engine back pressure brake Y12 Solenoid valve for brake oil cooling
A16 EDC print B27 Speed sensor, cartridge output S21 Switch, parking brake Y41 Solenoid valve, clutch 1
A21 SGR transmission controller B32 Temperature sensor, transmission oil S49/1 Switch, pressure filter Y42 Solenoid valve, clutch 2
A21/2 12-pin plug connection B35 Speed sensor, planetary carrier 1/2 X3/23 3-pin plug connection Y43 Solenoid valve, clutch 3 Y59
A21/3 12-pin plug connection B47 Pressure sensor for transmission X4/25 4-pin plug connection Y44 Solenoid valve, clutch 4 1
system pressure Y45 Solenoid valve, clutch, forward A21/5
A21/4 12-pin plug connection X4/61 4-pin plug connection 4V
A21/5 12-pin plug connection B51 Pressure sensor for transmission X5 2-pin plug connection Y46 Solenoid valve, clutch, reverse 6
lubrication pressure Y57 Solenoid valve, parking interlock ON GND
A21/6 2-pin plug connection X10/4 10-pin plug connection Y58 Solenoid valve, parking interlock OFF 7 2
A21/7 2-pin plug connection R23 Potentiometer for limit load X14/4 14-pin plug connection Y59 Solenoid valve, all-wheel
A21/8 2-pin plug connection S2/58/1 Switch, speed ranges X24/3 24-pin plug connection (16) Ground point, starter

Sva 6-52632 EN Edition 06-2006

4011-722

BLANK PAGE

Sva 6-52632 EN Edition 06-2006

SGR 4011-723

FUNCTIONAL SCHEMATIC DIAGRAM FOR FMGR - SGR FROM DBD100001

ARMREST
A12 A24 HYDROSTAT

X30/11
F19 5A F51 10A F18 5A
+15/1 +15/1
A30 PRINT ARU 3R7
(11) F20 5A F14 7.5A F9 10A
X21 X30/1 X18/4 +15/1 +30 +30
M
A31 2 9 8 10 X24/2 17 18 X24/2 1 6 X24/2 21 23
1 1 7 13 3R7

S60/1 9 9
13 3 (11) (11)
X30/7 A4/3 10 14 13 A4/4 X16/21 13 12 3 X6/9 E F L M H K B
CAN H
S60/2 2 16 A4 FMGR 17 1 A21 SGR

GND
CAN H CAN L

11 V
11 11 3 17 3 18 2 Supply
CAN L Supply
4 18 2
S60/3
A23 1 12 2 11 9 10 3
10 12 S4/4

0 V or 5 V
X6/3 X24/3 A4/2 LIMP HOME circuit
S60/4 3 10 8 NEUTRAL
9 4 X16/21
2 11 7 DEAD MAN GND
GSV2 10
S60/5 4 12 6 12 V
Shuttle lever 14 Select 0 V** with FORWARDS
12 5 1 2 2 12 V
8 Select 0 V** with REVERSE A23 ELECTRONICS
5 1 1 7 11 FORWARDS
**) Only if the A23 8 5 7 6
6 3 3 8 10 REVERSE
X4/59/b (A) and X4/59/c (B)

X4/59/b
X4/59/a
plug connection is linked.
A21/4 X6/1
11 4

CAN H
CAN L
X24/3 12 1
2 19 A21/5
1 21 3 3
A12 X14/15 X10/11 A13 X10/12 P8 P8 ICU P8/1 3 20 9 2
F45 5A
+15/1 12 7 6 7 4 X4/59/c
5 3 A1 ADIC S60/3 Speed button +
X4/14 X24/3 A4/2 Brake A3 EEM3 S60/4 Speed button -
3 GSV2
1 12 6 A4 FMGR S60/5 HTS button
S25 3.9 Ω
3 4 14 3 V A4/1 18-pin plug connection X4/14 4-pin plug connection
A14 X10/3 X10/14 X14/14 P8/2 3 4 A4/2 18-pin plug connection X4/59/a 3-pin plug connection
F212 5A S5 2 5 13 3 V A4/3 15-pin plug connection X4/59/b 3-pin plug connection
+30 6 7 4 (7)
A4/4 18-pin plug connection X4/59/c 3-pin plug connection
(8) A12 Central print X4/70 4-pin plug connection
X24/3 A4/2 Clutch A13 Roof print X6/1 4-pin plug connection
GSV2 A14 Engine print X6/3 6-pin plug connection
1 12 6
3.9 Ω A21 SGR transmission controller X6/9 7-pin plug connection
S46 A4/1 A21/4 12-pin plug connection X10/3 10-pin plug connection
2 24 15 3 V A21/5 12-pin plug connection X10/11 10-pin plug connection
CAN H
CAN L

A23 Electronics X10/12 10-pin plug connection

A4/4 A23 12-pin plug connection X10/14 10-pin plug connection
GND A24 Hydrostat X10/18 10-pin plug connection
1 13 4
5.6V A30 Print ARU X14/14 14-pin plug connection
B17 2 14 11 A31 Multi controller X14/15 14-pin plug connection
U 3 15 12 1.1 to 4 V B17 Angle of rotation sensor, clutch X16/21 16-pin plug connection
CN3 26-pin plug connection X18/4 18-pin plug connection
A1 ADIC CN3 P8 ICU X21 14-pin plug connection
CAN L P8 10-pin plug connection X24/2 24-pin plug connection
25 X4/70 A4/4 Accelerator pedal
CAN H GND P8/1 4-pin plug connection X24/3 24-pin plug connection
26 1 1 P8/2 4-pin plug connection X30/1 14-pin plug connection
3 6 4.4 to 0.8 V R8 Potentiometer, accelerator pedal X30/7 4-pin plug connection
X89/1 35 34 R8
5.8V S4/4 Shuttle lever X30/11 16-pin plug connection
2 10 S5 Switch for brake light X89/1 89-pin plug connection
A3 EEM3
4 3 0.8 to 4.4 V S25 Switch for steering brake (7) Ground point, roof hood, left
S46 Switch, clutch (8) Ground point, roof hood, right
S60/1 F/R button (11) Ground point, engine cable
X89/1 X10/18 X24/3 S60/2 Cruise control button carrier, rear
79 10 16

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4011-724

BLANK PAGE

Sva 6-52632 EN Edition 06-2006

SGR 4011-725

A4 FMGR A21 SGR

A4/2 A21/2
GSV3 5V
1 p 1 4
B47 GND
S8 2 7 A21/3 Y41
X4/61 X4/61 A4/2
U 3 6 0.2 to 3.1 V 6 4V
1
GND
2 1 17 Seat contact A21/2 7
5V
S21 p 1 11 2
GND
X4/25 X4/25 A4/2 B51 2 8
2 1 16 Parking brake (open) U 3 5 0.2 to 1.2 V A21/3 Y42
4V
5 1
S20 A21/2 GND
t 8
A4/1 1 3
B32 PTC 1 kΩ to 4.4 kΩ 2
2 1 3 Engine back pressure 2 10
R
brake
X5 A21/4 A21/3 Y43
A16 GND 4V
X14/4 A4/1 1 2 9 4 1
GSV1 GND
8 18 S49/1 2 1 3 GND 9
p Opens at a difference in pressure of 2
1 2 X10/4 S2/58/1 > 5 bar
Speed ranges A21/3
0
X24/5 A4/1 12 V
1 Y44
4V
1 23 16 increase "+" 3 1
2 Y11 GND
7 5 17 decrease "-" 10
3 2
1 Sensors and 2
A4/3 solenoid valves
S2/58/2 12 V
Brake oil cooling 5 1 A21/3 Y45
Y12 4V
OFF
8 2 1
GND
ON
2 11
X24/5 A4/1 2
5 1 8 5 Manual mode A21/7
S2/59 (11) n 1 A21/3 Y46
B24 10 to 6000 Hz 4V
0
f 2 1 1
GND
1
X24/5 A4/1 12
2
Management A21/8
5 3 1 2
3 and n 1
1 4 2 all-wheel B25 10 to 6000 Hz
f 2

X3/23 X24/5 A4/4 A21/9

5.8 V
a 1 11 14 Potentiometer n 1
B26 10 to 6000 Hz
R23 b 3 12 15 0 to 5.8 V for limit load f 2 Y57
S2/61 GND
c 2 13 5 A21/5 1
A21/10 10 V
4
OFF
X24/5 A4/1 n 1 GND
ON
B27 10 to 6000 Hz 8 2
18 13 3.0 V f 2
Switch for parking X17
1 3 X24/3 A4/2 Y58
GSV2 interlock A21/6
12 6 2
n 1
B35 10 to 6000 Hz A21/5
A4 FMGR A21/10 2-pin plug connection S2/61 Switch for parking interlock f 2 10 V
5 1
A4/1 18-pin plug connection B24 Speed sensor, cartridge input S8 Seat switch
A4/2 18-pin plug connection B25 Speed sensor, planetary carrier 3/4 S20 Switch, engine back pressure brake
A4/3 15-pin plug connection B26 Speed sensor, cartridge output S21 Switch, parking brake Y12 Solenoid valve for brake oil cooling
A4/4 18-pin plug connection B27 Speed sensor, cartridge output S49/1 Switch, pressure filter Y41 Solenoid valve, clutch 1
A16 EDC print B32 Temperature sensor, transmission oil X3/23 3-pin plug connection Y42 Solenoid valve, clutch 2
A21 SGR transmission controller B35 Speed sensor, planetary carrier 1/2 X4/25 4-pin plug connection Y43 Solenoid valve, clutch 3 Y59
A21/2 12-pin plug connection B47 Pressure sensor for transmission X4/61 4-pin plug connection Y44 Solenoid valve, clutch 4 A21/5 1
A21/3 12-pin plug connection system pressure X5 2-pin plug connection Y45 Solenoid valve, clutch, forward 4V
A21/4 12-pin plug connection B51 Pressure sensor for transmission X10/4 10-pin plug connection Y46 Solenoid valve, clutch, reverse 6
A21/5 12-pin plug connection lubricating pressure X14/4 14-pin plug connection Y57 Solenoid valve, parking interlock ON GND
7 2
A21/6 2-pin plug connection R23 Potentiometer for limit load X17 Y - distributor Y58 Solenoid valve, parking interlock OFF
A21/7 2-pin plug connection S2/58/1 Switch, speed ranges X24/3 24-pin plug connection Y59 Solenoid valve, all-wheel
A21/8 2-pin plug connection S2/58/2 Switch, manual mode X24/5 24-pin plug connection (11) Ground point, engine cable carrier, rear
A21/9 2-pin plug connection S2/59 Switch, all-wheel Y11 Solenoid valve for brake oil cooling

Sva 6-52632 EN Edition 06-2006

 5001
Chapter
5001
FUNCTIONAL DESCRIPTION, TROUBLESHOOTING
AND SETTINGS
Front Axle with Independent Suspension 20.25S

135 HP, 145 HP and 155 HP

CNH ÖsterreichGmbH Sva 6-51450 EN © 2003 CNH Österreich GmbH

Technical Documentation May 2003
A - 4300 St. Valentin, Steyrer Straße 32
5001- 2

TABLE OF CONTENTS
SPECIAL TOOLS ....................................................................................................................................................... 3
GENERAL DESCRIPTION ......................................................................................................................................... 4
COMPONENTS .......................................................................................................................................................... 5
OPERATION .............................................................................................................................................................. 6
Main Switch, Suspension ON / OFF ................................................................................................................ 6
Auxiliary switch ................................................................................................................................................. 6
Indicator lamp on the instrument panel ............................................................................................................ 6
FUNCTION OF THE SUSPENSION .......................................................................................................................... 7
Calibration procedure ....................................................................................................................................... 7
Control Function ............................................................................................................................................... 8
AXLE SENSORS ........................................................................................................................................................ 9
General Remarks ............................................................................................................................................. 9
Testing the "Sensor Settings" ........................................................................................................................ 10
Adjusting the Sensors .................................................................................................................................... 12
LOWERING THE FRONT AXLE MANUALLY .......................................................................................................... 13
ERROR CODES ....................................................................................................................................................... 14
TROUBLESHOOTING USING THE DIAGNOSTIC SYSTEM ................................................................................. 15
Measurement table ........................................................................................................................................ 16
Test – solenoid valve control .......................................................................................................................... 18
Circuit Diagram, Sprung Front Axle ............................................................................................................... 19

Sva 6-51450 EN Edition 05-03

 5001- 3

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5001- 4

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‡ 4-wheel drive planetary steering axle with independent suspension, cast main housing with front cover, centrally
located swing bearing and drive, bevel drive pinion borne in the main housing, differential fitted from the front end,
differential drive gear secured in the main housing by bridge type bracket.
‡ Mechanical differential lock 100%, shift mechanism integrated into the front cover, electro-hydraulically operated.
‡ Independent suspension at both sides through: two trapezoidal links, one hydraulic cylinder, one hydro-reservoir
and one torsion bar acting in opposition to the hydro-reservoir.
‡ One control block, fitted with three solenoid valves and the two hydro-reservoirs, each of 1,4 litres capacity, is lo-
cated on the right-hand side of the vehicle chassis and forms the link between the two hydraulic system cylinders.
Connected in parallel to the hydraulic system (load sensing).
‡ Each side and thus the movement of each wheel, within the total spring travel range of 90 mm, is actively monitored
by an angle of rotation sensor.
‡ The sensor signal is decisive for the reaction of the hydraulics to increase or decrease the charge in the reservoir
This firstly forms the basis for the weight independent height control and secondly, actively assists the function of
the hydro-reservoir when necessary.
‡ Conversion of the sensor signals, to control the hydraulics or solenoid valves respectively, is carried out in the elec-
tronic circuitry, designed as an independent element on the hydraulic control block.

Sva 6-51450 EN Edition 05-03

 5001- 5

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8
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1. TRAPEZOIDAL LINK 5. CONTROL BLOCK

2. HYDRAULIC CYLINDER 6. SOLENOID VALVE

3. HYDRO-RESERVOIR 7. ANGLE OF ROTATION SENSOR

4. TORSION BAR 8. ELECTRONICS

Sva 6-51450 EN Edition 05-03

5001- 6

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This switch has the following positions:
‡ Switch pressed to the left
 Suspension 2)) (suspension inhibited)
 The suspension lowers the axle to the limit of the suspension cylinder.
 Recommended mode for driving in hilly terrain and contour lines.
 Stipulated mode prior to opening the system. (reservoir pressure-free)
‡ Switch in the mid position
 Suspension 21 (100% spring travel), indicator lamp lights. The suspension goes to or remains in the middle of
the total range of travel, independent of weight.

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‡ Switch pressed briefly to the right (pushbutton function)

 End the calibration procedure.
 Activating 100% spring travel, under any operating conditions.
‡ Pushbutton function, held pressed for 10 sec’s. (until the indicator lamp blinks at regular intervals)
 Start the calibration procedure.

$X[LOLDU\VZLWFK(pushbutton function only, pressed to the left – lower, to the right – raise)
‡ Holding the button pressed
 Active at 100% suspension travel – alteration of ground clearance in the respective direction.
 During the calibration procedure – stipulating the upper and lower limits of suspension travel.
‡ Push-button pressed briefly
 Height control OFF
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 Lamp does not light: Suspension OFF or suspension without height control.
 Lamp lights: 100% suspension travel and height control active.
 Lamp blinks regularly – confirms calibration procedure.
 Lamp blinks irregularly: an error code will be presented (see error code list Page 14)

Sva 6-51450 EN Edition 05-03

 5001- 7

)81&7,212)7+(6863(16,21
The suspension can be operated in several operating modes. The relevant operating mode is indicated by the indi-
cator lamp on the instrument panel as follows:
‡ Indicator lamp OFF
 System switched OFF, reservoir or system free of pressure.
 Axle at its limit, no suspension or suspension inhibited.
 Manual height adjustment (ground clearance adjustment) has been made. Suspension from the newly selected
position only through the reservoir. Suspension travel is hereby restricted, in one direction, to the remaining travel
up to the limit. Changes in weight and leakage are not compensated for.
‡ Indicator lamp lit
 Height control from the middle of the total suspension travel, 100% suspension travel up and down, independent
of load and leakage, is or remains available through active reservoir pressure adaptation.
‡ Indicator lamp blinks regularly (1 Hz)
 Calibration process active.
‡ Indicator lamp blinks irregularly (3 Hz)
 An error code will be displayed
 The blink pattern is interrupted by a long and a short pause.
Example: Error code 21 – long pause, blinks twice, short pause, blinks once.
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This serves to stipulate the upper and lower end limits of the suspension on both sides. If the control system does not
receive any recognisable data, the calibration procedure will be automatically activated when the supply voltage is
switched ON.
The calibration procedure can also be selected by the driver at any time (as described in the Operating Manual). Ca-
libration itself is always carried out in the following way:
 Hold the main switch, pressed to the right, for at least 10 sec's. (indicator lamp must blink regularly).
 Select and hold the auxiliary switch to the "raise" position until the upper limit is reached.
 Select and hold the auxiliary switch to the "lower" position until the lower limit is reached.
 To complete the procedure, press the main switch briefly to the right.
 The indicator lamp must now be lit.
 The suspension moves to the centre of its travel – the procedure is complete.
 When the indicator lamp once again starts to blink, repeat the procedure.

Sva 6-51450 EN Edition 05-03

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For active control, the position of the suspension is acquired every 100 ms.
The electronics recognise whether the suspension is within the fixed tolerance range, programmed in the E-Box, by
the sensor signals received or whether it makes significant changes for brief periods of time. The basis for this is the
mean value (S Nom) calculated from the relevant sensor signal from the total spring travel.
If this range is exceeded, in either direction, for longer than 2.5 sec’s. the valves will be regulated and the correspon-
ding change in reservoir pressure will be initiated. The valves will only then stop being regulated, when the position
signals acquired are once again within the tolerance range.
How often and for how long the valves will be regulated is always dependent upon the sensor signals received and
can not be influenced by the driver.
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Sva 6-51450 EN Edition 05-03

 5001- 9

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‡ Adjustment must always be carried out, when one or both of the sensors have been replaced or if the sensor fa-
stening was loosened.
‡ Prior to adjusting the sensors, ensure that the drive wheel (rubber wheel) is correctly fitted and the guide wheel has
freedom of movement, not only externally in the bolt but also internally on the sensor. The tightening torque of the
securing bolts must also be strictly adhered to.
If either of the above mentioned items is not adhered to, or carried out incorrectly, the function will be impaired due to
deformation of the sensor housing.
The following limits are valid for the basic adjustment of both sensors:
Suspension (axle) at its lower limit .................................................................................................. >5 mA <6.5 mA
Suspension ( axle) at its upper limit ................................................................................................ <18.68 mA
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Sva 6-51450 EN Edition 05-03

5001- 10

7HVWLQJWKH6HQVRU6HWWLQJV Connect the measuring cables to the multimeter in or-

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Put the tractor on solid, level ground and apply the par-
king brake. Lower the axle to its lower mechanical limit
and switch the engine OFF. Place chocks in front of and
behind the rear wheels.
der to test the voltage. In order to test the power supply
for the right-hand sensor, connect the measuring ca-
(red cable to red socket, blue cable to black socket).
67(3
Start the tractor and read the supply voltage value off
the multimeter.
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3 In order to test the left-hand sensor, connect the
measuring cables to the sockets in the blue field and re-
peat STEP 4.

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Remove the protective cover from the control block.
Separate the plug-in connector and connect the mea-
surement adapter  into the sensor line.
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Switch the engine OFF. In order to test the right-hand

sensor’s signal current, remove the plug-in jumper from
4 the red field on the measurement adapter 
and replace it with the measuring cables. Plug the
measuring cables into the multimeter sockets "40 mA"
and "COM".
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Sva 6-51450 EN Edition 05-03


67(3
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Start the tractor and allow it to run at idling speed. Press
the main suspension switch briefly to the right and wait
until the axle is in the mid position.
Press the auxiliary switch to the left until the axle has
reached the lower mechanical limit. Read the value in-
5001- 11
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Press the auxiliary switch to the right until the axle has
reached the upper mechanical limit. Read the value in-
dicated off the multimeter and make a note of it.
67(3
The following values should be indicated:
Lower limit .............................................. min. 5.00 mA
Upper limit ........................................... max. 18.68 mA
The difference between the values indicated must not
be less than P$.
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PDQXDOO\VHH3DJH re-connect the sensor cable connectors. Re-fit the pro-
tective cover to the control block.

Sva 6-51450 EN Edition 05-03

5001- 12
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67(3
Put the tractor on solid, level ground and apply the par-
king brake. Lower the axle to its lower mechanical limit
and switch the engine OFF. Place chocks in front of and
behind the rear wheels.
67(3
2
1
3 meterindicates a value of 6 mA ±0,5. Tighten the secu-

6'&
Remove the protective cover from the control block.
Separate the plug-in connector and connect the mea-
surement adapter  into the sensor line.
67(3
4 67(3
6'&
To adjust the right-hand sensor, remove the plug-in
jumper from the measurement adapter’s red field and
replace it by the measuring cables.
Plug the measuring cables into the multimeter sockets
"40 mA" and "COM". Insert the plug-in jumper (4) into
the sockets in the blue field.
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5
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Remove the sensor covers (5) from both sides.
Turn the ignition switch to ON and loosen the sensor
securing screws. Adjust the sensor, so that the multi-
ring screws to a torque of 169 Nm.
67(3
Check the reading on the multimeter and repeat STEP
4 if necessary.
67(3
Turn the ignition switch to OFF. To adjust the left-hand
sensor, plug the measuring cables into the sockets in
the blue field and insert the plug-in jumper into the sok-
kets in the red field.
Repeat STEP 4 and STEP 5 to adjust the left-hand sen-
sor.
67(3
Re-fit the sensor covers to both sides and tighten the
securing screws to a torque of 13 Nm.
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67(3
Disconnect the measurement adapter and
re-connect the sensor cable connectors. Re-fit the pro-
tective cover to the control block.
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67(3 67(3
Put the tractor on firm, level ground, apply the parking
brake and switch the motor OFF. Place chocks in front
of and behind the rear wheels.

67(3

6'&

1 chanical limit and the pressure reservoirs will be relie-
6'&
Remove the protective cover from the control block.
Remove the plastic cover (1) from the discharge valve.
Loosen the locking nut and turn the valve screw (2) out
by approx. one turn. The axle will sink to the lower me-
ved of pressure.
67(3
When the reservoirs are pressure-free, close the valve
screw and tighten the locking nut. Re-fit the plastic cap
to the discharge valve.

Sva 6-51450 EN Edition 05-03

5001- 14

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Indication of an error code by the indicator lamp in the instrument panel blinking at 3 Hz.
127( ,QWKHFDOLEUDWLRQPRGHWKHLQGLFDWRUODPSEOLQNVUHJXODUO\DWDIUHTXHQF\RI+]7KLVLVQRWDQHUURUFRGH
The following error codes can be displayed:

(UURU&RGH )DXOW/RFDWLRQ 6\VWHP5HDFWLRQ 3RVVLEOH)DXOW

&DXVH
Left-hand sensor signal Axle remains in the cur- • Cable defective or sensor disconnected
not ok rent position • Short circuit or short to earth
 • Sensor incorrectly adjusted
• Signal <4 mA or >19.68 mA
Right-hand sensor Axle remains in the cur- • Cable defective or sensor disconnected
signal not ok rent position • Short circuit or short to earth
 • Sensor incorrectly adjusted
• Signal <4 mA or >19.68 mA
No power supply to the Axle remains in the cur- • Cable or plug defective
E-box. rent position • Potential 30, fuse (F27)defective
(potential 30 is missing)

Left-hand control valve Axle remains in the cur- • Cable defective or solenoid disconnected
does not function rent position • Short circuit in the solenoid or cable
• E-Box output stage defective
Right-hand control Axle remains in the cur- • Cable defective or solenoid disconnected
 valve does not function rent position • Short circuit in the solenoid or cable
• E-Box output stage defective

FAULTS WITHOUT ERROR CODES

Fault Location / System Reaction Possible Fault

Cause
Signal variation at one Calibration is not possible, • Sensor shaft stiff
or both sensors too there is no middle position (Sensor fitted under tension, rust on the
small (uneven spring travel) sensor shaft, centering disk missing)
• Rubber disk (sensor shaft drive)
worn out
• Contact fault in the signal line (oxidation)
• Sensor defective
Signal variation at one Calibration is not possible, • Bearing of one or several
or both sensors too there is no middle position trapezoidal links stiff
small (uneven spring travel) • Hydraulic pressure too low
• Front axle load too high

Sva 6-51450 EN Edition 05-03

 5001- 15

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380000058 Diagnostic box, 100 pole General
380000059 Intermediate cable Connection between diagnostic box
and 12 pole ’Y’ adapter
380000064 12 pole ’Y’ adapter For X12/20 (electronics – A61 on the
control block)
380000066 2 pole 'Y' adapter Solenoid valve on the control block
Measuring cable 1.5 m, red, blue (pin diameter 4mm) General
Multimeter (Fluke 79 or equally) General
Test lamp with 45 W bulb As a load during various measure-
ments

6\PEROOHJHQG

Ignition switch "OFF"

Ignition switch "ON"

Engine running

Plug connected to the electronics box

Plug disconnected from the electronics box

Connect the test lamp, with prescribed wattage, as a load

0HDVXUHPHQWV
V Voltage
∆V Voltage drop
R Resistance
∞ Resistance infinity = open circuit (multimeter indication OL)

Sva 6-51450 EN Edition 05-03

5001- 16

0HDVXUHPHQWWDEOH

Measurement
Cable colour
Measure

X12/20
Pin
Designation Requirements from pin Value
to pin

Power supply, electronics box A61

----- 45W 6 9 -----
Ground 9 B max. 1.0
∆V 45W 9 Battery -ve pole
VDC

----- 45W 8 10 -----

Ground 10 B max. 1.0
∆V 45W 10 Battery -ve pole
VDC
G315 A313

12 - 14
Permanent plus F27 10 A 6 V 45W 6 9
VDC

12 - 14
Permanent plus F28 5 A 8 V 45W 8 10
VDC

Input signals from the main switch S2/15/2

Suspension inhibited
C307

12 - 14
Main switch (S2/15/2) 4 V Switch pressed to the 4 9
VDC
in position 2 left

Suspension active
C307

Main switch (S2/15/2) 4 V Main switch in mid 4 9 0 VDC

in position 0 position

Suspension active
C308

Main switch (S2/15/2) 5 V Main switch in mid 5 9 0 VDC

in position 0 position

Calibration
C308

12 - 14
Main switch (S2/15/2) 5 V Main switch pressed to 5 9
VDC
in position 1 the right

Input signals from the auxiliary switch S2/15/1

C302 C301

2 V 2 9 0 VDC
Auxiliary switch (S2/15/1)
in position 0 Auxiliary switch not
3 V 3 9 0 VDC
pressed

Lower front axle

C301

12 - 14
Auxiliary switch (S2/15/1) 2 V Auxiliary switch 2 9
VDC
in position 2 pressed to the left

Raise front axle

C302

12 - 14
Auxiliary switch (S2/15/1) 3 V Auxiliary switch 3 9
VDC
in position 1 pressed to the right

Sva 6-51450 EN Edition 05-03

 5001- 17

Measurement
Cable colour
Measure

X12/20
Pin
Designation Requirements from pin Value
to pin

Input signal – resume "suspension active"

127( For this test, it is necessary that the driving speed is indicated correctly. If necessary, carry out speedo-
meter calibration.

C281
Switching voltage from A60 approx.
12 V 12 9
ECCU electronic - box at v = > 14 km/h: 13,8 VDC

Switching voltage from A60

12 C281 V 12 9
approx. 0
ECCU electronic - box at v = < 14 km/h: VDC

Output signal to indicator lamp "front axle suspension"

approx. 0
B143

Indicator lamp
11 V Main switch pressed 11 9 VDC
lights
briefly to the right (ground)
B143

Indicator lamp
11 V Main switch pressed to 11 9 7 - 11 VDC
does not light
the left

Sva 6-51450 EN Edition 05-03

5001- 18

7HVW±VROHQRLGYDOYHFRQWURO
To carry out these tests, the multimeter must be connected to the individual solenoid valves using the "Y" adapter
380000066 and the measuring cables.
Test the solenoid valves in accordance with the table below.
Solenoid valve energised  9'&
Solenoid valve not energised  9'&

Function SV SV SV
blue plug green plug black plug
Raise front axle (auxiliary switch pressed to the right)
Lower front axle (auxiliary switch pressed to the left)
Control – increase pressure right and left
Control – raise right only
Control – raise left only
Control – decrease pressure right and left
Control – decrease pressure right only
Control – decrease pressure left only

5HVLVWDQFHDQGLQVXODWLRQWHVWVRQWKHYDOYHVROHQRLGV
Measurement

Measure
Designation Requirements from pin Value
to pin

R 1 2 on the solenoid 8 Ω ± 10%

Valve solenoid-
plugs blue, green R 1 valve housing •
and black
R 2 valve housing •

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Electrical equipment
A1 ADIC
A12 Print, central electrics
A60 ECCU
A61 Sprung front axle electronics
F27 Sprung front axle fuse
potential 30
F28 Sprung front axle fuse
potential 15/2
S2/15/1 Auxiliary switch RAISE/LOWER
S2/15/2 Main switch
X2/45 Plug-in connection - rump, sprung front axle
X4/45 Plug-in connection, sprung front axle
X9/4 Plug-in connection, combination instrument
X12/20 Plug-in connection, sprung front axle
X24/1 Plug-in connection line, ADIC

Sva 6-51450 EN Edition 05-03

 Chapter
5002
FUNCTIONAL DESCRIPTION,

5002
TROUBLESHOOTING
AND SETTINGS
Front Axle with
Independent Suspension 20.29S

170 HP and 190 HP

CNH Österreich GmbH Sva 6-51500 EN © 2003 CNH Österreich GmbH

Technical Documentation May, 2003
A - 4300 St. Valentin, Steyrer Straße 32
5002- 2

Table of Contents
SPECIAL TOOLS ....................................................................................................................................................... 3
GENERAL DESCRIPTION ......................................................................................................................................... 4
COMPONENTS .......................................................................................................................................................... 5
OPERATION .............................................................................................................................................................. 6
Main Switch, Suspension ON / OFF ................................................................................................................ 6
Auxiliary switch (pushbutton function only, pressed to the left – lower, to the right – raise) ............................ 6
Indicator lamp on the instrument panel ............................................................................................................ 6
FUNCTION OF THE SUSPENSION .......................................................................................................................... 7
Calibration procedure ....................................................................................................................................... 7
Control Function ............................................................................................................................................... 8
AXLE SENSORS ........................................................................................................................................................ 9
General Remarks ............................................................................................................................................. 9
Testing the "Sensor Settings" ........................................................................................................................ 10
Adjusting the Sensors .................................................................................................................................... 12
LOWERING THE FRONT AXLE MANUALLY .......................................................................................................... 14
ERROR CODES ....................................................................................................................................................... 15
FAULTS WITHOUT ERROR CODES ...................................................................................................................... 15
TROUBLESHOOTING USING THE DIAGNOSTIC SYSTEM ................................................................................. 16
Measurement table ........................................................................................................................................ 17
Test – solenoid valve control .......................................................................................................................... 19
Circuit Diagram, Sprung Front Axle ............................................................................................................... 20

Sva 6-51500 EN Edition 05-03

 5002- 3

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6'& 6''

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Sva 6-51500 EN Edition 05-03

5002- 4

*(1(5$/'(6&5,37,21
‡ 4-wheel drive planetary steering axle with independent suspension, cast main housing with swing bearing, diffe-
rential carrier screwed in from the rear. Bevel pinion mounted directly in the differential carrier, differential drive gear
mounted in the differential carrier by means of bridge-type brackets.
‡ Adjustment of the position of the bevel pinion by means of a packing ring. Adjustment of the bevel pinion bearings
by means of a shrunk-on sleeve and bevel pinion nut (slotted nut). Adjustment of the differential bearings and tooth
flank play by means of 2 slotted nuts.
‡ Differential lock 100%, multi-disk version running in oil bath, integrated in the differential housing. Electro-hydrau-
lically controlled. The system pressure is used as the control pressure P2 (20 bar). The pressure oil is fed from the
differential carrier (stationary) to the differential housing (rotating) without any leakage via special sealing elements.
‡ Independent suspension on both sides through: two trapezoidal links, one hydraulic cylinder, one hydro-reservoir
and one torsion bar acting in opposition to the hydro-reservoir. The steering-knuckle is mounted in two ball joints.
‡ The universal drive shafts from the differential to the wheel drive are made in two parts. A sliding piece provides
axial compensation. The section of the universal drive shaft on the differential side is guided by the bearing in the
centering bush, which is fixed in the main housing of the front axle. The section of the universal drive shaft on the
wheel side is guided axially in the axle stub / radially in the protective sleeve.
‡ A control block, fitted with three solenoid valves and two hydro-reservoirs, each of 1.4 litres capacity, is located on
the right-hand side of the vehicle chassis. Nitrogen is used as a cushioning element in the hydro-reservoir. The pre-
load pressure is 35 bar. The control block forms the link between the two cylinders and the hydraulic system. Con-
nected in parallel to the working hydraulic system (load sensing).
‡ Each side, and thus the movement of each wheel, within the total spring travel range of 87 mm, is actively monito-
red by an angle of rotation sensor. The electronics box detects the momentary wheel position via the size of the
signal current (mA).
‡ The sensor signal is decisive for the reaction of the hydraulic control to increase or decrease the charge in the re-
servoir. This firstly forms the basis for the weight independent height control and secondly, actively assists the
function of the hydro-reservoir when necessary.
‡ The right and left-hand sides of the front axle have separate and independent sensors and control elements for the
independent suspension.
‡ Conversion of the sensor signals, to control the hydraulics or solenoid valves respectively, is carried out in the elec-
tronic circuitry, designed as an independent element on the hydraulic control block.

Sva 6-51500 EN Edition 05-03

 5002- 5

&20321(176

8
6

;
3
2 3
5
7

66&

1 2

66-
1 4

1. TRAPEZOIDAL LINK 5. CONTROL BLOCK

2. HYDRAULIC CYLINDER 6. SOLENOID VALVE

3. HYDRO-RESERVOIR 7. ANGLE OF ROTATION SENSOR

4. TORSION BAR 8. ELECTRONICS

Sva 6-51500 EN Edition 05-03

5002- 6

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This switch has the following positions:
‡ Switch pressed to the left
 Suspension 2)) (suspension inhibited)
 The suspension lowers the axle to the limit of the suspension cylinder.
 Recommended mode for driving in hilly terrain and contour lines.
 Stipulated mode prior to opening the system. (reservoir pressure-free)
‡ Switch in the mid position
 Suspension 21 (100% spring travel), indicator lamp lights. The suspension goes to or remains in the middle of
the total range of travel, independent of weight.

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‡ Switch pressed briefly to the right (pushbutton function)

 End the calibration procedure
 Activating 100% spring travel, under any operating conditions
‡ Pushbutton function, held pressed for 10 sec’s. (until the indicator lamp blinks at regular intervals)
 Start the calibration procedure.

$X[LOLDU\VZLWFK(pushbutton function only, pressed to the left – lower, to the right – raise)
‡ Holding the button pressed
 Active at 100% suspension travel – alteration of ground clearance in the respective direction.
 During the calibration procedure – stipulating the upper and lower limits of suspension travel.
‡ Push-button pressed briefly
 Height control OFF
127( :KHQWKHWUDFWRULVVWDUWHGWKHIXQFWLRQZKLFKZDVODVWLQXVHZLOOWDNHHIIHFW7KHWUDFWRUVSHHGPXVWKRZH
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 Lamp does not light: Suspension OFF or suspension without height control.
 Lamp lights: 100% suspension travel and height control active.
 Lamp blinks regularly – confirms calibration procedure.
 Lamp blinks irregularly: an error code will be presented (see error code list Page 15).

Sva 6-51500 EN Edition 05-03

 5002- 7

)81&7,212)7+(6863(16,21
The suspension can be operated in several operating modes. The relevant operating mode is indicated by the in in-
dicator lamp on the instrument panel as follows:
‡ Indicator lamp OFF
 System switched OFF, reservoir or system free of pressure.
 Axle at its limit, no suspension or suspension inhibited.
 Manual height adjustment (ground clearance adjustment) has been made. Suspension from the newly selected
position only through the reservoir. Suspension travel is hereby restricted, in one direction, to the remaining travel
up to the limit. Changes in weight and leakage are not compensated for.
‡ Indicator lamp lit
 Height control from the middle of the total suspension travel, 100% suspension travel up and down, independent
of load and leakage, is or remains available through active reservoir pressure adaptation.
‡ Indicator lamp blinks regularly (1 Hz)
 Calibration process active.
‡ Indicator lamp blinks irregularly (3 Hz)
 An error code is displayed.
 The blink pattern is interrupted by a long and a short pause.
Example: Error code 21 – long pause, EOLQNVWZLFH, short pause, EOLQNVRQFH
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This serves to stipulate the upper and lower end limits of the suspension on both sides. If the control system does not
receive any recognisable data, the calibration procedure will be automatically activated when the supply voltage is
switched ON.
The calibration procedure can also be selected by the driver at any time (as described in the Operating Manual). Ca-
libration itself is always carried out in the following way:
 Hold the main switch, pressed to the left, for at least 10 sec's. (indicator lamp must flash regularly).
 Select and hold the auxiliary switch to the "raise" position until the upper limit is reached.
 Select and hold the auxiliary switch to the "lower" position until the lower limit is reached.
 To complete the procedure, press the main switch briefly to the right.
 The indicator lamp must now be lit.
 The suspension moves to the centre of its travel – the procedure is complete.
 When the indicator lamp once again starts to flash, repeat the procedure.
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For active control, the position of the suspension is acquired every 100 ms.
The electronics recognise whether the suspension is within the fixed tolerance range, programmed in the E-box, by
the sensor signals received or whether it makes significant changes for brief periods of time. The basis for this is the
mean value (S nom) calculated from the relevant sensor signal from the total spring travel.
If this range is exceeded, in either direction, for longer than 2.5 secs., control valves are regulated and the correspon-
ding change in reservoir pressure is initiated. The valves will only then stop being regulated, when the position signals
acquired are once again within the tolerance range.
How often and for how long the valves are regulated is always dependent upon the sensor signals received and can
not be influenced by the driver.

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 5002- 9

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‡ Adjustment must always be carried out, when one or both of the sensors have been replaced or if the sensor fa-
stening was loosened.
‡ Prior to adjusting the sensors, ensure that the drive wheel (rubber wheel) is correctly fitted and the guide wheel has
freedom of movement, not only externally in the bolt but also internally on the sensor. The tightening torque of the
securing bolts (3 Nm) must also be strictly adhered to.
If either of the above mentioned items is not adhered to, or carried out incorrectly, the function will be impaired due to
deformation of the sensor housing.
The following values are valid for both sensor settings:
Suspension (axle) at its lower limit ................................................................................................. .. 7.8 mA ± 0.5
Suspension (axle) at its upper limit ................................................................................................ 16.0 mA ± 0.5
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Sva 6-51500 EN Edition 05-03

5002- 10

7HVWLQJWKH6HQVRU6HWWLQJV Connect the measuring cables to the multimeter in or-

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VVHDW bles to the sockets in the red field of the test adapter
67(3
Put the tractor on solid, level ground and apply the par-
king brake. Lower the axle to its lower mechanical limit
and switch the engine OFF. Place chocks in front of and
behind the rear wheels.
der to test the voltage. In order to test the power supply
for the right-hand sensor, connect the measuring ca-
(red cable to red socket, blue cable to black socket).
67(3
Start the tractor and read the supply voltage value off
the multimeter.
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67(3
3 In order to test the left-hand sensor, connect the
measuring cables to the sockets in the blue field and re-
peat STEP 4.

6'-
67(3
Remove the protective cover from the control block.
Separate the plug-in connector and connect the mea-
surement adapter  into the sensor line.
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67(3
0HDVXULQJFDEOH 0XOWLPHWHU
4

6'&

Switch the engine OFF. In order to test the right-hand

sensor’s signal current, remove the plug-in jumper from
4 the red field on the measurement adapter 
and replace it with the measuring cables Plug the
measuring cables into the multimeter sockets "40 mA"
and "COM".
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67(3
Press the auxiliary switch to the right until the axle has
reached the upper mechanical limit. Read the value in-
dicated off the multimeter and make a note of it.

$X[LOLDU\VZLWFK 66(
Start the tractor and allow it to run at idling speed. Press
the main suspension switch briefly to the right and wait
67(3
The following values must be reached:
Lower limit ............................................... 7.8 mA ± 0.5
Upper limit ............................................. 16.0 mA ± 0.5
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until the axle is in the mid position.
Press the auxiliary switch to the left until the axle has
reached the lower mechanical limit. Read the value in-
dicated off the multimeter and make a note of it.
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67(3
Disconnect the measurement adapter and
re-connect the sensor cable connectors. Re-fit the pro-
tective cover to the control block.
PDQXDOO\VHH3DJH

Sva 6-51500 EN Edition 05-03

5002- 12

$GMXVWLQJWKH6HQVRUV 67(3

67(3
Put the tractor on solid, level ground and apply the par- 5
king brake. Lower the axle to its lower mechanical limit
and switch the engine OFF. Place chocks in front of and
behind the rear wheels.

67(3

1
6'-

Remove the sensor covers (5) from both sides.

Turn the ignition switch to ON and loosen the sensor
securing screws. Adjust the sensor, so that the multi-
meterindicates a value of
7.8 mA ± 0.5. Tighten the securing screws to a torque of
169 Nm.

6'-
67(3
Remove the protective cover from the control block. Check the reading on the multimeter and repeat STEP
Separate the plug-in connector (1) and connect the 4 if necessary.
measurement adapter  into the sensor line.
67(3
67(3 Turn the ignition switch to OFF. To adjust the left-hand
sensor, plug the measuring cables into the sockets in
the blue field and insert the plug-in jumper into the sok-
kets in the red field.
4
67(3
Repeat STEP 4 and STEP 5 to adjust the left-hand sen-
sor.

6'&

To adjust the right-hand sensor, remove the plug-in

jumper from the measurement adapter’s red field and
replace it by the measuring cables.
Plug the measuring cables into the multimeter sockets
"40 mA" and "COM". Insert the plug-in jumper (4) into
the sockets in the blue field.
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Sva 6-51500 EN Edition 05-03


67(3
Checking the measured value for both sensors at the
upper limit:
Start the engine and turn the main switch to the middle
position. Press the auxiliary switch to the right until the
front axle (rightandleft) has reached the upper mecha-
nical limit. The measured value must lie within a range
of 16.0 mA ± 0.5.
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Sva 6-51500 EN
5002- 13
67(3
Re-fit the sensor covers to both sides and tighten the
securing screws to a torque of 13 Nm.
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Disconnect the measurement adapter and
re-connect the sensor cable connectors. Re-fit the pro-
tective cover to the control block.
Edition 05-03
5002- 14

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67(3 67(3
Put the tractor on firm, level ground, apply the parking When the reservoirs are pressure-free, close the valve
brake and switch the motor OFF. Place chocks in front screw and tighten the locking nut. Re-fit the plastic cap
of and behind the rear wheels. to the discharge valve.

67(3

6'-

Remove the protective cover from the control block.

Remove the plastic cover (1) from the discharge valve.

67(3

2
6'-

Loosen the locking nut and turn the valve screw (2) out
by approx. one turn. The axle will sink to the lower me-
chanical limit and the pressure reservoirs will be relie-
ved of pressure.

Sva 6-51500 EN Edition 05-03

 5002- 15

(5525&2'(6
Indication of an error code by the indicator lamp in the instrument panel blinking at 3 Hz.
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The following error codes can be displayed:
)DXOW/RFDWLRQ 6\VWHP5HDFWLRQ 3RVVLEOH)DXOW
(UURU&RGH
&DXVH
Left-hand sensor signal Axle remains in the cur- • Cable defective or sensor disconnected
not ok rent position • Short circuit or short to earth
 • Sensor incorrectly adjusted
• Signal < 4 mA or >19.68 mA
• Sensor defective
Right-hand sensor Axle remains in the cur- • Cable defective or sensor disconnected
signal not ok rent position • Short circuit or short to earth
 • Sensor incorrectly adjusted
Signal < 4 mA or >19.68 mA
• Sensor defective
No power supply to the Axle remains in the cur- • Cable or plug defective
E-box. rent position • Potential 30, fuse defective (F27)
(potential 30 is missing)

Left-hand control valve Axle remains in the cur- • Cable defective or solenoid disconnected
does not function rent position • Short circuit in the solenoid or cable
• E-box output stage defective
Right-hand control Axle remains in the cur- • Cable defective or solenoid disconnected
 valve does not function rent position • Short circuit in the solenoid or cable
• E-box output stage defective

)$8/76:,7+287(5525&2'(6
)DXOW/RFDWLRQ 6\VWHP5HDFWLRQ 3RVVLEOH)DXOW
&DXVH
Signal variation at one Calibration is not possible, • Sensor shaft stiff
or both sensors too there is no middle position (Sensor fitted under tension, rust on the
small (uneven spring travel) sensor shaft, centering disk missing)
• Rubber disk (sensor shaft drive)
worn out
• Contact fault in the signal line (oxidation)
• Sensor defective
Signal variation at one Calibration is not possible, • Bearing of one or several
or both sensors too there is no middle position trapezoidal links stiff
small (uneven spring travel) • Hydraulic pressure too low
• Front axle load too high

Sva 6-51500 EN Edition 05-03

5002- 16

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380000058 Diagnostic box, 100-pole General
380000059 Intermediate cable Connection between diagnostic box
and 12 pole ’Y’ adapter
380000064 12 pole ’Y’ adapter For X12/20 (electronics – A61 on the
(or 380000063) control block)
380000066 2 pole 'Y' adapter Solenoid valve on the control block
Measuring cable 1.5 m, red, blue (pin diameter 4mm) General
Multimeter (Fluke 79 or equally) General
Test lamp with 45 W bulb As a load during various measure-
ments

6\PEROOHJHQG

Ignition switch "OFF"

Ignition switch "ON"

Engine running

Plug connected to the electronics box

Plug disconnected from the electronics box

Connect the test lamp, with prescribed wattage, as a load

0HDVXUHPHQWV
V Voltage
∆V Voltage drop
R Resistance
∞ Resistance infinity = open circuit (multimeter indication OL)

Sva 6-51500 EN Edition 05-03

 5002- 17

0HDVXUHPHQWWDEOH

Measurement
Cable colour
Measure

X12/20
Pin
Designation Requirements from pin Value
to pin

Power supply, electronics box A61

----- 45W 6 9 -----
Ground 9 S 9 Battery -ve max.
∆V 45W
pole 1.0 VDC

----- 45W 8 10 -----

Ground 10 S 10 Battery -ve max.
∆V 45W
pole 1.0 VDC
A313

12 - 14
Permanent plus F27 10 A 6 U 45W 6 9
VDC
G315

12 - 14
Permanent plus F28 5 A 8 U 45W 8 10
VDC

Input signals from the main switch S2/15/2

Suspension inhibited
C307

12 - 14
Main switch (S2/15/2) 4 U Switch pressed to the 4 9
VDC
in position 2 left

Suspension active
C307

Main switch (S2/15/2) 4 U Main switch in mid 4 9 0 VDC

in position 0 position

Suspension active
C308

Main switch (S2/15/2) 5 U Main switch in mid 5 9 0 VDC

in position 0 position

Calibration
C308

12 - 14
Main switch (S2/15/2) 5 U Main switch pressed 5 9
VDC
in position 1 to the right

Input signals from the auxiliary switch S2/15/1

C301

2 U 2 9 0 VDC
Auxiliary switch (S2/15/1)
in position 0
C302

Auxiliary switch not

3 U 3 9 0 VDC
pressed

Lower front axle

C301

12 - 14
Auxiliary switch (S2/15/1) 2 U Auxiliary switch 2 9
VDC
in position 2 pressed to the left

Raise front axle

C302

12 - 14
Auxiliary switch (S2/15/1) 3 U Auxiliary switch 3 9
VDC
in position 1 pressed to the right

Sva 6-51500 EN Edition 05-03

5002- 18

Measurement
Cable colour
Measure

X12/20
Pin
Designation Requirements from pin Value
to pin

Input signal – resume "suspension active"

NOTE: For this test, it is necessary that the driving speed is indicated correctly. If necessary, carry out
speedometer calibration.

Switching voltage from A60

12 C881 U 12 9
approx.
ECCU electronics box When driving forwards 13.8 VDC
v = > 14 km/h
C881

Switching voltage from A60 approx.

12 U When driving forwards 12 9
ECCU electronics box 0 VDC
v = < 14 km/h

Output signal to indicator lamp "front axle suspension"

approx.
B143

Indicator lamp
11 U Main switch pressed 11 9 0 VDC
briefly to the right (ground)
B143

Indicator lamp
11 U Main switch pressed 11 9 7 - 11 VDC
does not light
to the left

Sva 6-51500 EN Edition 05-03

 5002- 19

7HVW±VROHQRLGYDOYHFRQWURO
To carry out these tests, the multimeter must be connected to the individual solenoid valves using the "Y" adapter
380000066 and the measuring cables.
Test the solenoid valves in accordance with the table below.
Solenoid valve energised  9'&
Solenoid valve not energised  9'&

Function SV SV SV
blue plug green plug black plug
Raise front axle (auxiliary switch pressed to the right)
Lower front axle (auxiliary switch pressed to the left)
Control – increase pressure right and left
Control – raise right only
Control – raise left only
Control – decrease pressure right and left
Control – decrease pressure right only
Control – decrease pressure left only

5HVLVWDQFHDQGLQVXODWLRQWHVWVRQWKHYDOYHVROHQRLGV
Measurement

Measure
Designation Requirements from pin Value
to pin

R 1 2 on the solenoid 8 Ω ± 10%

Valve solenoid –
plugs blue, green R 1 valve housing •
and black
R 2 valve housing •

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Electrical equipment
A1 ADIC
A12 Print, central electrics
A60 ECCU
A61 Sprung front axle electronics
F27 Sprung front axle fuse
potential 30
F28 Sprung front axle fuse
potential 15/2
S2/15/1 Auxiliary switch RAISE/LOWER
S2/15/2 Main switch
X2/45 Plug-in connection - rump, sprung front axle
X4/45 Plug-in connection, sprung front axle
X9/4 Plug-in connection, combination instrument
X12/20 Plug-in connection, sprung front axle
X24/1 Plug-in connection line, ADIC

Sva 6-51500 EN Edition 05-03

 )5217$;/(&$55$52

)5



CNH Österreich GmbH Sva 6-51550 EN © 2004 CNH Österreich GmbH

Technical Documentation July, 2004
A – 4300 St. Valentin, Steyrer Straße 32
 5005-3

7$%/(2)&217(176

SPECIAL TOOLS ............................................................................................................................................ 5

GENERAL INFORMATION ............................................................................................................................. 7

Using the Manual ...................................................................................................................................... 7
General Remarks ...................................................................................................................................... 7
General Instructions for Disassembly and Assembly ............................................................................... 7
Type plate ................................................................................................................................................. 9

TECHNICAL DATA ....................................................................................................................................... 10

Sealant and Locking Fluid ...................................................................................................................... 11
Tightening Torques ................................................................................................................................. 12
Dimensions 20.25 ................................................................................................................................... 13
Dimensions 20.25 FR ............................................................................................................................. 14

TRUNNIONS GROUP AND FLANGE .......................................................................................................... 15

Disassembly ........................................................................................................................................... 15
Assembly ................................................................................................................................................ 17

STEERING CYLINDER GROUP .................................................................................................................. 19

Disassembly ........................................................................................................................................... 19
Assembly ................................................................................................................................................ 20

EPICYCLIC REDUCTION GEAR GROUP ................................................................................................... 22

Disassembly ........................................................................................................................................... 22
Assembly ................................................................................................................................................ 23

BRAKE GROUP ............................................................................................................................................ 25

Disassembly ........................................................................................................................................... 25
Assembly ................................................................................................................................................ 28

WHEEL HUB GROUP AND SWIVEL HOUSING ......................................................................................... 31

Disassembly ........................................................................................................................................... 31
Assembly ................................................................................................................................................ 34

AXLE BEAM GROUP ................................................................................................................................... 37

Disassembly ........................................................................................................................................... 37
Assembly ................................................................................................................................................ 38

DIFFERENTIAL SUPPORT GROUP ............................................................................................................ 40

Disassembly ........................................................................................................................................... 40
Assembly ................................................................................................................................................ 42
Bevel gear marking test .......................................................................................................................... 45

DIFFERENTIAL LOCKING GROUP ............................................................................................................. 47

Disassembly ........................................................................................................................................... 47
Assembly ................................................................................................................................................ 48

DIFFERENTIAL GROUP .............................................................................................................................. 50

Disassembly ........................................................................................................................................... 50
Assembly ................................................................................................................................................ 51

Sva 6-51550 EN Edition 07-2004

5005-4

PINION GROUP ............................................................................................................................................53

Disassembly ............................................................................................................................................53
Assembly .................................................................................................................................................55

TRACK ALIGNMENT ....................................................................................................................................58

Sva 6-51550 EN Edition 07-2004

 5005-5

SPECIAL TOOLS
Wrench for differential nut Wrench for bevel pinion nut

SS02A055 SS02A056

380000406 (1TSW 532) 380000021 (CAS 1885A; 1TSW 504)

NOTE: Dolly 380000020 (CAS 2483) is additionally
Driver for cartridge sealing ring, hub
required.

Measuring disks (meshing adjustment)

SS02A062

380000042 (1TSW 549)

SS02A059
Measuring shaft (meshing adjustment)
380000440

Clamping device (meshing adjustment)

SS02A060

380000439
SS02A076

380000018

Sva 6-51550 EN Edition 07-2004

5005-6

Driver for bushing - swivel housing and Driver for shaft seal - swivel housing
axle housing

SS02A063

SS02A061
380000032 (1TSW 551)
380000024 (1TSW 552)

Driver for sealing ring - bevel pinion and

axle housing

SS04G033

380000702 (1TSW 550)

Sva 6-51550 EN Edition 07-2004

 5005-7

GENERAL INFORMATION
Using the Manual
Maintenance
• Trouble-free operation of the mechanical components is influenced by regular and correct maintenance.
• The use of qualified personnel during maintenance and repairs guarantees a longer lifetime of the components
and trouble-free operation.
• READ THE MANUAL. Non-observance of recommended worksteps can reduce the lifetime and the durability of
the unit and can result in damage or accidents.

Repairs
The instructions for removal and fitting were drawn up for an overall repair of the axle and constitute the correct order
of the tasks to be performed. Drawings and photos provide personnel with a complete and safe guide through all work
steps.
A good knowledge of the axle makes it possible to assess the repair, and as a result, it is often the case that only
certain parts have to be removed.

Information Property Rights

This repair manual contains confidential information. All rights remain reserved.
No part of this manual may be reproduced or copied without written permission from CNH Österreich GmbH. The
manufacturer assumes no liability for direct or indirect damages to persons, objects or animals as a result of incorrect
use of this manual.

Diagrams
Photos and drawings are NOT to exact scale.
Photos are only intended to clarify the sequence of worksteps.

Definition of the Driving Direction

Specifications such as "left side" or "right side" must always be seen from the driver's seat in the FORWARDS driving
direction of the vehicle.

General Remarks
• The axle should only be repaired by qualified personnel, who are acquainted with all of its technical
characteristics, and under strict compliance with the corresponding safety standards.
• The axle must be carefully cleaned before carrying out a repair. Dirt and/or grease must be removed.
• All disassembled parts must be cleaned using a suitable cleaning agent to avoid possible damage.
• Damaged or worn parts must be replaced to avoid possible subsequent damage. In particular, motion and
sealing elements must be checked if they are subject to larger amounts of stress, wear and ageing.
• The renewal of the bevel pinion or differential master gear necessitates the renewal of the entire set.
• Only use original spare parts

General Instructions for Disassembly and Assembly

IMPORTANT: Before commencing removal or fitting, read the following instructions carefully:

Shaft sealing rings

• Check the running surfaces of sealing rings for scoring and their surface condition.
• Check sealing rings for damage, tears or scratches.
• Insert shaft sealing rings so that the sealing lip is in the direction of the inner side of the housing (oil side).
Exception: another mounting position has been specified.
• Lubricate the sealing lips with oil and fill the ring cavity 3/4 full with grease.
• During assembly, use a suitable insertion tool and, when stipulated, special tools.
• If necessary, protect sealing rings by push sliplocks during assembly (special tool).

Sva 6-51550 EN Edition 07-2004

5005-8

Cartridge sealing rings

• Only fit using special tools.
• When fitting, moisten the rubberized inner surface of the cartridge sealing ring with a mixture of white spirits and
water.

‘O’ rings
Grease before installing.

Shims
Always individually measure the shims used.

Bearings
We advise that you warm up the bearing inner rings to 80 °C - 90 °C before assembly. Bearing outer rings should be
cooled down before assembly.
Always use suitable extractors when removing bearings. Always use suitable insertion tools when inserting bearings.

Sprung dowel pins

Always insert sprung dowel pins with the slit in the direction of the load.

Sealant and Locking Fluid

Only use prescribed sealant and locking fluid (see page 11). Before re-assembling, all parts must be clean, dry and
free of grease.

Draining oil
The oil must be drained before removing the planetary train and/or the axle housing.
WARNING: Dispose of old oil according to statutory regulations.

Cleaning
• All moving parts (bearing, gear wheels, shafts) must be cleaned carefully.
• Petrol, water or alkaline solutions should not be used. Do not use steam or hot water as it is difficult to remove
surface dampness.
• Clean all components using an air jet or a cloth to free the surfaces from any remains.
• All surfaces should be covered by a thin layer of oil to protect them from oxidation.

Using lubricants
Only use lubricants which meet the stipulated specifications (see Technical Data, page 10).

Sva 6-51550 EN Edition 07-2004

 5005-9

Type plate

AXLE TYPE CUSTOMER NUMBER CARRARO SERIAL NUMBER

TOTAL RATIO
CARRARO NUMBER

TYPE OF
DIFFERENTIAL LOCK

DIFFERENTIAL
OIL QUANTITY
DIRECTION OF
ROTATION OF
DRIVE SHAFT

RECOMMENDED
DIFFERENTIAL OIL

RECOMMENDED PLANETARY GEAR OIL PLANETARY GEAR OIL QUANTITY

SS01M134

Sva 6-51550 EN Edition 07-2004

5005-10

TECHNICAL DATA
DIFFERENTIAL
Number of teeth – pinion shaft / diff. master gear ...................................................................................... 14 / 32
Differential transmission ratio ................................................................................................................... 2.286 /1
Pinion shaft initial bearing tension (P)
(measured at pinion shaft Ø = 34.8 mm, without sealing ring) ..................................................... P = 92 to 137 N
Total initial bearing tension – pinion bearing and differential (T)
(measured at pinion shaft Ø = 34.8 mm, without sealing ring) .................................. T = 92 (+40) to 137 (+60) N
Bevel pinion / differential master gear tooth flank play ................................................................ 0.17 to 0.24 mm
Compensating washer thickness for pinion height .............................. at least 2.5 mm to a maximum of 3.4 mm

PLANETARY DRIVE
Planetary drive transmission ratio ........................................................................................................... 6.923 / 1
Total transmission ratio (differential + planetary drive) .......................................................................... 15.824 / 1

BRAKE (optional)
Type .................................................................................................................................................wet disk brake
Nominal brake disc thickness................................................................................................................. 10±0.1 mm
Maximum brake disc wear (per side) ........................................................................................................1-0.2 mm

SS04G032

STEERING
Steering angle .................................................................................................................... adjustable up to 50° -2

DIFFERENTIAL LOCK
Type ............................................................................ Radial pin lock, running in oil bath – 100 % locking value
Activation .................................................................................................................................... electro-hydraulic
Control pressure ...................................................................................................................................... 18+2 bar

TRACK ALIGNMENT
toe-in ...................................................................................................................................................... 0 to 2 mm

LUBRICANTS / TYPES OF OIL

(Prescribed oil type - see operator manual!)

FILLING QUANTITIES
Planetary drive without brake (each side) ............................................................................................... 1.5 litres
Planetary drive with brake (each side) ........................................................................................................ 2 litres
Differential ............................................................................................................................................... 8.0 litres

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 5005-11

Sealant and Locking Fluid


$*,308(3

7HFQROXEH32/<0(5(

$*,308(3
7HFQROXEH32/<0(5(









7HFQROXEH32/<0(5(



/RFWLWH SS04F082

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Tightening Torques

1P
1P 1P

1P
1P

1P

1P

1P

1P 1P
1P

1P

1P

1P 1P
1P

1P
1P

1P

1P
1P
1P
1P 1P 1P

SS04F088

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 5005-13

Dimensions 20.25


0[


∅



  


∅ 
∅ 

  




∅ 

SS04F91

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5005-14

Dimensions 20.25 FR


0[


∅



  


∅ 
∅ 

  




∅ 

SS04F089

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 5005-15

TRUNNIONS GROUP AND FLANGE

20
15
18

16

19

17
13
11
10
6 8

14
3 4 12

9
7

5
1
2
SS04F061

Disassembly
STEP 1 STEP 2

4
2

2 5
1
SS04F062 SS04F063

Remove the nut (3) and bolt (2). Remove the bolt (4).
Remove the flange (1). Remove the rear support (5) from the differential
support.
Remove the bushes (6) from rear support (5).

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STEP 3 STEP 6
7
20

18

8 19

15
6

SS04F063 SS04F067

Remove the O-Ring (8) from the bush (7). Remove the bolt (19).
Remove the bush (7) from the rear support (5). Remove the front support (20) from the axle housing
(15).
STEP 4
Remove the bush (18) from the front support (20).
STEP 7

15 16
13
11

17

12
SS04F065

Remove the cover (11) from differential support.

SS04F068
Remove the O-Ring (12) and the seal ring (13) from
the cover (11). Remove the bush (17) and washer (16) from axle
housing (15) only if necessary.
STEP 5
127( It is advisable to heat the bush (17) to
facilitate this operation.

10

SS04F066

Remove the bush (9) and washer (10) from differential

support only if necessary.
127( It is advisable to heat the bush (17) to
facilitate this operation.

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Assembly STEP 3
STEP 1
6
7

10

9
8

5
4
SS04F069

SS04F066
Apply Loctite 542 on bushes (6) contact surface.
Assemble the bushes (6) to the rear support (5).
Insert the washer (10) onto the differential support.
Assemble the bush (7) in the rear support (5).
Heat the bush (9) to 110-120 °C than assemble it to
the differential support. 127( Align the bush hole with the fastening bolt (4)
hole.
127( If necessary assemble the bush (9) with a
driver and a hammer. Assemble and tighten the fastening bolt (4) to the
requested torque.
STEP 2
Tightening torque......................................... 70 Nm
Lubricate a new O-Ring (8) with grease and assemble
it in the bush (7).
127( Insert the O-ring on the shown support side.
13
STEP 4
11

12
SS04F065

Assemble the seal ring (13) to the cover (11) with the
special tool 380000702.
4
Assemble the new O-Ring (12) to the cover (11).
Lubricate the O-Ring (12) and the seal ring (13). 5
Assemble the cover (11) to differential support. SS04F070

Insert the rear support (5) on the differential support.

:$51,1* Do not damage the O-ring (8) when
inserting the rear support on the central body.

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STEP 5 STEP 7

20

3 18

19

2
15

1 2
SS04F062 SS04F067

Assemble the flange (2) to the pinion shaft end (14).
Lock the flange (1) with the bolt (2) and nut (3).
Tighten the nut (3) to the requested torque.
Tightening torque ..........................................57 Nm
STEP 6
15 16
Assemble the bush (18) into the front support (20) with
a suitable driver and a hammer.
:$51,1* Align the bush hole with the fastening
screw (19) hole.
Mount the fastening screw (19).
Tighten the fastening screw (19) to the requested
torque
Tightening torque .......................................... 70 Nm
Assemble the front support (20) to the axle housing.

17

SS04F068

Insert the washer (16) onto the axle housing (15).

Heat the bush (17) at 110÷120 °C than assemble it to
the axle housing (15).
127( If necessary assemble the bush (17) with a
driver and a hammer.

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STEERING CYLINDER GROUP

19
21 12
11
20 10

17
18
15

7
16
14 6
8 9
5
13 4
3

2
1

SS03M070

Disassembly
STEP 1 STEP 2
3 12
2

11
6
10

1 4
7

5
3
SS03M083

SD03M004
Loosen the nut (1) with enough turns till it is protruding
over the threaded pin end of the tie rod (3).
Beat on the nut (1) with an appropriate hammer in
order to disjoin the tie rod (3) from the swivel housing
(2).
:$51,1* Do not strike on the threaded pin end of
the tie rod (3).
Repeat the whole sequence at the other side.
Remove the tie rods (3) and (12) by loosing the nuts
(4) and (11) with a suitable wrench. Unscrew also the
ball joints (5 and 10). Check the condition of the parts
removed.
Unscrew the fastening screws (6) and take the
steering cylinder (7) out of its housing, if necessary
use a rubber hammer.
Remove only parts that need to be overhauled and/or
replaced.

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STEP 3 Assembly
19 20 STEP 1
19 20

14 17 21
15
14 17 21
13
18 15
13
18

16
SS03M084

Detach the cylinder head (15) from the cylinder case 16

(19) and remove it from the rod (17).
Remove the rod (17) from the cylinder case (19).
Remove all the seals and O-Rings (13, 14, 16, 18, 20
and 21) from the cylinder case (19), the cylinder head
(15), and the rod (17).
SS03M084
Assemble new seals and O-Rings (13, 14, 16, 18, 20
and 21) on the cylinder head (15), on the rod piston
(17) and on the cylinder case (19).
STEP 2

17

19
15
SD03M005

Fit the cylinder head (15) on the rod (17).

Slide the pre-assembled rod (17) into the cylinderbody
(19).
STEP 3
12

11
6
10

4
7

17
5
3
SS03M083

Fit the tie rods (3) and (12), the ball joints (5) and (10),
the nuts (4) and (11) to the ends of the rod (17), then
tighten with a torque wrench.
Tightening torque .................... (pos. 5, 10) 300 Nm
Tightening torque .................... (pos. 4, 11) 250 Nm

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STEP 4 STEP 6
6 3

7 1

SD03M006
2 SS01M015

Install the steering cylinder (7) already assembled on Insert the ball joint of the tie rod (3) into the swivel
the central body. housing (2).
Assemble and tighten the screws (6) with a torque Assemble and tighten the lock nut (1) with a torque
wrench. wrench.
Tightening torque ........................................ 120 Nm Tightening torque........................................ 220 Nm
STEP 5 Repeat the whole sequence of the mentioned
operations to the other side.
12
11 STEP 7

11 12

8
SD03M007

Align the swivel housing (8) with the axle.

Screw the tie rod (12) so that its ball joint can be SD03M009

inserted into the swivel housing (8) arm. Screw the lock nuts (4) and (11) of the tie rods (3) and
127( It is important to unscrew the lock nut (11) to (12) only when the toe-in adjustment has been carried
carry out this operation. out (see Page 58).

Repeat the whole sequence of the mentioned

operations to the other side.

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EPICYCLIC REDUCTION GEAR GROUP

11

1 10
9

6
5
4

12

2
SS04F071

Disassembly
STEP 1 STEP 2

SD04F037
SS04F038

Drain the oil completely from the epicyclic reduction Unscrew the fastening screws (2) of the planetary
gear. carrier (1).

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STEP 3 Assembly
1 3 STEP 1
7

1 4

10
9
6
5

11 SD04F039

Remove the planetary carrier (1) from the wheel hub SS04F072
(11) and collect the relative O-Ring (3).
Collect all epicyclic reduction gear parts:
Position the planetary carrier (1) on a workbench and
check its wear conditions. - the planetary carrier (1),
- the thrust washer (4),
STEP 4 - the planetary gear (6) with the roller bearings (5),
- the washers (7) and (9),
7 - the fixing screw (10) of every planetary carrier
4 pin.
1
10 127( With new planetary gears (6) it is advisable to
assembly new needle bearings (5).
9
6 STEP 2
5

SS04F072

If required replace the planetary gears as follows: 4

- remove the fastening bolts (10) on every pin;
- remove the washers (9) and (7);
- take the planetary gears (6) out of the pins;
- collect the needle bearings (5) checking their
conditions;
SD04F040
- collect the thrust washers (4).
Position the planetary carrier (1) on a workbench.
Insert the needles bearing (5) in the epicyclic gears
(6).
127( Apply plenty of grease to the needle bearings
(5).
Insert the thrust washers (4) and the assembled
epicyclic gears (6) in the planetary carrier (1) pins.

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STEP 3 STEP 5
9
12

SD04F041 SD03M014

Fit the thrust washers (7) and (9) to the planetary
carrier (1) pins.
127( The intermediate thrust washers (7) has a
hole for centering with the dowel pin (8) fitted on the
planetary carrier (1) pins.
Top up the oil on the wheel hub.
Fit the filling/drain and level oil plug (12) on the
planetary carrier (1) and tighten to the requested
torque.
Tightening torque .......................................... 80 Nm

Assemble the retaining bolts (10), then tighten them to

the requested torque.
Tightening torque ..........................................79 Nm
STEP 4

11
SS04F042

Assemble a new O-Ring (3) on the wheel hub (11).

Fit the epicyclic reduction gear assembly to the wheel
hub (11).
Screw the fixing screws (2) and tighten them to the
requested torque.
Tightening torque ..........................................25 Nm

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 5005-25

BRAKE GROUP

13

12

9
8 11

14

4 33
8 34

10 31 32
2 30

7 24
23 29
5
27 28
21

25 26
3 19

1 22
20

SS04F073

Disassembly
127( Before disassembling the brake group (if equipped with it) remove epicyclic reduction gear group. (see page
22)
STEP 1 STEP 2

SS04F074 SD03M015

Remove the lock ring (1). Using a lever to push the double U-Joint in the
Remove the brake counter disk (2) and disk (3). direction of the wheel hub to allow the lock ring (5)
removal.
,03257$17 Do not damage the double U-Joint.

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STEP 3 STEP 6

6 7

5
SD04F043 SD03M019

Remove the lock ring (5) from the double U-Joint shaft. Extract and remove the wheel carrier (10) together
Collect the washers (6) and (7). with the epicyclic ring gear (4).

STEP 4 STEP 7

SD03M017 SD03M020

Unscrew the fastening screws (8) from the wheel Remove the O-rings (11).
carrier (10). Remove the lock ring (12) and disjoin the wheel carrier
group (10) from the epicyclic ring gear (4).
STEP 5
STEP 8
9 26

22

19
25
24
21
23
SD03M018 20
SS04F075
For disassembing the wheel hub group use three
screws (M10). Unscrew the kit self-adjust fastening screws to
disassembly the separator disk (19) from the wheel
carrier (26).
127( Remove all of the self-adjusting parts.
Remove the steel lock ring (20) from the epicyclic ring
gear (4) only if necessary.

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STEP 9 STEP 11

26

SD02A016 SS04F077

In order to remove the brake piston (23) from the Remove the centering bushes (9) from the wheel
wheel carrier (26) screw in 2 screws (M4) into the carrier (26) with a hammer and a suitable ejector drift
existing threaded holes. Extract symmetrically the if necessary.
piston with a lever and an appropriate support as
shown in the above figure.
STEP 10

22
21

23
SS03M093

Remove the Quadrings (21) and (22) from the brake

piston (23).

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5005-28

Assembly STEP 4
STEP 1 26

27

SS03M091

SS03M095 Push the bushes (27) into the shown seats in the
wheel carrier (26) with an appropriate driver till they
Position the wheel carrier (26) on a workbench and
are leveled with the counter disk (19) supporting inner
force the bushes (9) to the carrier surface level with an
surface.
appropriate driver.
Assemble the others self-adjusting parts as shown in
STEP 2 the diagram.
127( See next step.
STEP 5

26

19

SD03M021
20
127( At least two bushes (diametrically-opposed)
should be set slightly higher than the carrier surface SS04F079
level to be used as dowel pins.
Assemble the steel lock ring (20) to the intermediate
STEP 3 seat of the epicyclic ring gear (4).
Assemble the separator disk (19) and the epicyclic
22
25
ring gear (4) to the wheel carrier (26) with the self-
adjust kit (27-34).
Tighten the self-adjust screws to the requested torque
23
Tightening torque .......................................... 10 Nm

26

21

24
SS04F078

Assemble two new Quadrings (22, 25) and two new

antiextrusion rings (21, 24) to the piston (23).
Insert the piston (23) into the wheel carrier (26).

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 5005-29

STEP 6 appropriate driver and a hammer.

Assemble the fastening bolts (8) and tighten to the
11 11 requested torque
Tightening torque....................................... 230 Nm
STEP 9

SD03M022

Assemble the lock ring (12) into its seat of the epicyclic
ring gear (4).
Insert two new greased O-Rings (11) in the wheel
carrier (26). SD03M015

STEP 7 Using a lever to push the double U-Joint in the

direction of the wheel hub to make easier the lock ring
(5) insertion.
STEP 10

6 7
SD03M023

Assemble the wheel carrier group on the wheel hub

(13) using the projecting bushes as dowel pins.
5
127( Check the position of the O-Rings (11). SD04F043

Screw in the screws (8) in order to put in contact the Slide the washers (6) and (7) onto the double U-Joint
group with the wheel hub. shaft end.
Insert the lock ring (5) and push it into its seat.
STEP 8
127( Check that the lock ring (5) is correctly fitted
in its seat.

SD03M024

Force all the hub dowel bushes (9) completely with an

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5005-30

STEP 11

3
2
SS04F080

Insert the brake disk (3) and the brake counterdisk (2),
as in figure.
127( See next step.
Lock the disks with the lock ring (1).
STEP 12.
19

p1

SS04F081

:$51,1* When replacing the brake disc only, the

brake counter disk (19) must be renewed. Use a
suitable driver (p1) and a hammer to help with this
operation.
127( Position the driver with accuracy to avoid
damaging the brake piston.

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WHEEL HUB GROUP AND SWIVEL HOUSING

25

17

16
20
24
12
23
11
21
9 10

5
4 13
19
18
14
3
1
7 15

6
2 SS01M098

Disassembly
127( Before disassembling the wheel hub group/swivel housing remove the epicyclic reduction gear group. (see
page 22)
STEP 1 STEP 2

SS04F074 SD03M015

Remove the lock ring and remove the brake disks. Using a lever to push the double U-Joint in the
(see page 25) direction of the wheel hub to allow the lock ring (1)
removal.
:$51,1*Do not damage the double U-Joint.

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5005-32

STEP 3 STEP 6

6 7

5
SD04F043 SD03M019

Remove the lock ring (1) from the double U-Joint shaft.
Remove the washers (2) and (3).
STEP 4
Extract and remove the wheel carrier (6) together with
the epicyclic ring gear as mentioned in the previous
section.
STEP 7

SD03M017
SD03M025
Unscrew and remove the fastening screws (4) from
the wheel carrier group (6). Remove the wheel hub (9) using levers and a hammer
to facilitate the operation.
STEP 5
127( Remove the bearing cone (7).

SD03M018

For disassembing the wheel hub group use three

screws (M10).

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 5005-33

STEP 8 STEP 10
7
7

SS03M099 SD03M027

Position the wheel hub (9) on a flat surface and Remove the swivel housing (12) from the axle beam.
remove the seal ring (11) with a lever. Remove the belleville washers (23) and (25).
Remove the bearing cups (7) and (10) using a
hammer and a suitable driver. STEP 11
Remove the bearing cone (10) from the swivel housing
end (12).
STEP 9

SD03M028

Position the swivel housing (12) on a flat surface and

take the seal ring (21) out with a lever.
Turn the swivel housing and take out the bush (20),
SD03M026
using a suitable driver and a hammer.
Unscrew and remove the fastening screws (17) and
(15) from the upper (16) and lower (14) king pin.
:$51,1* Before removing the king pins (16) and
(14), secure the swivel housing (12) with a belt or a
rope to a hoist or any other supporting device;
observe all current safety regulations.
Remove the king pins (16) and (14).

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Assembly STEP 3
STEP 1
12

13

26
19 14

18

SD03M030

SC04F092 Assemble the cone (13) of the spherical joint to the

lower king pin (14) using an appropriate driver under a
If it has been previously removed, reassemble the
press.
steering stop composed by the screw (19), nut (18)
Carefully grease the seats of king pins (14) and (16)
and the bush (26).
with AGIP MU/EP2.
Apply Loctite 638 on the bush (26).
Position the belleville washers (23) and (25) on the
127( Do not tighten the nut (18) until the steering king pin seats.
angle adjustment has been implemented.
STEP 4
STEP 2

SD03M027
SD03M029
:$51,1* Secure the swivel housing (12) with a
belt or a rope to a hoist or any other supporting
device.
Protect the splined end of the axle shaft by winding it
with an adhesive tape to avoid damage to the seal ring
(21).
Assemble the swivel housing (12) on the axle beam.
127( Completely remove the adhesive tape.

SS04G056

Force the bush (20) into the swivel housing (12) with
the special tool 380000024 and a hammer or a press.
Assemble the seal ring (21) on the swivel housing (12)
with the special tool 380000032 and a hammer.
Carefully grease the seal ring (21).

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 5005-35

STEP 5 STEP 7

SD03M031 SD03M033

Assemble the king pins, the lower (14) and the upper
(16), and tighten the retaining screws (15) and (17) to
the requested torque.
Tightening torque ........................................ 190 Nm
127( Ensure that the belleville washers (23) and
(25) remain in their position.
STEP 6
Assemble the bearing cone (10) on the swivel housing
(12) end.
Assemble the wheel hub (9) on the swivel housing (12)
and fit the bearing cone (7).
127( When fitting the wheel hub, moisten the inner
surface of the cartridge sealing ring with a mixture of
white spirits and water.
STEP 8

SD03M032

Force both bearing cups (7) and (10) to their wheel
hub (9) housings using an appropriate driver under a
press or with a hammer.
Insert the seal ring (11) into the wheel hub (9) with the
special tool 380000042 and a hammer.
127( Do not lubricate the seal ring (11).
SD03M023
Assemble the wheel carrier group (6) according to the
previous section.
Assemble the wheel carrier group on the wheel hub
using the two projecting bushes (5) as dowel pins and
screw the relative screws (4) in order to put in contact
the ring bevel gear with the wheel hub.

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5005-36

STEP 9 STEP 11

SD03M024 SD03M015

Force all the hub dowel bushes (5) completely with an Using a lever to push the double U-Joint in the
appropriate driver and a hammer. direction of the wheel hub to facilitate the insertion of
Apply locking fluid Loctite 270 on fastening screws (4) the lock ring (1).
thread.
STEP 12
Assemble the fastening screws (4) and tighten to the
requested torque.
Tightening torque ........................................230 Nm
STEP 10

C A C

SD03M016

B Slide the thrust washers (3) and (2) onto the double U-
Joint shaft end (22).
Insert the lock ring (1) at the end of the splined hub and
SD03M014 push it into its housing.
The special operation “Set Right” of the bearings (10) 127( Check that the lock ring (1) is correctly fitted
and (12) does not require preload or backlash in its seat.
adjustment. Anyway, before assembling new
components check the indicated dimensions.
A= 17.950 - 18.000 mm
B= 64.275 - 64.325 mm
C= 23.070 - 23.172 mm

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 5005-37

AXLE BEAM GROUP

1
2

4
5

6
3

SS03M102

Disassembly
127( Before disassembling the double U-joints remove the wheel hub group. (see page 31)
STEP 1 STEP 2

1
4

6
5

5
SD03M034 SS03M103

Remove the two double U-Joints (6) from the axle Remove the seal rings (5) from the axle beam (1).
beam (1). Remove the bush (4) from the axle beam (1) only if the
wear conditions require this.
,03257$17 Be careful not to damage the bush
housing.

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STEP 3 Assembly
STEP 1
2

3
SS03M104
3
Remove the upper king pin bush (2) and the ball SS03M105
bearing cup (3) from the king pin housings using a
Cool the upper king pin bush (2) and the ball bearing
suitable extractor only if the wear conditions require
cup (3) at a temperature lower than -100 °C with liquid
this.
nitrogen.
:$51,1*Wear safety gloves.
Assemble the upper king pin bush (2) on the axle
beam housing with an appropriate driver and a
hammer.
Assemble the ball bearing cup (3) on the axle beam
housing with an appropriate driver and a hammer.
STEP 2

1
4

5
SS03M106

Assemble the bush (4) on the axle beam (1) with the
driver 380000024 and a hammer.
Assemble the seal ring (5) on the axle beam with the
driver 380000702 and a hammer.
127( Carefully grease the seal rings with
Tecnolube POLYMERE 400.

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 5005-39

STEP 3

4 5

SS03M107

:$51,1*Assemble the seal ring (5) as illustrated.

STEP 4

SD03M035

Insert the double U-Joint (6) inside the axle beam (1).
:$51,1* Be careful not to damage the seal ring
(5).

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DIFFERENTIAL SUPPORT GROUP

14

8 9 12
7 11
6
10

2 4 13
3

SS04F083

Disassembly
127( Before dissasembling the differential support group remove the axle beam group. (see page 37)
STEP 1 STEP 2

9
14
8

2 1
SS04F084 SS04F093

Drain the oil completely from the differential. Loosen and remove the screws (9) to take out the two
Loosen and remove the screws (2) on the differential ring nut retainers (8).
support (1).
Remove the differential support (1) from the axle
housing (14).
:$51,1* Support the differential support with a
rope or other appropriate means.

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 5005-41

STEP 3 STEP 6

11 4
6
1

SS04F094 SS04F097

Before removing the bolts, mark both half-collars (11)
and the differential support with permanent reference
marks to avoid inverting them during re-assembly.
Mark the area between the ring nuts (3) and (7) and
the differential support (1) as well.
STEP 4
Remove the differential housing (5).
The bearing cups (4) and (6) are removed together
with the differential housing.
:$51,1* Do not invert the bearing cups if the
bearings are not replaced.

a1
SS04F095

Unscrew the adjuster ring nuts (3) and (7) using tool
380000406 (a1).
STEP 5
12

11

10

SS04F096

Remove the 4 screws (12) and remove both half-

collars (11).
127( Check that the bushes (10) remain in their
housings.

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5005-42

Assembly STEP 3
STEP 1 12

11
5

4
10

SS04F100

SS04F098 Move the differential group so to place the bevel crown

gear on the pinion.
Assemble the bearings cups (4, 6) on the differential
Check that all bushes (10) are in their housings and
group (5) with locking differential sleeve. (see page
position both half collars (11) on their seats using the
52)
previously traced reference marks.
:$51,1* Do not invert the bearing cups if the Lock both collars with their fastening bolts (12).
bearings are not replaced.
STEP 4
STEP 2

SS04F099
Position the complete differential group with bearings
on the differential carrier (1). At the same time insert
the differential locking fork in the sleeve.
:$51,1* Check the right side of the bevel crown
assembly.
a1
SS04F095
Assemble the adjuster ring nuts (3) and (7) to the
differential support.
Tighten both ring nuts (3) and (7) with special tools
380000406 (a1), till the backlash is eliminated and the
differential bearings are slightly preloaded.
Check that the differential bearings are well settled. If
necessary, knock slightly with a soft hammer, in order
to properly set the bearings in position.

Sva 6-51550 EN Edition 07-2004


STEP 5
SS04F128
Position a magnetic-base dial gauge on the differential
support, so that the feeler stylus touches the surface
of one tooth of the crown gear with a 90° angle.
STEP 6
SS03M119
Lock the pinion and move the crown gear alternatively
and note the pinion-ring gear backlash, measured with
the comparator.
Repeat the operation on 2 or more points (teeth),
rotating the crown gear, so that to obtain an average
value.
Check if the measured backlash value is within the
requested range:
0.17÷ 0.24 mm
Set the bevel gear backlash by turning adjusting rings
(3) and (7) with the appropriate tool 380000406.
Sva 6-51550 EN
5005-43
STEP 7
A A
B B
SS04F130
Adjust the ring nuts (3) and (7), remembering that:
(A)- if the measured backlash is greater than the
given tolerance range, unscrew the adjuster ring nut
(7) and screw in the adjuster ring nut (3) by the same
measure.
(B)- if the measured backlash is less than the given
tolerance range, unscrew the adjuster ring nut (3) and
screw in the adjuster ring nut (7) by the same
measure.
STEP 8
SS04F128
Once the adjustment of the pinion-ring gear backlash
has been carried out, check also that there is a
minimum preloading on the differential box bearings.
Repeat the whole sequence of the above mentioned
operations until the indicated conditions are reached.
Edition 07-2004
5005-44

STEP 9 STEP 11

SS04F131 SS04F032

Once the pinion-ring gear backlash has been Once all the adjustment operations have been
established, measure the total preloading (T) of the completed, fit the ring nut locks (8) and their screws
bearings (pinion-crown bevel gear system), using a (9), tightening them to the requested torque.
dynamometer whose cord is wound on the pinion Tightening torque ......................................... 13 Nm.
splined end. The measured value should be within the
following range: STEP 12
T= 92(+40) ÷ 137(+60) N
(T=preloading pinion + bevel gear)
:$51,1* All preloadings must be measured
without seal ring (pinion).
STEP 10

A A

SS04F133

Tighten the bolts (12) of both half collars (10) to the

B B
requested torque.
Tightening torque ....................................... 266 Nm.

SS04F130

If the measurement is not within the requested range,

check well the assembly of each component and
operate on the adjuster ring nuts (3) and (7) of the
differential support:
(A)- if the total preloading is less than the given
range, screw in both adjuster ring nuts (3) and (7) by
the same measure, keeping the pinion-ring gear
backlash value unchanged;
(B)- if the total preloading is greater than the given
range, unscrew both adjuster ring nuts (3) and (7) by
the same measure, keeping the pinion-ring gear
backlash value unchanged.

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 5005-45

STEP 13 Bevel gear marking test

STEP 1

14
13

13
SS04F134

Before matching surfaces, make sure that they are SS03M125

perfectly clean, degrease and clean them with
To test the marks of the bevel gear teeth, paint the ring
appropriate detergents.
gear with red lead paint.
Spread a film of adhesive (Loctite 510) on the contact
surface between the axle beam (14) and the The marking test should be always carried out on the
differential carrier (1). ring bevel gear teeth and on both sides.

127( Check the correct seat of the two dowel pins STEP 2
(13) in their housing.
STEP 14

14

SS03M126

1 OK -> Correct contact:

2
SS04F084 If the bevel gear is well adjusted, the mark on the teeth
surfaces will be regular.
Position the differential support (1) on the axle housing
(14), and tighten the retaining screws (2) to the
Z -> Excessive contact on the tooth tip:
requested torque.
Approach the pinion to the ring bevel gear and then
Tightening torque ........................................ 169 Nm
move the ring bevel gear away from the pinion in order
127( Top up the oil. to adjust the backlash.

X -> Excessive contact at the tooth base:

Move the pinion away from the ring bevel gear and
then approach the ring bevel gear to the pinion in order
to adjust the backlash.

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STEP 3

SS03M127

Movements to correct:
1 -> move the pinion for type X contact adjustment.
2 -> move the pinion for type Z contact adjustment.

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 5005-47

DIFFERENTIAL LOCKING GROUP

14

16 12

10
8
15
13
11 6

9
4

2
1

SS03M128

Disassembly
127( Before disassembling the differetial locking group remove the differential housing. (see page 40)
STEP 1 STEP 2

15
9
16
10

11
12
13
14

SS03M129 SS03M130

Unscrew the bolt (16) and remove the cylinder support
(15).
Collect the piston (13) and the O-rings (14) and (12).
Remove the lock ring (11) keeping the bush (10) that
is pushed out by the spring (9).
:$51,1* Possible ejection of the bush (10) and
spring (9).
Remove the bush and the spring from the control shaft
(3).

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STEP 3 Assembly
STEP 1
2 1

4
5 8
6

SS03M131

Remove the bolt (1) and the cover (2) keeping the
bush (4) that is pushed out by the spring (5).
:$51,1* Possible ejection of the bush (4) and
spring (5).
Remove the bush, the spring and spacer (6) from the
control shaft (3).
STEP 4
SS03M133
Place the differential support on a workbench.
Assemble the lock ring (11) in the housing at the end
of the control shaft (3).
Insert the spacer (10) and the spring (9) on the control
shaft (3).
Insert the shaft in the differential support and in the
fork (8), paying attention to the illustrated position for
each element.
STEP 2

15
16

12
SS03M132
13
Remove off the control shaft (3), collecting the lock 14
ring (7) that is still in the housing on the shaft and
remove the fork (8). SS03M134

Insert the piston (13) with new O-rings (14) and (12) at
the ends of the shaft and assembly the support (15),
screwing the relative fastening screws to the
requested torque.
Tightening torque ....................................... 27.6 Nm

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 5005-49

STEP 3

SS03M135

Insert the lock ring (7) on the control shaft (3) from the
fork side by pushing it in the housing with a pipe of
suited dimension.
Insert the spacer (6), the spring (5) and the bush (4) on
the control shaft.
Apply sealant (Loctite 518) on the cover (2).
Assembly the cover (2), pushing the spring (5), with
the fastening screws (1).
:$51,1* Possible ejection of the bush and the
spring.

Tighten the screws to the requested torque.

Tightening torque ....................................... 27.6 Nm

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5005-50

DIFFERENTIAL GROUP

11

13
9

12
1
10 5

2 7
5

6
4

SS04F085

Disassembly
127( Before disassembling the differential group remove the differential housing. (see page 40)
STEP 1 STEP 2

1
13

12

11

SD03M036 SD03M037

Remove the differential group from differential
support.
Remove the sleeve (13) and the pins (11) from the
differential housing (12).
Unscrew the fastening screws (1) and remove the
bevel gear crown (3).
127( This will make both differential half boxes (4)
and (12) free, so take care not to drop the internal
components.

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 5005-51

STEP 3 Assembly
STEP 1

4
12

SS04F086

Disassemble the differential box in two half boxes (4) SD03M038

and (12) complete with the relative components.
Heat the bearing cones (2) at 80 °C than assemble the
127( Mark the two half boxes before disjoining bearing cones on the half boxes (3) and (10).
them, in order to reassemble them in the same
position as the one before disassembling. STEP 2
Disassemble all the components.
Check the operating and wear conditions of the
components.
STEP 4
4
2 4
12

SS04F086

Position a half housing (4) on a workbench and

assemble all inner components (locking differential
counterdiscs (5), sun gears (9 and 10), spiders (8),
12 2
spider gears (7), thrust washers (6)), as shown in
SS04F087 figure.
Join the two half boxes, aligning the reference marks
Take the bearings (3) out of the half boxes (4) and
made during disassembly.
(12), using two levers or a three-hold extractor.

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5005-52

STEP 3 STEP 5

SD03M039 SD03M014

Before matching surfaces, make sure that they are $VVHPEOHWKHVOHHYHRQWKHGLIIHUHQWLDOKRXVLQJ
perfectly clean, degrease and clean them with 
appropriate detergents.
,03257$17 Take care to assemble it in the correct
Place the bevel gear (3) on the differential housing. position.
Apply locking fluid (Loctite 270) on the threads and
tighten the bolts (1) to the requested torque.
Tightening torque ..........................................95 Nm
STEP 4

SD03M040

Assemble the pins (11) into their seats.

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 5005-53

PINION GROUP

2
3

7
4
5
6

9
10

SS03M139

Disassembly
127( Before disassembling the pinion group remove the differential housing. (see page 40)
STEP 1 STEP 2

9
10

SS03M140 SS03M141

Fit the differential carrier in a vise. Remove the lock nut (10) and collect its retaining
Unscrew the lock nut (10) using special tools washer (9).
380000021 and 380000020.
127( This operation will irretrievably damage the
lock nut (10).

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5005-54

STEP 3 STEP 5
8

5 2

1
6
4
SS03M142 SS03M144

Tap the shaft with a soft hammer to remove the bevel To remove the bearing cone (3) of the bevel pinion (1),
pinion (1). use a standard extractor.
127( Take care not to drop the bevel pinion (1). Remove the the leveling shim (2).

Collect the washers (4) and (6), the collapsible spacer STEP 6
(5) and the bearing cone (8).
STEP 4
5

10

8
SS03M143
Place the differential carrier (7) on a flat surface and
remove the bearing cups (3) and (8) using an
appropriate driver and a hammer.
SS03M181
Check all pinion components for wear.
,03257$17 The lock nut (10) and the collapsible
spacer (5) must be replaced when reassembling the
unit.

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 5005-55

Assembly and fix it with the clamping device 380000018.

STEP 1 , 0 3 2 5 7$ 1 7 T i g h t e n u n t i l t h e b a c k l a s h i s
eliminated.
The bearings must be rotatable by hand.

3 STEP 4

7
7

SS03M143

Place the differential support (7) on a workbench.

Fit the bearing cups (3) and (8) using an appropriate
SS03M184
driver and a hammer.
STEP 2 Insert measuring shim 380000440 with the measuring
shaft 380000439 in the housing. Adjust the flat surface
of the measuring shaft parallel to the pinion bearing.
Mount the bearing covers and fasten them with
screws.
STEP 5

X
SS04G058

Prepare the special tools for determination of the

leveling shim S:
Measuring shim 380000440
Measuring shaft 380000439
SS04G059
Clamping device - pinionbearing 380000018
Commercial depth gauge Insert the feeler of the depth gauge through the cut of
the measuring shaft until it attaches the bearing.
STEP 3 Read and note distance X.

SS04G057

Insert the bearing cones (3) and (8) in their housing

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5005-56

STEP 6 STEP 9
3 6
5
4

1 1

SS03M186 SS03M188

In order to determine the necessary thickness value
(S) between the pinion and the bearing, subtract the
value (V), stamped on the pinion head (V=requested
conical distance), from the measured value (X).
S = X - V mm
STEP 7
Insert the chosen shim (2) with the chamfer against
the gear onto the pinion shaft (1).
Heat the inner bearing ring to 90 °C and attache it on
the pinion.
Insert the shims (4) and (6) and a new collapsible
spacer (5).
,03257$17 Always use a new collapsible spacer
(5).
STEP 10

SS03M187

Select the shim (2) of thickness value (S) among the 7

range of available shims.
SD03M014

SHIMS RANGE Assemble the bevel pinion (1) unit into the differential
support housing (7) and the bearing cone (8).
Thickness 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
mm Use an appropriate driver to drive the bearing (8).

Quantity -- -- -- -- -- -- -- -- -- --

STEP 8
Remove the measuring tool from the differential
housing (7).

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 5005-57

STEP 11 STEP 13
7

9
10

SS03M141 SS03M121

Insert the ring nut washer (9) and screw a new lock
ring nut (10) on the pinion end.
STEP 12
Carry out the preloading measurement P of the pinion
taper roller bearings (3) and (8) by using a
dynamometer.
The adjustment is carried out by increasing the lock
nut (10) torque gradually, being careful not to exceed.
,03257$17 All preloadings must be measured
without the seal ring.
P=92 ÷ 137 N
STEP 14

SD03M014

Screw in the lock nut (10), using the special tools

380000021 and 380000020.
, 03 2 5 7$1 7 T he to r qu e s e tt i ng is g i ve n b y
preloading the bearings (3) and (8); tighten the lock
SS01M015
nut (10) gradually.
Once the requested preloading value is achieved,
127( If the tightening is excessive, the collapsible
secure the lock nut (10), using a suitable punch.
spacer (5) must be replaced and the procedure
repeated. When you check the preloading, it is
advisable to beat slightly both pinion ends (1) with a
soft hammer, so as to help setting the bearings (3)
and (8).

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5005-58

TRACK ALIGNMENT

Ä$³
'ULYLQJGLUHFWLRQ

Ä%³

SS03M274

127( Before aligning the track, check the tyre air pressure (see Operating Manual).
STEP 1 STEP 5
Make marks on the rear inside of the wheel rim (rim
flange), at the same height as the centre of the wheel Z
hub.
127( The front wheels must face straight ahead. Z
STEP 2
Measure the distance B between these marks and X
make a note of it.
STEP 3
Drive the tractor forwards until the marks at the front
are level with the centre of the wheel hub. X
STEP 4 SS03M275
Measure the distance (A) between these marks and
make a note of it. The track must be adjusted so that Loosen the locking nuts (X). Extend or shorten the
value A is 0 to 2 mm smaller than value B. track rods by turning the knuckle joints (Z). Repeat
toe-in ........................................................0 to +2 mm STEP 1 to STEP 4.
When the track has been aligned correctly, tighten the
127( If the value determined is outside the
locking nuts (X).
prescribed setting, the track alignment must be
corrected in accordance with 67(3 Tightening torque ........................................ 250 Nm

Sva 6-51550 EN Edition 07-2004

 5006
Chapter
5006
Independently Suspended
Front Axle
20.25S and 20.25SI FR

CNH Österreich GmbH Sva 6-51600 EN © 2005 CNH Österreich GmbH

Technical Documentation March, 2005
A - 4300 St. Valentin, Steyrer Straße 32
 5006-3

TABLE OF CONTENTS

SPECIAL TOOLS ........................................................................................................................................................5

GENERAL INFORMATION .........................................................................................................................................7

Using the Manual ..............................................................................................................................................7
General Instructions for Disassembly and Assembly .......................................................................................8
Type plate .........................................................................................................................................................9

TECHNICAL DATA ...................................................................................................................................................10

Sealant and Locking Fluid ..............................................................................................................................11
Tightening Torques .........................................................................................................................................12
Dimensions 20.25 S ........................................................................................................................................13
Dimensions 20.25 SI FR .................................................................................................................................14

GENERAL NOTES ....................................................................................................................................................15

PLANETARY DRIVE .................................................................................................................................................15

Removing and Fitting ......................................................................................................................................15
Disassembly/Re-assembly .............................................................................................................................16

BRAKE ......................................................................................................................................................................17
Disassembly ...................................................................................................................................................17
Assembly ........................................................................................................................................................20
Bleeding the brakes ........................................................................................................................................22

WHEEL HUB .............................................................................................................................................................23

Disassembly/Re-assembly .............................................................................................................................23

SECTIONAL DRAWING THROUGH THE PLANETARY GEAR AND WHEEL HUB ...............................................25

PIVOT BEARING HOUSING ....................................................................................................................................26

Removing and Fitting ......................................................................................................................................26

KING PIN HOUSING .................................................................................................................................................28

Removing and Fitting ......................................................................................................................................28
Disassembly ...................................................................................................................................................32
Assembly ........................................................................................................................................................34

SECTIONAL DRAWING, THROUGH THE PIVOT BEARING HOUSING AND THE KING PIN HOUSING .............36

DRIVE SHAFTS ........................................................................................................................................................37

Disassembly/Re-assembly .............................................................................................................................37

4-WHEEL DRIVE AXLE ............................................................................................................................................38

Removing and Fitting ......................................................................................................................................38

PIVOTED BEARING .................................................................................................................................................41

Disassembly/Re-assembly .............................................................................................................................41
Fitting Instructions for the PIVOTED BEARING .............................................................................................41

SWINGING ARMS ....................................................................................................................................................42

Disassembly ...................................................................................................................................................42
Assembly ........................................................................................................................................................44
Adjusting the Torsion Bars ..............................................................................................................................48

AXLE HOUSING .......................................................................................................................................................51

Disassembly ...................................................................................................................................................51

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5006-4
DIFFERENTIAL UNIT .............................................................................................................................................. 56
Disassembly ................................................................................................................................................... 56
Assembly ....................................................................................................................................................... 56
Adjusting the Pinion Shaft .............................................................................................................................. 58
Pinion Shaft Unit ............................................................................................................................................ 60
Fitting the Differential Unit .............................................................................................................................. 62
Adjusting the Crown Wheel Tooth Flank Play ................................................................................................ 64
Adjusting the Differential Bearing Pre-Tension .............................................................................................. 65

TRACK ALIGNMENT ............................................................................................................................................... 67

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 5006-5

SPECIAL TOOLS
DIFFERENTIAL ADJUSTMENT TOOLS AXLE SUSPENSION TOOLS

11 12 13
3 1
5

14
2
DD99K234 DD99K237
1. GAUGING TUBE 380001925 (CAS1839/1) 11. SLEEVE FITTING TOOL 380000027 (CAS2717)
2. ALIGNMENT ADAPTER 380001919 (CAS2489-4) 12. SLEEVE FITTING TOOL 380001922 (CAS2718)
3. GRIP 380002420 (CAS1596A-4) 13. SLEEVE FITTING TOOL 380000029 (CAS2719)
4. BOLT 380002421 (CAS1596A-7) 14. GRIP 380001920 (CAS2555)
5. MEASUREMENT CYLINDER 380001918 (CAS2489-2)
TOOLS FOR PIVOT BEARING HOUSING AND AXLE PIVOT BOLT
DIFFERENTIAL HOUSING TOOLS
18 16
6

17
15
7 8 SS00B036
SD00B035 15. GRIP 380000506 (CAS1924)
6. PINION NUT WRENCH 380000021 (CAS1885A) 16. FITTING TOOL, CARTRIDGE SEALING RING
7. DOLLY 380000020 (CAS2483) 380000042 (1TSW549)
8. WRENCH AND FITTING TOOL 380000037 (CAS2714) 17. SLEEVE FITTING TOOL 380001921 (CAS2716)
18. FITTING TOOL, SLEEVE 380000024 (CAS2723)
FITTING TOOL, SEALING RING 380000032 (CAS2723)
KINGPIN HOUSING TOOLS

10

DD99K236
9. WRENCH 380000038 (CAS2713)
10. FITTING TOOL, CARTRIDGE SEALING RING
380000025 (CAS2720)

Sva 6-51600 EN Edition 03-2005

5006-6

EMTY PAGE

Sva 6-51600 EN Edition 03-2005

 5006-7

GENERAL INFORMATION
Using the Manual
Maintenance
• Trouble-free operation of the mechanical components is influenced by regular and correct maintenance.
• The use of qualified personnel during maintenance and repairs guarantees a longer lifetime of the components
and trouble-free operation.
• READ THE MANUAL. Non-observance of recommended worksteps can reduce the lifetime and the durability of
the unit and can result in damage or accidents.

Repairs
The instructions for removal and fitting were drawn up for an overall repair of the axle and constitute the correct order
of the tasks to be performed. Drawings and photos provide personnel with a complete and safe guide through all
worksteps.
A good knowledge of the axle makes it possible to assess the repair, and as a result, it is often the case that only
certain parts have to be removed.

Property Rights of the Information

This repair manual contains confidential information. All rights remain reserved.
No part of this manual may be re-printed or copied without written permission from CNH Österreich GmbH. The
manufacturer assumes no liability for direct or indirect damages to persons, objects or animals as a result of incorrect
use of this manual.

Diagrams
Photos and drawings are NOT to exact scale.
Photos are only intended to clarify the sequence of worksteps.

Definition of the Driving Direction

Specifications such as "left side" or "right side" must always be seen from the driver's seat in the FORWARDS driving
direction of the vehicle.

General Remarks
• The axle should only be repaired by qualified personnel, who are aquainted with all of its technical
characteristics, and under exact observance of the corresponding safety standards.
• The axle must be carefully cleaned before carrying out a repair. Dirt and/or grease must be removed.
• Put the tractor on firm, level ground, apply the parking brake and fully lower the front axle onto its lowest
mechanical limit (if necessary, open the discharge valve at the hydraulic control unit – refer to Chapter 5001).
Switch the engine OFF and remove the ignition key.
• All disassembled parts must be cleaned using a suitable cleaning agent to avoid possible damage.
• Damaged or worn parts must be replaced to avoid possible subsequent damage. In particular, motion and
sealing elements must be checked if they are subject to larger amounts of stress, wear and ageing.
• The renewal of the bevel pinion or differential master gear necessitates the renewal of the entire set.
• Only use original spare parts

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5006-8

General Instructions for Disassembly and Assembly

IMPORTANT: Before commencing removal or fitting, read the following instructions carefully:

Shaft sealing rings

• Check the running surfaces of sealing rings for scoring and their surface condition.
• Check sealing rings for damage, tears or scratches.
• Insert shaft sealing rings so that the sealing lip is in the direction of the inner side of the housing (oil side).
Exception: another mounting position has been specified.
• Lubricate the sealing lips with oil and fill the ring cavity 3/4 full with grease.
• During assembly, use a suitable insertion tool and, when so stipulated, special tools.
• If necessary, protect sealing rings by push sliplocks during assembly (special tool).

Cartridge sealing rings

• Only fit using special tools.
• When fitting, moisten the rubberized inner surface of the cartridge sealing ring with a mixture of white spirits and
water.

‘O’ rings
Grease before installing.

Shims
Always individually measure the shims used.

Bearings
We advise that you warm up the bearing inner rings to 80 °C - 90 °C before assembly. Bearing outer rings should be
cooled down before assembly.
Always use suitable extractors when removing bearings. Always use suitable insertion tools when inserting bearings.

Sprung dowel pins

Always insert sprung dowel pins with the slit in the direction of the load.

Sealant and Locking Fluid

Only use prescribed sealant and locking fluid (see page 11). Before re-assembling, all parts must be clean, dry and
free of grease.

Draining oil
The oil must be drained before removing the planetary train and/or the axle housing.
WARNING: Dispose of old oil according to statutory regulations.

Cleaning
• All moving parts (bearing, gear wheels, shafts) must be cleaned carefully.
• Petrol, water or alkaline solutions should not be used. Do not use steam or hot water as it is difficult to remove
surface dampness.
• Clean all components using an air jet or a cloth to free the surfaces from any remains.
• All surfaces should be covered by a thin layer of oil to protect them from oxidation.

Using lubricants
Only use lubricants which meet the stipulated specifications (see Technical Data, page 10).

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 5006-9

Type plate
AXLE TYPE CUSTOMER NUMBER CARRARO SERIAL NUMBER

OVERALL RATIO
CARRARO NUMBER

TYPE OF
DIFFERENTIAL LOCK

DIFFERENTIAL
DIRECTION OF OIL QUANTITY
ROTATION OF
DRIVE SHAFT

RECOMMENDED
DIFFERENTIAL OIL

RECOMMENDED PLANETARY GEAR OIL PLANETARY GEAR OIL QUANTITY

SC04M056

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TECHNICAL DATA
DIFFERENTIAL
Number of teeth – pinion shaft / diff. Master gear ...................................................................................... 14 / 32
Differential transmission ratio .................................................................................................................. 2.286 / 1
Pinion shaft initial bearing tension (measured at the pinion shaft Ø = 34.8 mm) ............................... 92 to 137 N
Pinion Bearing and Differential
Total initial bearing tension (measured at the pinion shaft Ø = 34.8 mm) ......................................... 112 to 167 N
Differential master gear tooth flank play ..................................................................................... 0.18 to 0.23 mm
Compensating washer thickness for pinion height ............................... at least 2.5 mm to a maximum of 3.4 mm

PLANETARY DRIVE
Planetary drive transmission ratio ........................................................................................................... 6.923 / 1
Total transmission ratio (differential + planetary drive) .......................................................................... 15.824 / 1

STEERING
Steering lock ................................................................................................................................................... 50°

DIFFERENTIAL LOCK
Type ....................................................................................................................................... 100% elliptical lock
Differential operating pressure .................................................................................................................... 20 bar

WHEEL ALIGNMENT
Axle in mid-position .................................................................................................................................... 0±3 mm

LUBRICANTS / TYPES OF OIL

Grease ........................................................................................................................................ Polymer 400/L
Types of oil
Differential...................................................................................................SAE 80W-90 gearbox oil (API GL5)
Planetary drive without brake ....................................................................SAE 80W-90 gearbox oil (API GL5)
Planetary drive with brake.................................................... SAE 10W-30 UTTO multi-purpose oils (API GL4)

FILLING LEVELS
Differential..............................................................................................................................................2,2 litres
Planetary drive without brake (each side) ............................................................................................1,5 litres
Planetary drive with brake (each side) ..................................................................................................2,0 litres

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Sealant and Locking Fluid

270 542

542 510 542 270

542

510
542

542
510

270

= Loctite
SS04M021

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Tightening Torques

SS04M022

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Dimensions 20.25 S

SS04M025

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Dimensions 20.25 SI FR

SS04M020

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GENERAL NOTES
NOTE: The all-wheel drive axle must not be removed for work on the following components:
• Planetary drive, see page 15.
• Brake,see page 17
• Wheel hub, see page 23.
• Pivot bearing housing, see page 26.
• King pin housing, see page 28.
• Drive shafts, see page 37.

PLANETARY DRIVE

Removing and Fitting

NOTE: The parts are numbered in order of removal. Re-fit parts in the same manner but in the reverse order.
The following points must be observed prior to removing the planetary gear unit:
• Put the tractor on firm, level ground, apply the parking brake and fully lower the front axle onto its lowest
mechanical limit. Switch the motor OFF and remove the ignition key.
• Place chocks in front of and behind the rear wheels.
• Loosen the front wheel nuts. Place a jack under the centre of the front axle, raise the tractor and lower it
onto suitable front axle support trestles. Remove the front wheels.
NOTE: When re-fitting the front wheels, tighten the nuts to a torque of 570 Nm.

STEP 1 STEP 2

1
2
2

SD00B029 SD00B029

Turn the drain/level plug (1) to point downwards. Place
a container, with a minimum capacity of 2 litres, under
the wheel hub.
Remove the drain/level plug (1) and remove the ‘O’
ring. Drain the oil.
NOTE: When re-assembling, turn the wheel hub so
that the drain/level plug (1) is positioned horizontally to
the centre of the axle. Fill the wheel hub with the cor-
rect type of oil, to the prescribed level, refer to the
”Technical Data” on page 10. Replace the drain/level
plug (1) with ‘O’ ring and tighten it to a torque of
80 Nm.
Remove the two countersunk screws (2).
NOTE: When re-fitting the screws (2), tighten them to
a torque of 25 Nm.
STEP 3
Tap the planetary gear carrier surface (3) with a soft-
faced hammer and remove the planetary gear carrier.
Remove the ‘O’ ring and dispose of it.
NOTE: Use a new ‘O’ ring when re-assembling.
NOTE: Re-fit parts in the same manner but in the
reverse order.

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Disassembly/Re-assembly
NOTE: The parts are numbered in order of disassembly. Re-assembly is carried out in reverse order to
disassembly.

Tightening torque = 79 Nm
5 4
6
7
1
2
3

DS99D050

1. SECURING BOLT 5. PLANETARY GEAR

2. WASHER 6. NEEDLE BEARING
3. THRUST WASHER 7. THRUST WASHER
4. SECURING PIN

STEP 4 STEP 6
Make alignment markings on the planetary gears (5) Clean all component parts in a cleaning solvent and dry
and the shaft. with compressed air. A protective face mask MUST be
worn when doing this. Check all component parts for
STEP 5 wear or damage and replace as necessary.

Remove the securing bolt (1), the washer (2), the thrust NOTE: Re-assemble parts in the same manner but in
washer (3) and the securing pin (4). Remove the the reverse order.
planetary gear (5), the needle bearing (6) and the thrust
washer (7). Repeat the procedure for the remainder of
the planetary gears.
NOTE: When re-assembling, ensure that there are 28
needle rollers per planetary gear (5). Hold the needle
rollers in place with grease (NL GI 2).
NOTE: When re-fitting the securing bolt (1), tighten it
to a torque of 79 Nm.

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BRAKE
HINWEIS: Before disassembling the brake, the planetary gear unit must be removed (see page 15)

Disassembly

STEP 1 STEP 4

13

SD04M001
SD04M004

Remove the circlip (1).

Disconnect the support frame carrier (13) using the
STEP 2 three screws (M10x60) and then remove it.
3 NOTE: When removing using the screws, burrs may
occur at the kingpin housing. Remove the burrs using
filers.
STEP 5

16

SD04M002 20
Remove the pressure plate (2) and the lining disk (3).
STEP 3
SD02A010

Remove the ’O’ rings (20). Remove the centre pins (16)
using a mandrel.
8

SD04M003

Remove all securing bolts (8) from the support frame

carrier.

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STEP 6 STEP 9
21 12

SD02A011 SD02A014

Remove the circlip (21). Remove the circlip (12) and the pressure plate (5).

STEP 7 STEP 10

18 22

SD02A016
SD02A012

Remove the piston (6) from the support frame carrier.

Loosen the securing screws (18 and 22). Remove the
washers, springs and sleeves. NOTE: To dismount the piston, mount two screws
(M4) into the existing thread. Using a levering tool and
NOTE: Mark the position of the support frame carrier
a suitable surface, press out the piston evenly.
to the pressure plate.
STEP 8

13

SD02A013

Remove the support frame carrier (13).

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STEP 11 STEP 12
7 24
9

10

11

SD02A015
Remove the sealing rings (9 and 11) and the support
rings (7 and 10) from the inside and outside piston
seal. Check the piston for damage and replace as re-
quired. Replace the sealing rings support rings.
SD02A017
Remove the clamping sleeve for automatic brake
adjustment (24).
NOTE: Check the sealing surface of the ring-shaped
brake cylinder in the support frame carrier for scoring
and wear and replace the support frame carrier if
necessary.

5
4

3
18
19
17
2 15
20
14
1

13 21

12
22
11
10
9
7
6

23
24
25

16

SS04M023

1. CIRCLIP 8. SCREW 14. SPRING 20. ’O’ RING

2. PRESSURE PLATE 9. SEALING RING 15. SLEEVE 21. CIRCLIP
3. BRAKE DISC 10. SUPPORT RING 16. SLEEVE 22. SCREW
4. INTERNAL GEARED WHEEL 11. SEALING RING 17. WASHER 23. WASHER
5. PRESSURE PLATE 12. CIRCLIP 18. SCREW 24. CLAMPING SLEEVE
6. PISTON 13. SUPPORT FRAME 19. RIVET 25. SLEEVE
7. SUPPORT RING CARRIER

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Assembly
STEP 1 STEP 4

SD01M129 SD02A020

Prefit the centring bushes in the ring gear carrier. Lea- Oil the piston sealing ring (6). Press the piston manu-
ve two bushes on opposite sides protruding slightly for ally and parallel into the support frame carrier (cylin-
subsequent assembly. der) until the sealing rings are slipped on. Then press
the piston fully in using a suitable assembly tool.
STEP 2
STEP 5
24 24
5

24

SD02A019

Mount the clamping sleeves (24) into the support

frame carrier with the bevel towards the brake disc.
SD02A021
NOTE: The clamping sleeves must be mounted flush
to the support frame carrier. Mount the pressure plate (5) onto the internal geared
wheel. Fit the circlip (12).
STEP 3
IMPORTANT: Fit the pressure plate with the free
7 location pointing towards the support frame carrier.

10

11

SD02A015

Fit new support rings (7 and 10) and sealing rings

(9 and 11) for the inside and outside piston seals.
NOTE: Observe the correct mounting position!
Mount the support rings facing towards the brake
disc.

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STEP 6 STEP 8
13

21
20

SD02A022
SD02A010
Align the support frame carrier (13) to the pressure pla-
te and mount onto the internal geared wheel. Fit the Grease the new ’O’ rings (20) and insert into the
circlip (21). support frame carrier.

STEP 7 IMPORTANT: Only use original ’O’ rings.

STEP 9
24 18

SD01M133

Fit the ring gear carrier on the knuckle housing and use
SD02A023
two screws to screw down onto the bushes protruding
Insert the springs (14) and sleeves (15) into the support inwards.
frame carrier. Mount the pressure plate (5) onto the STEP 10
support frame carrier using fixing screws (18) and
washers (17).
Tightening torque .......................................... 10 Nm
Insert the remaining three sleeves (25) into the holes
with the clamping sleeves (24). Insert the fixing screws
(22) with the washers (23) and tighten them.
Tightening torque .......................................... 10 Nm
SD01M134

Use an appropriate device to drive in all the other cent-

ring bushes. Then screw in and tighten all screws.
Tightening torque ........................................220 Nm

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STEP11 Bleeding the brakes

SS04M024
NOTE: If the lining disk (3) only is to be replaced, then
the piston (6) together with the pressure plate (5) must
be returned to the initial position. (Use a suitable drift.)
STEP 12
3
IMPORTANT: Before bleeding the brake, the front
wheels must be mounted and the wheel nuts must be
tightened to 570 Nm.
1. Attac a tube to the bleed screw and bleed to an oil
collector.
2. Start the engine
3. Open the bleed screw. Actuate the brake until the
hydraulic oil escapes without bubbles.
4. Tighten the bleed screw.
5. Repeat the same procedure on the second side.
6. Check the brakes for tightness and the level of the
hydraulic oil.
7. Take the tractor for a test drive and test the brakes.

SD04M002

Mount the lining disk (3) and the pressure plate (2).
IMPORTANT: Fit the pressure plate with the free
location pointing towards the planetary gear.
STEP 13

SD04M001

Fit the circlip (1).

STEP 14
Mount the planetary gear unit. (see page 16)

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WHEEL HUB

Disassembly/Re-assembly
NOTE: The parts are numbered in order of disassembly. Re-assembly is carried out in reverse order to
disassembly.
The following work must be carried out prior to disassembling the wheel hub:
• Remove the planetary gear unit, refer to page 15.

STEP 1
Remove the securing bolts (8). Fit two of the securing
bolts to the threaded holes (A) in the crown gear
carrier (9). Tighten the bolts evenly to loosen the crown
ring carrier.
NOTE: When re-fitting the securing bolts (8), tighten
them to a torque of 220 Nm.

13
11 12

15

10

A 14

Tightening torque = 220 Nm

16
8
DS99D049

8. SECURING BOLT 13. CARTRIDGE SEALING RING

9. CROWN WHEEL CARRIER 14. CIRCLIP
10. OUTER BEARING 15. CROWN WHEEL
11. WHEEL HUB 16. SLEEVE
12. INNER BEARING A. THREADED HOLE

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STEP 2 STEP 4
Use a soft-faced hammer to loosen the wheel hub from 14
the bearings Remove the outer bearing (10), the wheel
hub (11) and the inner bearing (12).

STEP 3

15
13
DI99E120

Remove the inner circlip (14) and the crown wheel

carrier (9) from the crown wheel (15).
11
STEP 5
DP99F145
Check the bearings (10 and 12) and the sleeve (16) for
Remove the cartridge sealing ring (13) and dispose wear or damage and replace as necessary. Use a
of it. hydraulic press to remove the sleeve (16).
NOTE: Re-assemble parts in the same manner but in
13 the reverse order.
NOTE: When forcing in the bushes, leave two bushes
on opposite sides protruding slightly for subsequent
assembly.
NOTE: When fitting the wheel hub (11), moisten the
inner surface of the cartridge sealing ring with a
mixture of white spirits and water.

Alignment
Wheel hub alignment is based on extremely small
tolerances and does not therefore require adjustment.
DI99D052 Before fitting, check that components dimensions are
within tolerance. Parts which are out of tolerance must
be replaced.
380000042

SD00C015

NOTE: When re-assembling, fit a new cartridge

sealing ring (13), using special tool 380000042.

SS00B186

A = 17.950 - 18.000 mm
B = 64.275 - 64.325 mm
C = 23.070 - 23.172 mm

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SECTIONAL DRAWING THROUGH THE PLANETARY GEAR AND WHEEL

HUB

5
11
13

12
10
1
16
7 3
2

15
14
DI99E116

1. SECURING BOLT 9. CROWN WHEEL CARRIER

2. WASHER 10. OUTER BEARING
3. THRUST WASHER 11. WHEEL HUB
4. SECURING PIN 12. INNER BEARING
5. PLANETARY GEAR 13. CARTRIDGE SEALING RING
6. NEEDLE BEARING 14. CIRCLIP
7. THRUST WASHER 15. CROWN WHEEL
8. SECURING BOLT 16. SLEEVE

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PIVOT BEARING HOUSING

Removing and Fitting

NOTE: The parts are numbered in order of removal. Re-fit parts in the same manner but in the reverse order.
IMPORTANT: If the pivot bearing housing has to be removed to facilitate work on the drive shafts, it is not
necessary to also remove the planetary gear unit and wheel hub.
The following items must be carried out if work is to be carried out on the pivot bearing housing.
• Remove the planetary gear unit, refer to page 15.
• Remove the wheel hub, refer to page 23.

Tightening torque = 190 Nm

6
2
9
10
SEE NOTE 1

11 7
12

Tightening torque = 220 Nm 8

Tightening torque = 190 Nm 4

3
DS99D051

1. NUT 7. PIVOT BEARING HOUSING

2. BALL HEAD CONNECTION 8. DISK SPRING
3. SECURING BOLT 9. DISK SPRING
4. KING PIN 10. THRUST WASHER
5. SECURING BOLT 11. SHAFT SEALING RING
6. KING PIN 12. SLEEVE

*1) NOTE: Check the sleeves in the king pin housing for wear or damage. To carry out work on the sleeves, refer to
STEP 15 on page 30.

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 5006-27

STEP 1 STEP 6
Loosen the nut (1). Remove the ball head connection
(2) from the pivot bearing housing (7) using the appro- 11
priate tools.
NOTE: When reassembling, fit a new nut (1) and
tighten it to a torque of 220 Nm.

STEP 2
Remove the king pin securing bolt (3) and the king
pin (4).

STEP 3 12
SS05C421
If the planetary gear unit and wheel hub are still fitted,
support the pivot bearing housing (7) with suitable
lifting gear.

STEP 4
Remove the upper king pin securing bolt (5) and the
king pin (6).
NOTE: When reassembling, grease the king pins (4),
(6) with NL GI 2 grease. Tighten the king pin securing
bolts (3) and (5) to a torque of 190 Nm.

STEP 5
Remove the pivot bearing housing (7) from the king pin
housing. Remove the disk springs (8) and (9) and thrust DD99K189

washer (10). Mark the disk springs for reassembly. Remove the shaft sealing ring (11) from the pivot
bearing housing (7) and dispose of it. Check the sleeve
NOTE: When reassembling, fill the bearing bushes in
(12) for wear or damage and replace as necessary.
the king pin housing with grease (NL GI 2). Fit the
thrust washer (10) with the grooved side up. Fit the NOTE: When assembling, use a new bush (12) and a
disk springs (8) and (9) with the concave side towards new shaft seal (11). Insert bush (12) with tool
the king pin housing (7) (refer to page 36). 380000024. Then insert shaft seal (11) with tool
380000032. Ensure that the sealing lip faces the bush
NOTE: Re-fit parts in the same manner but in the
(12).
reverse order. If the planetary gear unit and the wheel
hub are still fitted, ensure that the teeth on the drive
shaft are seated correctly in the planetary gear unit.

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KING PIN HOUSING

Removing and Fitting

NOTE: The parts are numbered in order of removal. Re-fit parts in the same manner but in the reverse order.
Before the king pin housing can be removed, the following work must be carried out:
• Put the tractor on firm, level ground, apply the parking brake and use the auxiliary switch RAISE/LOWER to fully
lower the front axle to its lowest limit. Switch the motor OFF and remove the ignition key.
• Place chocks in front of and behind the rear wheels.

IMPORTANT: If work is only to be carried out on the differential, carry out STEP 1 and STEP 2. Then carry out
STEP 7 to STEP 14 to remove the planetary gear housing, the wheel hub, the pivot bearing housing and the king pin
housing as one unit.

IMPORTANT: For reassembly, the king pin housing must be fully reassembled before the torsion bars are adjusted,
refer to page 48.

STEP 1 STEP 3
Remove the lower king pin securing bolt (3) and the
king pin (6).

STEP 4
If the planetary gear unit and wheel hub are still fitted,
support the pivot bearing housing (7) with suitable lifting
gear.

SD00B030
Jack the front end of the tractor up and lower the centre
of the axle onto suitable support trestles. Do NOT place
the trestles under the swinging arms. Loosen the front
wheel nuts and remove the front wheels
NOTE: When re-fitting the front wheels, tighten the
nuts to a torque of 570 Nm.
STEP 2
Loosen the nut (1). Separate the ball head connection
using the appropriate tools. Remove the nut and the
ball head from the pivot bearing housing (7).
NOTE: When reassembling, fit a new nut (1) and
tighten it to a torque of 220 Nm.
STEP 5
Remove the upper king pin securing bolt (5) and the
king pin (6).
NOTE: When reassembling, grease the king pins (4),
(6) with NL GI 2 grease. Tighten the king pin securing
bolts (3) and (5) to a torque of 190 Nm.
STEP 6
Remove the pivot bearing housing (7) from the king pin
housing. Remove the disk springs (8) and (9) and thrust
washer (10). Mark the disk springs for reassembly.
NOTE: When reassembling, fill the bearing bushes in
the king pin housing with grease (NL GI 2). Fit the
thrust washer (10) with the grooved side up. Fit the
disk springs (8) and (9) with the concave side towards
the king pin housing (7) (refer to page 36).
NOTE: If the planetary gear unit and the wheel hub
are still fitted, ensure that the teeth on the drive shaft
are seated correctly in the planetary gear unit.

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Tightening torque = 190 Nm

2
6

9
10

Tightening torque = 220 Nm 7

8
Tightening torque = 190 Nm

4
3
DR99D058

1. NUT 6. KING PIN

2. BALL HEAD CONNECTION 7. PIVOT BEARING HOUSING
3. SECURING BOLT 8. DISK SPRING
4. KING PIN 9. DISK SPRING
5. SECURING BOLT 10. THRUST WASHER

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5006-30
STEP 7
Remove the securing bolts (11) and sleeves (12).
Loosen the lock nut (14) and turn the adjusting screw
(13) out as far as it will go. Remove the cover (15) and
the circlip (16).
STEP 8
If the planetary gear unit and wheel hub and the pivot
bearing housing are still fitted, support the pivot bearing
housing and wheel hub with suitable lifting gear.
STEP 9
Remove the cover (17) and the circlip (18) from the
housing (25). Remove the torsion bar (19) with housing
(20) and seal (21). Check the pin (22) for wear or
damage and replace as necessary.
STEP 10
Remove the securing bolts (23) and sleeves (24).
Screw the bolt (23) into the threaded hole in the
housing (25) and pull the housing off.
STEP 11
Make alignment markings on the bolt (28) and king pin
housing. Loosen the lock nut (26) and remove the
securing bolt (27). Remove the bolt (28) and pivot the
swinging arm (29) downwards. Remove the ’O’ ring
from the bolt (28) and dispose of it.
STEP 12
Make alignment markings on the bolt (33) and king pin
housing. Loosen the lock nut (31) and remove the
securing bolt (32). Remove the bolt (33) from the upper
swinging arm. Remove the ‘O’ ring (34) and dispose
of it.
NOTE: When re-assembling, fit new ‘O’ rings (30) and
(34) and apply grease (NL GI 2) to the bolts (28) and
(33). Ensure that the markings on the bolts are aligned
to those on the housing. Tighten the securing bolts
(27) and (32) to a torque of 135 Nm. Tighten the lock
nuts (26) and (31) to a torque of 70 Nm.
STEP 13
Remove the king pin housing from the axle. When
disassembling, the hydraulic cylinder piston will come
completely out of the cylinder. Catch the piston and
inner drive shaft when disassembling.
NOTE: When reassembling, ensure that the hydraulic
piston is inserted into the cylinder correctly. Ensure
that the teeth on the inner drive shaft mesh correctly
with the differential.
Sva 6-51600 EN
STEP 14
Remove the shaft (35) and remove the swinging arm
(29) from the axle. Remove the ‘O’ rings (36) from the
axle housing and dispose of them. Remove the sealing
rings (37) and dispose of them (when reassembling, fit
the sealing rings (37) with to sealing lip facing towards
the swinging arm).
NOTE: When reassembling, observe the procedure
for adjusting the torsion bar, refer to page 48.
STEP 15
Check the sleeve (38) in the king pin housing for wear or
damage. If it is necessary to remove the sleeve, use a
blind-hole puller.
IMPORTANT: To reassemble, place the sleeve (38) in
a container with dry ice and then insert it into the king
pin housing. Grease the sleeve (38) and fill the hole for
the king pin with grease (NL GI 2).
WARNING: Always wear protective gloves,
! to prevent frost-burn, when handling parts
which have been deep frozen. SM118A
39
DI96K287
Check the bearing (39) on the lower king pin for wear or
damage. A hydraulic press must be used, if it is
necessary to remove the bearing.
NOTE: To reassemble, place the bearing’s inner ring
(38) in a container with dry ice and then insert it into
the king pin housing. Grease the bearing (38) and fill
the hole for the king pin with grease (NL GI 2).
WARNING: Always wear protective gloves,
! to prevent frost-burn, when handling parts
which have been deep frozen. SM118A
Edition 03-2005
 5006-31

STEP 16
Check the washers (40) and sleeves (41) at the bearings NOTE: Re-fit parts the king pin housing the same
for the upper and lower swinging arms for wear and manner but in the reverse order.
damage and replace as necessary.
NOTE: Use the special tool 380001921 to insert new
sleeves. Fit new washers (40) and fill the sleeves (41)
with grease (NL GI 2).

Tightening torque = 70 Nm

34

31 40
33
41

Tightening torque = 135 Nm

38
41 32
40 39
LOCTITE 518
LOCTITE 510 26
37 17 27
25 18
36

35 23
13 LOCTITE 542
14
19
12
24
30

29

22 28
21
11 20
16
LOCTITE 542 15
LOCTITE 510
SS00B185

11. SECURING BOLT 19. TORSION BAR 27. SECURING BOLT 35. SHAFT
12. SLEEVE 20. HOUSING 28. BOLT 36. ’O’ RING
13. ADJUSTING SCREW 21. SEALING RING 29. LOWER SWINGING ARM 37. SEALING RING
14. LOCK NUT 22. PIN 30. ’O’ RING 38. SLEEVE
15. COVER 23. SECURING BOLT 31. LOCK NUT 39. BEARING
16. CIRCLIP 24. SLEEVE 32. SECURING BOLT 40. WASHER
17. COVER 25. HOUSING 33. BOLT 41. SLEEVE
18. CIRCLIP 26. LOCK NUT 34. ’O’ RING

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Disassembly
NOTE: The parts are numbered in order of disassembly.

STEP 17 STEP 20
Remove the inner drive shaft from the king pin housing. Remove the ‘O’ ring (47) and dispose of it. Remove the
Remove the ‘O’ ring (42) and dispose of it. Ensure that outer needle bearing (49) and the cartridge sealing ring
the circlip (43) remains seated on the inner drive shaft. (50) from the drive shaft, using a standard puller.

STEP 18 STEP 21
Remove the inner bearing ring from the needle bearing
(53), the spacer ring (51) and the cartridge sealing ring
(52), using an inside puller. Remove the outer bearing
ring from the needle bearing (53) using an inside puller.
Remove the shim rings (54) and the circlip (55).
380000038 Remove the outer bearing ring from the needle bearing
(49).

STEP 22
Clean all component parts in a cleaning solvent and dry
with compressed air. A protective face mask MUST be
worn when doing this. Check all component parts for
DP99K225
wear or damage and replace as necessary.
Bend the tab on the locking washer (45) back. Use the
socket wrench 380000038 to remove the union nut
(44). Remove the locking washer (45) and dispose of it.

STEP 19

DP99F157

Use a hydraulic press to remove the drive shaft (46)

from the king pin housing. Support the drive shaft
during removal.
NOTE: The drive shaft (46) is fitted with a sealing plug
at one end. DO NOT exert force against this plug.

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 5006-33

42
44
45
52
51
53
54
49 43
50

46 47

48

55

DS99D053

42. ’O’ RING 47. ’O’ RING 52. CARTRIDGE SEALING RING
43. CIRCLIP 48. SPACER RING 53. INNER BEARING
44. SLOTTED ROUND NUT 49. OUTER BEARING 54. SHIM RINGS
45. LOCKING WASHER 50. CARTRIDGE SEALING RING 55. CIRCLIP
46. DRIVE SHAF’T 51. SPACER RING

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Assembly
STEP 23
380000038
DD99K191
Select the number of shim rings, so that the total
thickness of the shim ring package (54) is 0.5 mm. Fit
the circlip (55) and push the 0.5 mm shim ring package
(54) against the inside of the circlip. To re-insert the
outer bearing rings of needle bearings (49) (53) into the
king pin housing, use a hydraulic press and the socket
wrench 380000038. Ensure that the bearing rings are
pressed snugly against the circlip and the shim rings.
NOTE: Ensure that the correct number of shim rings
(54) are fitted. Shim rings are available in a sizes of
0.05 mm, 0.10 mm and 0.30 mm.
STEP 24
380000506
380000025
50
DD99K192
Grease the needle bearing with NL GI 2 grease and
insert it into the king pin housing. Insert the cartridge
sealing ring (50) with sleeve 380000025 into the king pin
housing.
Sva 6-51600 EN
STEP 25
46
SD00B034
Fill the king pin housing with 32 g of grease (NL GI 2).
Insert the spacer ring and the needle bearing (53) into
the king pin housing. Position the king pin housing onto
a hydraulic press and support the needle bearing (53)
with a pipe (A). Use the hydraulic press to press the
drive shaft carefully into the king pin housing, until it
bottoms.
NOTE: Align the pipe (A) precisely to the bearing (53),
so that the thread on the drive shaft (46) will not be
damaged when it is being pressed in!
STEP 26
380000506
380000025
52
DP99K214
Fit a new ’O’ ring to the drive shaft (46). Push the spacer
sleeve (51) into the cartridge sealing ring (52). Fit the
spacer sleeve (51) and the cartridge sealing ring (52)
into the king pin housing, using the sleeve 380000025.
Edition 03-2005
 5006-35

STEP 27 STEP 28
Fit a new ‘O’ ring (42) and ensure that the circlip (43) is
seated correctly in the groove in the inner drive shaft.
Fit the inner drive shaft into the king pin housing.

380000038

DP99K225

Insert a new locking washer (45), with the convex side

towards the union nut. Fit the slotted round nut (44) with
the chamfered side at the bottom. Tighten the slotted
round nut (44) to a torque of 175 Nm, using the hooked
wrench 380000038. Lock the slotted round nut (44) with
the locking washer (45).

55 54 52
50 51

47

48

46

43 42

44
49 53 45
Tightening torque = 175 Nm

DI99F167

42. ’O’ RING 47. ’O’ RING 52. CARTRIDGE SEALING RING
43. CIRCLIP 48. SPACER RING 53. INNER BEARING
44. SLOTTED ROUND NUT 49. OUTER BEARING 54. SHIM RINGS
45. LOCKING WASHER 50. CARTRIDGE SEALING RING 55. CIRCLIP
46. DRIVE SHAF’T 51. SPACER RING

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SECTIONAL DRAWING, THROUGH THE PIVOT BEARING HOUSING AND

THE KING PIN HOUSING

31 33
32
A 6

9
49 53
10
38

39
52

46
50
8
DI99E117

A. KING PIN HOUSING 31. LOCK NUT 46. DRIVE SHAFT

6. KING PIN 32. SECURING BOLT 49. OUTER BEARING
8. DISK SPRING 33. BOLT 50. CARTRIDGE SEALING RING
9. DISK SPRING 38. SLEEVE 52. CARTRIDGE SEALING RING
10. THRUST WASHER 39. BEARING 53. INNER BEARING

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DRIVE SHAFTS

Disassembly/Re-assembly
NOTE: The parts are numbered in order of disassembly. Re-assembly is carried out in reverse order to
disassembly.
The following work must be done before carrying out work on the drive shafts:
• Remove the pivot bearing housing, see page 26.
NOTE: In order to remove the drive shaft from the pivot bearing housing, the planetary gear unit and the wheel hub
need not be removed.
• Remove the king pin housing, see page 28.
• In order to remove the drive shaft, the king pin housing must be disassembled, see page 32.

6
2
1

5
3
DS99D054

1. CIRCLIP (16) 4. OUTER DRIVE SHAFT (2)

2. BEARING RINGS (16) 5. BEARING (4)
3. INNER DRIVE SHAFT (3) 6. FORK

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4-WHEEL DRIVE AXLE

Removing and Fitting

NOTE: The parts are numbered in order of removal. Re-fit parts in the same manner but in the reverse order.
Before the 4-wheel drive axle can be removed, the following preparatory work must be carried out:
• Put the tractor on firm, level ground, apply the parking brake and use the switch RAISE/LOWER to fully lower the
front axle to its lowest limit. Switch the motor OFF and remove the ignition key.
• Place chocks in front of and behind the rear wheels.
• Disconnect the battery (negative pole first).
NOTE: When re-connecting, connect the positive (+) pole(s) first.
NOTE: Steps 1 to 3 must only be carried out, if the tractor is fitted with the front lifting gear option.

STEP 1 STEP 2

2 2

3 X 3
1
SD00B017 SD00B018

Remove the brackets (2) for the hydraulic lines from the
support frame (1) (left and right).

4
4

SD00B019

Place a hydraulic jack under the support frame (1) and

remove the securing bolts (3). Loosen the locking nuts
on the setting screws (4) and turn the setting screws out
by two turns.
NOTE: When re-assembling, pre-tighten the
adjusting screws to 30 Nm. Then tighten them
alternately up to a torque of 40 Nm. Secure the
adjusting screws by means of lock nuts. Tighten the
hexagon bolts (X) to a torque of 195 Nm.

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STEP 3 STEP 6

8
5 5

SD00B020 SD00B021

Remove the securing bolts (5) and remove the support Loosen the securing bolts (8) and remove the front
frame. mudguard (if fitted).
NOTE: When assembling the screws (5), coat with
243 Loctite and tighten to 200 Nm. STEP 7

STEP 4
NOTE: For tractors fitted with front lifting gear, the
shaft protector for the 4-wheel drive shaft must first be
removed.
Place a hydraulic jack under the centre of the axle and
raise the tractor. Lower the front of the tractor onto
suitable support trestles and remove the front wheels.
NOTE: When re-fitting the front wheels, tighten the 10
nuts to a torque of 570 Nm. 9

STEP 5 SD00B022

Mark the steering cylinder connection hoses (9),

7 disconnect them and fit protective caps. Mark the
hydraulic hoses (10) to the axle suspension cylinder,
disconnect them and fit protective caps. Disconnect the
hydraulic hose to the differential lock and front PTO
shaft (if fitted) and fit protective caps.
Finish off the brake hoses (if brakes are fitted) and seal
with caps.
NOTE: In order to prevent the loss of hydraulic oil, the
6 hydraulic hoses must be securely tied with the open
ends upwards (towards the cab).

SS00B171

Place a container, with a capacity of at least 2.5 litres

under the oil drain plug (6), screw the oil drain plug out
and drain the oil.
NOTE: When re-fitting the drain plug (6), tighten it to a
torque of 60 Nm. Screw the filler plug (7) out and fill oil
to the recommended level, refer to the Technical Data
on page 10. Tighten the filler plug to a torque of
60 Nm.

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STEP 8 STEP 11

12 15
11

SD00B023 SD00B026

Loosen the securing screws (11) and remove the

potentiometer covers (12) (both sides).
NOTE: When re-fitting the securing screws (11),
tighten them to a torque of 13 Nm.

STEP 9

13 16

SD00B027
Place a hydraulic jack under the centre of the front axle.
Loosen the front and rear bearing block securing
bolts (15 and 16).
NOTE: The rear bearing block is fitted with two
SD00B024 sleeves (see page 41).
Mark the connectors (13) (both sides) and disconnect NOTE: For reassembly, lightly coat the securing
them. bolts (15 and 16) with LOCTITE 243 and tighten them
to a torque of 540 Nm.
STEP 10
STEP 12

14

SD00B025

Remove the 4-wheel drive shaft. SD00B028

NOTE: When re-assembling, ensure that the NOTE: Lower the front axle by means of the hydraulic
intermediate ring (14) is positioned correctly. jack and remove the jack.

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PIVOTED BEARING

Disassembly/Re-assembly
NOTE: The parts are numbered in order of disassembly. Re-assembly is carried out in reverse order to
disassembly. Clean all component parts in a cleaning solvent and dry with compressed air (wear a FACE MASK).
Check all component parts for wear or damage and replace as necessary.
NOTE: If the sleeves (2 and 6) are replaced, ensure correct alignment of the grease access hole when
reassembling.

1
2
A 3
4

11
10

12

9
8
7
10 11 6
SS00B171

8. FRONT BEARING BLOCK 12. REAR BEARING BLOCK 16. THRUST WASHER
9. SLEEVE 13. SLEEVE 17. GREASE NIPPLE
10. SLEEVE 14. ’O’ RING 18. SCREW-IN SUPPORT
11. THRUST WASHER 15. SLEEVE 19. SLEEVE

Fitting Instructions for the PIVOTED BEARING

Raise the tractor, so that the axle can pivot through to the limits.
Position the axle (A) so that it seats against the bearing block (5). Loosen the front bearing block (1) securing bolts.
Drive the bearing block (1) to the limit on the axle housing and tighten the front bearing block securing bolts to the
prescribed torque (see STEP 11, page 40).
Pivot the axle several times and measure the axial play of the pivoted bearing.
Permissible axial play ........................................................................ 0 - 1 mm
NOTE: If the axial play exceeds 1 mm, inspect thrust washers (4) and (9) and bearing blocks (1) and (5) for wear
and replace as necessary.

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SWINGING ARMS

Disassembly
NOTE: The parts are numbered in order of disassembly.
Before work can be carried out on the differential, the following preparatory work must be carried out:
• Remove the king pin housing as a complete unit together with the planetary gear unit, the wheel hub and pivot
bearing housing. Remove the king pin housing as a complete unit together. To do this, proceed in accordance with
STEP 7 to STEP 15 on page 30.

STEP 13
Make alignment markings on the potentiometer (2) and
the upper swinging arm (9). Loosen the securing
screws (1) and remove the potentiometer from the axle.
Remove the washers (3) and the rubber disk (4).
STEP 16
Remove the sealing ring (16), sleeves (16) and (17)
from the upper and lower swinging arms (9) and (20).
Remove the sealing ring (18), sleeves (19) from the
upper and lower swinging arms (9) and (20).

STEP 14
Make alignment markings on the bolt (8) and axle
housing. Loosen the lock nut (5) and remove the
securing bolt (6). Remove the bolt and the upper
swinging arm (9) from the axle. Remove the 'O' ring
(10) from the bolt (8) and dispose of it.
STEP 17
Inspect the washers (22) and sleeves (23) in the axle
housing for wear or damage and replace as necessary.
To replace sleeves and sealing rings, refer to the proce-
dure for reassembly on page 44.

STEP 15
Remove the circlip (11), the washer (12), the hydraulic
cylinder (13) and the thrust washer (14) from the bolt
(15).

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NOTE: The parts are numbered in order of disassembly.

12 11
14
15
13
6

2 1
22
4 3
23 17

16
18
19
10
17
23
22
8
21
10 9
16
17
18
19

20

16

17

SS00B057

1. SECURING BOLT 10. ’O’ RING 18. CIRCLIP

2. POTENTIOMETER 11. CIRCLIP 19. SLEEVE
3. WASHER 12. WASHER 20. LOWER SWINGING ARM
4. RUBBER DISK 13. HYDRAULIC CYLINDER 21. SLEEVE
5. LOCK NUT 14. THRUST WASHER 22. WASHER
6. SECURING BOLT 15. BOLT 23. SLEEVE
8. BOLT 16. SEALING RING
9. UPPER SWINGING ARM 17. SLEEVE

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Assembly
STEP 1 STEP 4

23
12
11

380000506 380001921
DP99K220 DP99F113

Fit new bearing sleeves (23) (both sides), using special Fit the washer (12) and the circlip (11).
tool 380001921.
STEP 5
STEP 2

22
380001920
380000027

17
DP99K217

DP99K221
Fit new sleeves (17) to the upper and lower swinging
Fit new washers (22). Grease the sleeves (22) and arms, using special tool 380000027 and the grip
washers (23) with NL GI 2 grease. 380001920. Fill the sleeves with grease (NL GI 2).

STEP 3 STEP 6

14
16

13

DP99F114 DK99D063

Fit the thrust washer (14), with the chamfered side to- Fit new sealing rings (16) and make sure that the
wards the housing and fit the hydraulic cylinder (13). sealing lips are facing towards the axle housing.

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 5006-45

STEP 7 STEP 8
18

380000506

19
380001922

DP99K223 DK99D065

Fit the circlips (18) and make sure that they are seated
A correctly in the grooves.

STEP 9

6 5 9

19

17
DI99E118
8
Fit new sleeves (19) in the upper and lower swinging 10
arms, using special tool 380001922. Make sure that the
graduated surface of the sleeve faces the sleeve (17). DP99F147

NOTE: The sleeves must be fitted at a depth (A) of
8.6 mm for the inner bolt and 3.6 mm for the outer bolt.
Make sure that the correct side of the special tool
380001922 is used for reassembly.
Fit new ’O’ rings at both ends of the bolt (8). Grease the
bolt with grease (NL GI 2) and fit it into the upper swin-
ging arm. Make sure that the alignment markings on the
bolt (8) and the housing coincide. Fit the securing bolt
(6) with lock nut (5) and tighten to a torque of 135 Nm.
Tighten the locking nut (5) to a torque of 70 Nm.

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STEP 10 STEP 13
B
36

37
DP99F109 DK99D067

Fit the rubber disk (4). Make sure that the tab (B) he
rubber disk meshes into the bolt and that the marking
"OUTSIDE" is facing outwards.
STEP 11
Fit new ‘O’ rings (item 36, page 31) in the lower seat of
the swinging arm. Fit new sealing rings (item 37,
page 31) and make sure that the sealing lips are facing
towards the swinging arm.
STEP 14

380001920

3 380000029
21

DP99F111

Fit the washer (3) and the potentiometer (2). Make sure DR99K222

that the flat side of the potentiometer is seated correctly in Fit new sleeves (21) to the lower securing arm, using a
the rubber disk and that the alignemt marking is correctly
hydraulic press and special tool 380000029. Fill the
aligned to the swinging arm.
sleeves with grease (NL GI 2).
STEP 12

DP99F112

Fit the securing screws and tighten them to a torque of

3 Nm.

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 5006-47

STEP 15

A
B

C
DP99K224

Grease the shaft (C) with grease (NL GI 2). Fit the
swinging arm and the shaft (C). Make sure that the
groves (A) in the shaft (C) are aligned vertically and are
on the same side as the pinion shaft (B).
NOTE: In order to fit the pivot bearing housing, the
wheel hub and the planetary gear unit, carry out
STEP 7 to STEP 14 (page 30) in the reverse order.

STEP 16
Fit the torsion bars and adjust them, refer to "Adjusting
the Torsion Bars" on page 48.

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Adjusting the Torsion Bars

STEP 1 STEP 3

21

22 20

SD00B037 DK99D125

Clean the flange surfaces and place a continuous line Insert the pins (22) and sealing rings (21) into the
of LOCTITE 518 around the hole in the lower swinging housing (20) Ensure that the sealing lip is towards the
arm. swinging arm.

STEP 2 STEP 4

25

23

SX 19 19 DX

SD00B038 SD00B039

Fit the housing (25) with the centring sleeves. Lightly
coat the securing screws (23) with LOCTITE 542 and
tighten the securing screws to a torque of 95 Nm.
Connect a suitable lifting device to the pivot bearing
housing and raise the suspension to the upper limit.
Support the suspension in the raised position, using
suitable support trestles.
Fit the torsion bar (19). Make sure, that the end of the
torsion bar with the punched marking is at the same
side as the pinion shaft. To differentiate between torsion
bars for the left and right-hand side of the axle, they are
punch marked as follows:
SX .............................................. Left-hand torsion bar
DX ........................................... Right-hand torsion bar

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 5006-49

STEP 5 STEP 7
11
18
12

19
20

DP99K232 SD00B040

Fit the housing (20). Align the pins in the housing (20)
to the grooves in the shaft of the lower securing arm Fit
the sleeves (12) and securing bolts (11) loosely, using
LOCTITE 542.
STEP 6
Fit the circlip (18). Fit the torsion bar (19) completely.
NOTE: If necessary, lower the suspension in order to
align the teeth on the torsion bar with the grooves in
the housing (20).
STEP 8

11

13
DP99K227
DP99K208
Turn the left-hand housing in an anti-clockwise
Turn the adjusting screw (13) in, till it seats on the axle
direction, so that the securing bolts (11) can be
housing. Turn the adjusting screw in 6 turns, in order to
aligned to the right-hand side of the slit.
achieve the correct pre-tension of the torsion bar.
Turn the left-hand housing in a clockwise direction, so
NOTE: During this procedure, the housing (20) turns
that the securing bolts (11) can be aligned to the right-
to pre-tension the torsion bar (19). If the adjusting
hand side of the slit.
screw (13) is difficult to turn, make sure that the
screws (11), which were fitted during STEP 5, are not
over-tightened.

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5006-50

STEP 9 STEP 11
Repeat STEP 1 to STEP 10 to fit the other torsion bar.
11
STEP 12
Fit the 4-wheel axle in the reverse sequence to that
used to remove it (see page 38).
14
STEP 13
Adjust the potentiometer and calibrate the axle. See
"Adjusting the Potentiometer" and "Axle Calibration" in
chapter 5001 – FUNCTIONAL DESCRIPTION; ADJU-
STMENTS AND TROUBLESHOOTING INDEPEN-
DP99K209 DENTLY SUSPENDED FRONT AXLE.
Tighten the locking nut (14) to a torque of 45 Nm.
Tighten the securing screws (11) to a torque of 169 Nm.

STEP 10

16

15

DP99K210

Fit the circlip (16) and the cover (15 and 17) (both
ends).
NOTE: Clean the sealing faces of the covers (15 and
17) and apply LOCTITE 510.

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 5006-51

AXLE HOUSING
Disassembly STEP 3
NOTE: The parts are numbered in order of disassem-
bly. When re-assembling, the position of the pinion
shaft must be set precisely. See "Adjusting the Pinion
Shaft" on page 58.

STEP 1

2
SD00B004

7 5
SD00B002
6
Remove the securing screws (1) and remove the front
housing cover (2).

STEP 2

SD00B005

Remove the piston (5) from the cylinder using a

compressed air gun. Remove the ‘O’ rings (6) and (7)
3 and dispose of them.
4
WARNING: When removing the piston, using com-
pressed air, catch it in a cloth.

STEP 4
SD00B003

Remove the securing screws (3) and remove the

differential operating cylinder (4).

10

SD00B006

Remove the circlip (8), spacer ring (9) and the spring
(10).

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5006-52

STEP 5 STEP 7

380000037

11

SD00B007 DP99F152

Remove the clamping rings using special tool

380000037. Remove the ‘O’ rings (21) and dispose of
them. Remove the sealing rings (22) and sleeves (23)
from the clamping rings (20).

13 15 STEP 8
12
Mark the position of the differential unit (24) with
14 respect to the axle housing (A) for later alignment.
Remove the screws (19) and bearing cover (16).
Remove the differential unit (24) from the differential
housing.
NOTE: Make marks on the differential unit and the
11 axle housing, for correct alignment during reassembly.
SD00B008

Remove the circlip (11). Remove the shaft (12), the shift STEP 9
fork (13), the spring (15), the washer (14) and the
circlip (11).

STEP 6
26
A

25

SD00B009

16 Remove the shift ring (25) and the four locking pins (26)
from the differential unit.

SD00B041
Make alignment markings on both the bearing cover
(16) and the differential housing (A). Remove the
locking screws (17). Loosen the screw (19).
STEP 10
Remove the securing screws (27) and remove the
flange (28) from the pinion shaft. Remove the sealing
cover (29). Remove the shaft sealing ring (31) and
'O' ring (30) from the sealing cover (29) and dispose of
them.

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 5006-53
NOTE: The parts are numbered in order of disassembly.

1 19
2 4 3 17 21
7
6
5
8
9 16
10
20
12 22
11 23
26
13

19 17
14
15 16
25

21
24

20
34 23
22
39
38
36
37
36
35
33
32
31
30
29
28
A

27
SS00B063

1. SECURING BOLT 11. CIRCLIP 22. SEALING RING 32. SLOTTED ROUND NUT
2. HOUSING COVER 12. SHAFT 23. SLEEVE 33. WASHER
3. SECURING BOLT 13. SHIFT FORK 24. DIFFERENTIAL UNIT 34. PINION SHAFT
4. CYLINDER 14. WASHER 25. SHIFT RING 35. BEARING
5. PISTON 15. SPRING 26. LOCKING PINS 36. WASHER
6. ‘O’ RING 16. BEARING COVER 27. SECURING BOLT 37. SPRING COLLET
7. ‘O’ RING 17. LOCKING SCREW 28. FLANGE 38. BEARING
8. CIRCLIP 19. SECURING BOLT 29. SEALING COVER 39. PACKING RING
9. SPACER RING 20. CLAMPING RING 30. ‘O’ RING
10. SPRING 21. ‘O’ RING 31. SHAFT SEAL

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5006-54
STEP 11
Unlock the slotted round nut (32) and put the socket
wrench 380000021 on it. Fit the rod 380000020 to the
input flange (28), using 2 bolts, in order to block the
pinion shaft. Remove the union nut (32) and locking
washer (33) and dispose of them.
STEP 12
34
SD00B042
Press the pinion shaft (34) out of the axle housing,
using a hydraulic press. Support the pinion shaft during
removal. Do not re-use the washers (36) and spring
collet (37).
Sva 6-51600 EN
STEP 13
38
SD00B010
Remove the bearing (35). Remove the bearing (38)
from the pinion shaft, using a bearing puller. Remove
the packing ring (39).
Clean all component parts in a cleaning solvent and dry
with compressed air. A protective face mask MUST be
worn when doing this. Check all component parts for
wear or damage and replace as necessary.
NOTE: When reassembling, the position of the pinion
shaft must be set precisely. See "Adjusting the Pinion
Shaft" on page 58.
Edition 03-2005
 5006-55
NOTE: The parts are numbered in order of disassembly

1 19
2 4 3 17 21
7
6
5
8
9 16
10
20
12 22
11 23
26
13

19 17
14
15 16
25

21
24

20
34 23
22
39
38
36
37
36
35
33
32
31
30
29
28
A

27

SS00B063

1. SECURING BOLT 11. CIRCLIP 22. SEALING RING 32. SLOTTED ROUND NUT
2. HOUSING COVER 12. SHAFT 23. SLEEVE 33. WASHER
3. SECURING BOLT 13. SHIFT FORK 24. DIFFERENTIAL UNIT 34. PINION SHAFT
4. CYLINDER 14. WASHER 25. SHIFT RING 35. BEARING
5. PISTON 15. SPRING 26. LOCKING PINS 36. WASHER
6. ‘O’ RING 16. BEARING COVER 27. SECURING BOLT 37. SPRING COLLET
7. ‘O’ RING 17. LOCKING SCREW 28. FLANGE 38. BEARING
8. CIRCLIP 19. SECURING BOLT 29. SEALING COVER 39. PACKING RING
9. SPACER RING 20. CLAMPING RING 30. 'O' RING
10. SPRING 21. ‘O’ RING 31. SHAFT SEAL

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DIFFERENTIAL UNIT

Disassembly STEP 20
NOTE: Make alignment markings on the housing
sections for later re-assembly.
9
STEP 14
Remove the securing bolts (3) and differential master
gear (4). 7
STEP 15
Remove the bearing (5) from the differential housing.

STEP 16
SD00B013

Remove the differential unit housing section (R).

Fit the thrust washer (7) and the axle bevel gear (9) into
Remove the thrust washer (7) and the axle bevel
the housing section (R).
gear (8).
STEP 21
STEP 17
Remove the balancing shaft (12), compensating gears
(11) and thrust washers (10) as a complete unit.
Remove the axle bevel gear (9) and the thrust
washer (7).

STEP 18
Clean all component parts in a cleaning solvent and dry
with compressed air. A protective face mask MUST be
worn when doing this. Check all component parts for
wear or damage and replace as necessary.

Assembly SD00B011

Fit the balancing shaft (12), compensating gears (11)

STEP 19 and thrust washers (10).
Heat the bearings (5) to 90° C in a bearing heater and
fit them to the housing sections. Make sure that the
STEP 22
needle bearing seats correctly against the shoulder.
7
WARNING: Always wear protective gloves,
! to prevent burns, when handling parts which
have been heated. SM121A
8

SD00B012

Fit the axle bevel gear (8) and the thrust washer (7).

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 5006-57

1
2

10

11
5
6 12 R

Tightening torque = 95 Nm 2
4
3 7
9

11
10
LOCTITE 270 7 8

L
5
SS00B080

1. SHIFT RING 6. DIFFERENTIAL HOUSING 11. DIFFERENTIAL BEVEL GEAR (4)

2. LOCKING PIN (4) 7. THRUST WASHER (2) 12. BALANCING SHAFT (2)
3. SECURING BOLT (12) 8. AXLE BEVEL GEAR L LEFT-HAND HOUSING SECTION
4. DIFFERENTIAL MASTER GEAR 9. AXLE BEVEL GEAR (LOCKING SIDE) R RIGHT-HAND HOUSING SECTION
5. BEARING (2) 10. THRUST WASHER (4)

STEP 23 STEP 24

2
2
4

SD00B014 SD00B015

Position housing section (L) on housing section (R) and
align them to the markings. Fit the differential master
gear (4). Fit the securing bolts (3) with LOCTITE 270
and tighten them to a torque of 95 Nm.
Fit the locking pin (2) into the differential housing and
push the shift ring (1) on.
NOTE: To fit the differential unit, see page 62.

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Adjusting the Pinion Shaft

STEP 1 STEP 5
Fit the outer bearing rings (1) and (2) into the axle
housing (3). Make sure that the bearing rings seat B
correctly against the shoulders.

STEP 2
Assemble the alignment adapter 380001919 (4) and the
measurement cylinder 380001918 (5) with the screw 10
380002421 (6).

STEP 3

5
DP99F159

Measure the gap (B) between the measuring cylinder (5)

and the gauging tube (10) with a feeler gauge. Make a
note of dimension (B).

9 A +B=C
DP99F161
Fit the inner bearing ring (8), using the special tool
assembled in STEP 2. Fit the inner bearing ring (7) and fit
the grip (9) 380002420. Hand tighten the grip (9) until the
bearings (7) and (8) can only be turned with difficulty.
NOTE: Turn the grip, so that the bearings are aligned
to the bearing rings.
STEP 4
10
11
STEP 6
To determine the shim thickness for correct adjustment
of the pinion shaft, proceed as follows:
C – D = X (shim thickness required)
A = Measurement constant 110.04 mm – calculated
from:
“r” differential bearing (45,00 mm) + length of the
measurement cylinder (5) (65.04 mm)
B = dimension measured in STEP 5
C = Housing dimension (measured with pinion shaft
bearing)
D = Pinion dimension (etched into the end of the pinion
shaft)
X = Shim
Example:
A = ............................................................ 110.04 mm
B = ............................................................ +0.25 mm
C = ............................................................ 110.29 mm
C = ............................................................ 110.29 mm
D = ........................................................... -107.25 mm
X = ............................................................ 3.04 mm

Shim thickness required = 3.00 mm

12
IMPORTANT: Shims are available in a thickness of
DP99F158
2.5 mm to 3.4 mm (in increments of 0.1 mm). If the cal-
Fit the gauging tube 380001925 (10), in place of the culated thickness of the shim is less than 2.5 mm or
differential unit, with the bearing covers (11). Fit the more than 3.4 mm, repeat STEP 1 to STEP 5 in order to
screws (12) and tighten evenly to a torque of 266 Nm. eliminate a measurement error.
NOTE: Make sure that the alignment markings, made
during disassembly, are aligned correctly to one
another.

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266 Nm

12
11
380001925
10 3
380001918

380002421
6

2
4
380001919
8

9
380002420

SS00B083

1. OUTER BEARING RING 7. NEEDLE BEARING INNER RING

2. OUTER BEARING RING 8. NEEDLE BEARING INNER RING
3. DIFFERENTIAL HOUSING 9. GRIP
4. ALIGNMENT ADAPTER 10. GAUGING TUBE
5. MEASURING CYLINDER 11. BEARING COVER
6. SCREW 12. SECURING BOLT

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Pinion Shaft Unit

STEP 7 STEP 13
Remove the pinion adjustment tools and the needle
bearings from the axle housing.

STEP 8
Fit the shim (1), the size which was calculated in
STEP 6 to the pinion shaft (6), making sure that the
chamfered side of the shim faces the pinion wheel.

STEP 9
Heat the bearing (2) to 90° C in a bearing heater and fit
it to the pinion shaft.
NOTE: Make sure that the bearing is in contact with
the shim (1).
WARNING: Always wear protective gloves,
! to prevent burns, when handling parts which
have been heated. SM121A
STEP 10
Fit a new washer (3), a new spring collet (4) and a new
washer (5) to the pinion shaft (6). Fit the pinion shaft (6)
into the axle housing.
STEP 11
Heat the bearing (7) to 90° C in a bearing heater and fit
it to the pinion shaft or into the axle housing repsective-
ly. Fir a new washer (8) and a new slotted round nut (9)
to the pinion shaft (6).
6
SD00B043
Tie a piece of string to the pinion shaft (6) and wind the
string, without overlapping it, around the pinion shaft.
Tie a spring balance to the end of the string and mea-
sure the rolling resistance.
Tighten the slotted round nut, until the rolling resistance
is between 92 and 137 N.
NOTE: If the slotted round nut is overtightened and
the rolling resistance is still out of tolerance, the spring
collet (4) must be replaced (refer to STEP 11 and
STEP 12 on page 54).
STEP 14
Lock the slotted round nut (9) with a suitable pin in the
groove in the pinion shaft (6).

STEP 12

B
A
SD00B044

Fit the socket wrench 380000021 to the slotted round

nut (9). Fit the rod 380000020 (B) to the input flange
(A), using 2 bolts, in order to block the pinion shaft.
Tighten the slotted round nut until the pinion shaft in the
axle housing is free of play.

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3
4
6 5

1
2

7
8
9

SS00B086

1. SHIM 7. BEARING
2. BEARING 8. WASHER
3. WASHER 9. SLOTTED ROUND NUT
4. SPRING COLLET A. FLANGE
5. WASHER
6. PINION SHAFT

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Fitting the Differential Unit

STEP 15 STEP 18

A 380000037

B
DP99K233 SD00C005

Fit the sleeve to the wrench 380000037. Press the new
sleeves (1) into the clamping ring (7) using a hydraulic
press.
NOTE: When pressing the sleeves in, make sure that
the pins (A) on the wrench 380000037 are aligned cor-
rectly to the holes (B) in the clamping ring.
STEP 16
Fit the bearing cover (5) and make sure to align the
markings.
STEP 19
Hand tighten the bolts (6) evenly.
IMPORTANT: Before finally tightening the bolts (6),
make sure that there is freedom of travel between the
differential master gear and the pinion.

STEP 20
A 380000037 380000037

B
DP99K228

Remove the sleeve from the wrench. Press the new

SD00C006
sealing ring (2) into the clamping ring (7) using a
hydraulic press and wrench 380000037. Fit new Fit the clamping rings (7) using the wrench 380000037.
’O’ rings on the clamping ring (7). Grease the ’O’ ring (3)
and sealing ring (2) with NL GI 2 grease.
NOTE: When pressing the sleeves in, make sure that
the pins (A) on the wrench 380000037 are aligned cor-
rectly to the holes (B) in the clamping ring.

STEP 17
Fit the differential unit (4) into the axle housing (A) and
make sure that the alignment markings coincide.

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266 Nm 6 3
2
5 1
7

7
1
2
3
DI99G016

1. SLEEVE 5. BEARING COVER

2. SEALING RING 6. BOLT
3. ’O’ RING 7. CLAMPING RING
4. DIFFERENTIAL UNIT A. AXLE HOUSING

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Adjusting the Crown Wheel Tooth Flank Play

STEP 21
380000037
SD00C006
Turn the clamping ring on the crown wheel side of the
differential, using the wrench 380000037, in a clockwi-
se direction, until the crown wheel makes contact with
the pinion. Simultaneously tap the bearing covers with
a soft-faced hammer, to align the bearings.
STEP 24
In order to reduce the tooth flank play, the clamping ring
on the crown wheel side of the differential must be
turned in a clockwise direction and the clamping ring on
the opposite side of the crown wheel is turned by the
same amount in an anti-clockwise direction.
In order to increase the tooth flank play, the clamping
ring on the crown wheel side of the differential must be
turned in an anti-clockwise direction and the clamping
ring on the opposite side of the crown wheel is turned
by the same amount in a clockwise direction.
Check the tooth flank play and repeat the procedure if
necessary, until the tooth flank play has been adjusted
to within tolerance.
STEP 25
Tighten the bolts (6) to a torque of 266 Nm. Check that
the tooth flank play is still within tolerance.

STEP 22
Turn the clamping ring at the opposite side of the crown
wheel in a clockwise direction, until there is no play in
the bearings. Simultaneously tap the bearing covers
with a soft-faced hammer, to align the bearings. Play
has been eliminated, when the clamping ring can only
be turned with difficulty.

STEP 23

SD00C007

Place a dial test indicator on one tooth of the crown

wheel and measure the tooth flank play between crown
wheel and pinion. The tooth flank play must be measu-
red at three equidistant points around the circumfe-
rence of the crown wheel.
tooth flank play ................................ 0.18 to 0.23 mm

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Adjusting the Differential Bearing Pre-Tension

STEP 26 STEP 28
Make sure that the tooth flank play between crown
wheel and pinion is within tolerance and that the bea- 7
ring cover bolts are tightened to a torque of 266 Nm.
8
STEP 27
When the crown wheel and pinion are meshed correctly
and the tooth flank play has been adjusted to within
tolerance, the differential bearing pre-tension is
adjusted as follows:

SD00C008

When the pre-tension has been correctly adjusted, fit

the locking screw (8) with LOCTITE 542 and tighten it
to a torque of 13 Nm.
NOTE: When fitting the locking screw (8), make sure
that the screw engages in the teeth of the clamping
ring (7). If necessary, rotate the clamping ring (7)
slightly.

STEP 29
SD00B043
Tie a piece of string to the pinion shaft and wind the
string, without overlapping it, around the pinion shaft.
Tie a spring balance to the end of the string and mea-
sure the rolling resistance of the pinion wheel.
The rolling resistance must be 20 N to 30 N above the 9
bearing pre-tension, which was measured during
10
STEP 13 on page 60.
If the rolling resistance exceeds the prescribed value,
both clamping rings must be turned, in an anti-
clockwise direction, by the same amount.
If the rolling resistance is below the prescribed value,
both clamping rings must be turned, in a clockwise SD00C009

direction, by the same amount.
NOTE: If the clamping rings require adjustment,
STEP 23, to check the tooth flank play, must be subse-
quently repeated. If the tooth flank play is now out of
tolerance, loosen the bolts (6) and repeat STEP 24 to
STEP 25.
Clean the surfaces on the cover (9) and on the axle
housing. Apply a continuous line of LOCTITE 518 to the
sealing surfaces. Fit the cover and make sure that the
shift fork (10) engages in the shift ring. Fit the securing
bolts with LOCTITE 542 and tighten them to a torque of
169 Nm.

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STEP 30
Press a new sealing ring (12) into the sealing cover
(14). Fit the sealing cover, with a new ’O’ ring (13) into
the axle housing. Fit the flange (15) to the pinion shaft,
using the bolts (16).
12

14
15

16 13
SS00B087

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TRACK ALIGNMENT

"A"

Driving direction

Axle in mid position

"B"
SS02B101

NOTE: Before aligning the track, check that tyre pressures are correct (see Operating Manual).

STEP 1 STEP 7
The front axle must be recalibrated before starting the
track alignment.
(see Chapter 5001) 1
STEP 2
Lower the front axle to the lower limit and then activate
the suspension. Once the axle is in the middle position,
switch 2
off the engine and apply the parking brake.
NOTE: The front wheels must face straight ahead.
STEP 3
Make marks on the rear inside of the wheel rim (rim
flange), at the same height as the centre of the wheel SS00C121
hub.
Loosen the locking nuts (1). Extend or shorten the track
STEP 4 rods by turning the knuckle joints (2). Repeat STEP 2 to
Measure the distance B between these marks and make STEP 6.
a note of it. When the track has been aligned correctly, tighten the
locking nuts (1).
STEP 5
Drive the tractor forwards until the marks at the front are Tightening torque........................................ 250 Nm
level with the centre of the wheel hub.
STEP 6
Measure distance A between the marks and note down.
The track must be set so that value “A“ equals value “B“.
Setting:
Axle in “mid-position“ ...................................... 0±3 mm
NOTE: If the value determined is outside the prescribed
setting, the track alignment must be corrected in
accordance with STEP 7

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 Chapter
5007
Independently Suspended

5007
Front Axle 20.29SI / FR

CNH Österreich GmbH Sva 6-51651 EN © 2004 CNH Österreich GmbH

Technical Documentation April, 2004
A – 4300 St. Valentin, Steyrer Straße 32
 5007-3

7$%/(2)&217(176

SPECIAL TOOLS ............................................................................................................................................ 5

GENERAL INFORMATION ............................................................................................................................. 9

Using the Manual ...................................................................................................................................... 9
Maintenance ......................................................................................................................................... 9
Repairs ................................................................................................................................................. 9
Property Rights of the Information ........................................................................................................ 9
Diagrams .............................................................................................................................................. 9
Definition of the Driving Direction ......................................................................................................... 9
General Remarks ...................................................................................................................................... 9
General Instructions for Disassembly and Assembly ............................................................................... 9
Shaft sealing rings ................................................................................................................................ 9
Cartridge sealing rings ........................................................................................................................ 10
‘O’ rings ............................................................................................................................................... 10
Shims .................................................................................................................................................. 10
Bearings .............................................................................................................................................. 10
Sprung dowel pins .............................................................................................................................. 10
Sealant and Locking Fluid .................................................................................................................. 10
Draining oil .......................................................................................................................................... 10
Cleaning .............................................................................................................................................. 10
Using lubricants .................................................................................................................................. 10
Type plate ............................................................................................................................................... 11

TECHNICAL DATA ....................................................................................................................................... 12

Sealant and Locking Fluid ...................................................................................................................... 13
Tightening Torques ................................................................................................................................. 14
Dimensions 20.29 SI ............................................................................................................................... 16
Dimensions 20.29 SI FR ......................................................................................................................... 17

GENERAL NOTES ....................................................................................................................................... 19

PLANETARY DRIVE ..................................................................................................................................... 19

Disassembly ........................................................................................................................................... 19
Assembly ................................................................................................................................................ 22

BRAKE .......................................................................................................................................................... 23
Disassembly ........................................................................................................................................... 23
Assembly ................................................................................................................................................ 26
Bleeding the brakes ............................................................................................................................ 28

WHEEL HUB ................................................................................................................................................. 30

Disassembly ........................................................................................................................................... 30
Assembly ................................................................................................................................................ 32
Adjusting the wheel bearing ................................................................................................................ 32

TORSION BAR ............................................................................................................................................. 34

Removal .................................................................................................................................................. 34
Fitting ...................................................................................................................................................... 37
Setting the torsion bar ............................................................................................................................. 39

KING PIN HOUSING .................................................................................................................................... 41

Removal .................................................................................................................................................. 41
Fitting ...................................................................................................................................................... 45

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HYDRAULIC CYLINDER ...............................................................................................................................49
Removal ..................................................................................................................................................49
Fitting .......................................................................................................................................................50

Drive shaft .....................................................................................................................................................51

Removal ..................................................................................................................................................51
Fitting .......................................................................................................................................................55

SENSORS .....................................................................................................................................................58
Removal ..................................................................................................................................................58
Fitting .......................................................................................................................................................59
Adjusting the Sensors .........................................................................................................................60

Swinging arm .................................................................................................................................................61

Removing the upper swinging arm ..........................................................................................................61
Removing the lower swinging arm ..........................................................................................................63
Installing the lower swinging arm ............................................................................................................66
Installing the upper swinging arm ............................................................................................................68

Steering cylinder ............................................................................................................................................71

Removal ..................................................................................................................................................71
Fitting .......................................................................................................................................................73

4-WHEEL DRIVE AXLE ................................................................................................................................76

Removing and Fitting ..............................................................................................................................76

PIVOTED BEARING ......................................................................................................................................79

Removal ..................................................................................................................................................79
Fitting .......................................................................................................................................................80

DIFFERENTIAL .............................................................................................................................................82
Removal ..................................................................................................................................................82
Removing the Pinion Shaft ......................................................................................................................83

DIFFERENTIAL UNIT ....................................................................................................................................86

Disassembling .........................................................................................................................................86
Assembly .................................................................................................................................................88
Adjusting the Pinion Shaft .......................................................................................................................90
Assembling the differential ......................................................................................................................92
Setting the differential bearing .............................................................................................................93
Correct meshing check ........................................................................................................................94

TRACK ALIGNMENT ....................................................................................................................................96

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SPECIAL TOOLS
Wrench for left differential nut Measuring disks (meshing adjustment)

SS02A055

380000406 (1TSW 532)

SS02A059

Wrench for right differential nut 380000440

Measuring shaft (meshing adjustment)

SS02A077

380000441 (293798) SS02A060

380000439
Wrench for bevel pinion, slotted nut
Clamping device (meshing adjustment)

SS02A056
SS02A076
380000021 (CAS 1885A; 1TSW 504)
380000018
NOTE: Dolly 380000020 (CAS 2483) is additionally
required. Insertion tool for cartridge sealing ring,
hub
Insertion tool for cartridge sealing ring,
bevel pinion

SS02A062

380001489 (CAS 2486) 180x150x14,5/16

SS02A058

380000022

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5007-6

Insertion tool for bush in axle stub Insertion tool for sealing ring in
protective sleeve

SS02A061
SS02A057
380000024
380000443
Insertion tool for sealing ring in axle stub
Insertion tool for needle bearing in
protective sleeve

SS02A063

380000032
SS02A072

Assembly sleeve for sealing ring 380000448 (294165-6)

in axle stub
Half-ring for sealing ring in
protective sleeve

SS02A075

380000034
SS02A074
Insertion tool for sealing ring in 380000398
protective sleeve
Wrench for slotted nut, lower
swinging arm

SS02A064

380000444
SS02A070

380000041

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 5007-7

Insertion tool for bush in upper Insertion tool for bush in lower
swinging arm swinging arm

SS02A065
SS02A068
380000445
380000447
Insertion tool for sealing ring,
Driver for sealing ring in centering bush
upper swinging arm

SS02A069

380000031 (294216)
SS03D086

380001488

Insertion tool for sealing ring and bush in

lower swinging arm

SS03D080

380001512

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GENERAL INFORMATION
Using the Manual
Maintenance
• Trouble-free operation of the mechanical components is influenced by regular and correct maintenance.
• The use of qualified personnel during maintenance and repairs guarantees a longer lifetime of the components
and trouble-free operation.
• READ THE MANUAL. Non-observance of recommended worksteps can reduce the lifetime and the durability of
the unit and can result in damage or accidents.

Repairs
The instructions for removal and fitting were drawn up for an overall repair of the axle and constitute the correct order
of the tasks to be performed. Drawings and photos provide personnel with a complete and safe guide through all
worksteps.
A good knowledge of the axle makes it possible to assess the repair, and as a result, it is often the case that only
certain parts have to be removed.

Property Rights of the Information

This repair manual contains confidential information. All rights remain reserved.
No part of this manual may be re-printed or copied without written permission from CNH Österreich GmbH. The
manufacturer assumes no liability for direct or indirect damages to persons, objects or animals as a result of incorrect
use of this manual.

Diagrams
Photos and drawings are NOT to exact scale.
Photos are only intended to clarify the sequence of worksteps.

Definition of the Driving Direction

Specifications such as "left side" or "right side" must always be seen from the driver's seat in the FORWARDS driving
direction of the vehicle.

General Remarks
• The axle should only be repaired by qualified personnel, who are aquainted with all of its technical
characteristics, and under exact observance of the corresponding safety standards.
• The axle must be carefully cleaned before carrying out a repair. Dirt and/or grease must be removed.
• Put the tractor on firm, level ground, apply the parking brake and fully lower the front axle onto its lowest
mechanical limit (if necessary, open the discharge valve at the hydraulic control unit – refer to Chapter 5002).
Switch the engine OFF and remove the ignition key.
• All disassembled parts must be cleaned using a suitable cleaning agent to avoid possible damage.
• Damaged or worn parts must be replaced to avoid possible subsequent damage. In particular, motion and
sealing elements must be checked if they are subject to larger amounts of stress, wear and ageing.
• The renewal of the bevel pinion or differential master gear necessitates the renewal of the entire set.
• Only use original spare parts

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General Instructions for Disassembly and Assembly

IMPORTANT: Before commencing removal or fitting, read the following instructions carefully:

Shaft sealing rings

• Check the running surfaces of sealing rings for scoring and their surface condition.
• Check sealing rings for damage, tears or scratches.
• Insert shaft sealing rings so that the sealing lip is in the direction of the inner side of the housing (oil side).
Exception: another mounting position has been specified.
• Lubricate the sealing lips with oil and fill the ring cavity 3/4 full with grease.
• During assembly, use a suitable insertion tool and, when so stipulated, special tools.
• If necessary, protect sealing rings by push sliplocks during assembly (special tool).

Cartridge sealing rings

• Only fit using special tools.
• When fitting, moisten the rubberized inner surface of the cartridge sealing ring with a mixture of white spirits and
water.

‘O’ rings
Grease before installing.

Shims
Always individually measure the shims used.

Bearings
We advise that you warm up the bearing inner rings to 80 °C - 90 °C before assembly. Bearing outer rings should be
cooled down before assembly.
Always use suitable extractors when removing bearings. Always use suitable insertion tools when inserting bearings.

Sprung dowel pins

Always insert sprung dowel pins with the slit in the direction of the load.

Sealant and Locking Fluid

Only use prescribed sealant and locking fluid (see page 13). Before re-assembling, all parts must be clean, dry and
free of grease.

Draining oil
The oil must be drained before removing the planetary train and/or the axle housing.
WARNING: Dispose of old oil according to statutory regulations.

Cleaning
• All moving parts (bearing, gear wheels, shafts) must be cleaned carefully.
• Petrol, water or alkaline solutions should not be used. Do not use steam or hot water as it is difficult to remove
surface dampness.
• Clean all components using an air jet or a cloth to free the surfaces from any remains.
• All surfaces should be covered by a thin layer of oil to protect them from oxidation.

Using lubricants
Only use lubricants which meet the stipulated specifications (see Technical Data, page 12).

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 5007-11

Type plate

AXLE TYPE CUSTOMER NUMBER CARRARO SERIAL NUMBER

OVERALL RATIO
CARRARO NUMBER

TYPE OF
DIFFERENTIAL LOCK

DIFFERENTIAL
OIL QUANTITY
DIRECTION OF
ROTATION OF
DRIVE SHAFT

RECOMMENDED
DIFFERENTIAL OIL

RECOMMENDED PLANETARY GEAR OIL PLANETARY GEAR OIL QUANTITY

SS01M134

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5007-12

TECHNICAL DATA
DIFFERENTIAL
Number of teeth – pinion shaft / diff. master gear ...................................................................................... 13 / 30
Differential transmission ratio ................................................................................................................... 2.307 /1
Pinion shaft initial bearing tension (P)
(measured at pinion shaft Ø = 34.8 mm, without sealing ring) ..................................................... P = 92 to 138 N
Total initial bearing tension – pinion bearing and differential (T)
(measured at pinion shaft Ø = 34.8 mm, without sealing ring) ................................ T = 92 (+92) to 138 (+107) N
Bevel pinion / differential master gear tooth flank play ................................................................ 0.20 to 0.28 mm
Compensating washer thickness for pinion height .............................. at least 2.5 mm to a maximum of 3.4 mm

PLANETARY DRIVE
Planetary drive transmission ratio ........................................................................................................... 6.923 / 1
Total transmission ratio (differential + planetary drive) .......................................................................... 15.976 / 1

STEERING
Steering angle ........................................................................................................................adjustable up to 50°

DIFFERENTIAL LOCK
Type .............................................................................. Multi-disk lock running in oil bath – 100 % locking value
Activation .................................................................................................................................... electro-hydraulic
Control pressure ......................................................................................................................................... 20 bar

TRACK ALIGNMENT
Axle in mid-position ..................................................................................................................... 0 to 4 mm toe-in

LUBRICANTS / TYPES OF OIL

Grease ........................................................................................................................................... Polymer 400/L
Types of oil
Differential .................................................................................................... SAE 80W-90 gearbox oil (API GL5)
Planetary drive without brake ..................................................................... SAE 80W-90 gearbox oil (API GL5)
Planetary drive with brake ...................................................... SAE 10W-30 UTTO multi-purpose oils (API GL4)

FILLING LEVELS
Planetary drive without brake (each side) .............................................................................................. 1.5 litres
Planetary drive with brake (each side) ................................................................................................... 2.0 litres
Differential ............................................................................................................................................... 5.5 litres

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Sealant and Locking Fluid

 










  



 SS03D055


/RFWLWH

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5007-14

Tightening Torques

SS04C056

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 5007-15

SS03D058

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5007-16

Dimensions 20.29 SI

SS01M136

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 5007-17

Dimensions6,)5

SS03D056

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GENERAL NOTES
127( The all-wheel drive axle must not be removed for work on the following components:
• Planetary drive
• Brakes, when equipped (see page 23)
• Wheel hub (see page 30)
• Torsion bar (see page 34)
• King pin housing (see page 41)
• Drive shaft (see page 51)
• Swinging arm (see page 61)
• Hydraulic cylinder (see page 49)
• Steering cylinder (see page 71)

PLANETARY DRIVE
127( The following points must be observed prior to removing the planetary gear unit:
• Put the tractor on firm, level ground, apply the parking brake and fully lower the front axle onto its lowest
mechanical limit (if necessary, open the discharge valve at the hydraulic control unit – refer to Chapter 5002).
Switch the engine OFF and remove the ignition key.
• Place chocks in front of and behind the rear wheels.
• Loosen the front wheel nuts. Place a jack under the centre of the front axle, raise the tractor and lower it onto
suitable front axle support trestles. Remove the front wheels.

Disassembly
STEP 1 STEP 3

2 3

SD01M023
SD01M026

Before dismantling, discharge the oil through the Remove the planetary gear carrier (item 3).
drain/filler plugs (item 1) into a suitable container.
Remove the two countersunk screws (item 2). STEP 4
STEP 2

17

SD01M027

SD01M025 Remove the ‘O’ ring (item 17) from the wheel hub.

Tap the planetary gear carrier surface with a soft- 127( Before assembling, replace the ’O’ ring.
faced hammer.

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5007-20

STEP 5 STEP 8

10

SD01M031

SD01M028 Check all component parts for wear and replace as

Tighten the securing screws (item 10) of the planetary necessary.
gears. 127( Check bearing rollers (item 5) for
completeness. (28 rollers for each planetary gear)
STEP 6
STEP 9
9

SD01M029

SS01M015
Remove both discs (items 7 and 9).
STEP 7 If one or more bearing journal, or the thrust washer of
the drive shaft is damaged then the entire planetary
gear (item 3) must be replaced.

SD01M030

Remove the planetary gear, the bearing rollers and the

thrust washers underneath. If necessary, dismount the
pin (item 8).

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 5007-21

3A 10
9
7

5
4

3
1
2 SS01M138

1. DRAIN PLUG / FILLER CAP 6. PLANETARY GEAR

2. COUNTERSINK SCREWS 7. WASHER
3. PLANETARY GEAR (WITHOUT BRAKES) 8. PIN
3A. PLANETARY GEAR (WITH BRAKES) 9. WASHER
4. THRUST WASHER 10. SECURING BOLT
5. BEARING ROLLERS

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Assembly
STEP 1 Attach both washers (items 7 and 9).
127( Align the hole X in the washer (item 7) onto
the pin.

4 STEP 5

SD01M135

Attach the washers (item 4) onto the planetary gears 10

using grease.
STEP 2
SD01M139

Screw in and tighten the securing screws (item 10).

Tightening torque ..........................................79 Nm
STEP 6

SD01M136

Attach the individual rollers (28 for each planetary

gear) onto the planetary gears using grease.
STEP 3

SD01M140

Attach a new ‘O’ ring (item 17) onto the wheel hub.
Place the planet carrier onto the wheel hub and
tighten it using countersink screws (item 2).
Tightening torque ..........................................25 Nm
127( Secure the countersink screws (item 2) with
Loctite 542.
If new wheel bolts are mounted in the wheel hub then
SD01M137
these should be secured using Loctite 270.
Mount the planetary gears (item 6) onto the bearing Tightening torque ..........................................70 Nm
journal of the planetary carrier.
STEP 7
STEP 4
Turn the wheel hub so that the drain/level plug (item 1)
9 is positioned horizontally to the centre of the axle. Fill
up the wheel hub to its prescribed level using the
X correct oil (see the Technical Specifications on page
12). Screw in the plugs (item 1, step 60) together with
the 'O' ring and tighten to a torque of 60 Nm.

SD01M138

Mount the pins(item 8) onto the bearing journal.

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 5007-23

BRAKE
127( Before disassembling the brake, the planetary gear unit must be removed (see page 19).

Disassembly
STEP 1 STEP 4

260

12

SD02A005 SD02A008

Remove the circlip (item 260). Remove all securing bolts (item 12) from the support
STEP 2 frame carrier.

262 STEP 5

271

261

SD02A006
SD02A009
Remove the pressure plate (item 261) and the lining
disk (item 262). Disconnect the support frame carrier (item 271) using
the three screws (M10x60) and then remove it.
STEP 3
127( When removing using the screws, burrs may
occur at the kingpin housing. Remove the burrs using
filers.





6''

Remove the circlip (item 90). Remove the thrust

washer (item 91) and the thrust washers (item 92).

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5007-24

STEP 6 STEP 9

13

277
271

SD02A010 SD02A013

Remove the ’O’ rings (item 277). Remove the centre Remove the support frame carrier (item 271).
pins (item 13) using a mandrel.
STEP 10
STEP 7
270
278

264

SD02A014

SD02A011
Remove the circlip (item 270) and the pressure plate
Remove the circlip (item 278). (item 264).

STEP 8 STEP 11

275 279

265

SD02A016
SD02A012
Remove the piston (item 265) from the support frame
Loosen the securing screws (items 275 and 279).
carrier.
Remove the washers, springs and sleeves.
127( To dismount the piston, mount two screws
127( Mark the position of the support frame carrier
(M4) into the existing thread. Using a levering tool
to the pressure plate.
and a suitable surface, press out the piston evenly.

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STEP 12 STEP 13
266 281
267

268

269

SD02A015
Remove the sealing rings (items 267 and 269) and the
support rings (items 266 and 268) from the inside and
outside piston seal. Check the piston for damage and
replace as required. Replace the sealing rings support
rings.
SD02A017
Remove the clamping sleeve for automatic brake
adjustment (item 281).
127( Check the sealing surface of the ring-shaped
brake cylinder in the support frame carrier for scoring
and wear and replace the support frame carrier if
necessary.

264
263

262
275
276
274
261 273
277
272
260

271 278

270
279
269
268
267
266
265
280

282
281

SS02A033

260. CIRCLIP 268. SUPPORT RING 276. RIVET

261. PRESSURE PLATE 269. SEALING RING 277. ’O’ RING
262. BRAKE DISC 270. CIRCLIP 278. CIRCLIP
263. INTERNAL GEARED WHEEL 271. SUPPORT FRAME CARRIER 279. BOLT
264. PRESSURE PLATE 272. SPRING 280. WASHER
265. PISTON 273. SLEEVE 281. CLAMPING SLEEVE
266. SUPPORT RING 274. WASHER 282. SLEEVE
267. SEALING RING 275. BOLT

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Assembly
STEP 1 STEP 4
Premount the centre pins into the support frame
carrier. (see step 4, page 32)
STEP 2
281 281

265
281
SD02A020

Oil the piston sealing ring (item 265). Press the piston
manually and parallel into the support frame carrier
SD02A019
(cylinder) until the sealing rings are slipped on. Then
Mount the clamping sleeves (item 281) into the press the piston fully in using a suitable assembly tool.
support frame carrier with the bevel towards the brake
disc. STEP 5
127( The clamping sleeves must be mounted flush 264
to the support frame carrier.
STEP 3

266
267

268

SD02A021
269
Mount the pressure plate (item 264) onto the internal
geared wheel. Fit the circlip (item 270).
SD02A015 ,03257$17 Fit the pressure plate with the free
location pointing towards the support frame carrier.
Fit new support rings (items 266 and 268) and sealing
rings (items 267 and 269) for the inside and outside pi-
ston seals.
127( Observe the correct mounting position!
Mount the support rings facing towards the brake
disc.

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 5007-27

STEP 6 STEP 8
271 271

278
277

SD02A022
SD02A010
Align the support frame carrier (item 271) to the
pressure plate and mount onto the internal geared Grease the new ’O’ rings (item 277) and insert into the
wheel. Fit the circlip (item 278). support frame carrier.

STEP 7 ,03257$17 Only use original ’O’ rings

STEP 9
281 Mount the support frame carrier (item 271) together
275 with the preassembled internal geared wheel onto the
axle stub housing. (see step 7 - 11, page 33)
6&+5,77

SD02A023

Insert the springs (item 272) and sleeves (item 273)

into the support frame carrier. Mount the pressure
plate (item 264) onto the support frame carrier using 66'
fixing screws (item 275) and washers (item 274).
Tightening torque .......................................... 10 Nm 127( ,IWKHOLQLQJGLVNLWHPRQO\LVWREHUHSOD
FHGWKHQWKHSLVWRQLWHPWRJHWKHUZLWKWKHSUHV
Insert the remaining three sleeves (item 282) into the
VXUH SODWH LWHP  PXVW EH UHWXUQHG WR WKH LQLWLDO
holes with the clamping sleeves (item 281). Insert the
SRVLWLRQ8VHDVXLWDEOHGULIW
fixing screws (item 279) with the washers (item 280)
and tighten them.
Tightening torque .......................................... 10 Nm

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5007-28

STEP 11 STEP 13
262 Mount the planetary gear unit. (see page 19)

Bleeding the brakes

,03257$17 Before bleeding the brake, the front
wheels must be mounted and the wheel nuts must be
tightened to 570 Nm. (Tightening torque only applies
to the braked front axle)
1. Attac a tube to the bleed screw (item 82 page 44)
and bleed to an oil collector.
2. Start the engine
261
3. Open the bleed screw. Actuate the brake until the
hydraulic oil escapes without bubbles.
SD02A006
4. Tighten the bleed screw.
Mount the lining disk (item 262) and the pressure plate 5. Repeat the same procedure on the second side.
(item 261). 6. Check the brakes for tightness and the level of the
,03257$17 Fit the pressure plate with the free hydraulic oil.
location pointing towards the planetary gear. 7. Take the tractor for a test drive and test the
brakes.
STEP 12

260

SD02A005

Fit the circlip (item 260).

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 5007-29

THIS PAGE REMAINS EMPTY

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5007-30

WHEEL HUB
127( The following work must be carried out prior to disassembling the wheel hub:
• Remove the planetary gear unit (see page 19)
• Remove the pressure plate and the brake disc when equipped (see page 23)
Disassembly
STEP 1 STEP 4






14
6''

Move the drive shaft in the direction of the sun gear. SD01M035

Remove the circlip (item 90). Remove the thrust was- Remove the support frame carrier (item 14).
hers (items 91 and 92).
STEP 5
STEP 2

15
13
12

SD01M033 SD01M036

Loosen all the securing screws (item 12) of the Place the support frame carrier onto a workbench and
support frame carrier. drive out the centre pins (item 13) using a suitable
mandrel.
STEP 3
Remove the circlip (item 15) and the support frame
carrier.
STEP 6

14

SD01M034

Pull out the support frame carrier (item 14) using

screws. SD01M037

Tap the wheel hub with soft hammer to dismount it

from the kingpin housing.

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 5007-31

STEP 7

21

SD01M038

Remove the cartridge sealing ring (item 21) and

dispose of it. The drive out both outer bearing rings.












$





 SS03D059





11. INTERNAL GEARED WHEEL 17. ’O’ RING 90. CIRCLIP

12. SECURING BOLT 18. GRUB SCREW 91. THRUST WASHER
13. SLEEVE 19. WHEEL HUB (WITHOUT BRAKES) 92. THRUST WASHER
14. SUPPORT FRAME CARRIER 19A. WHEEL HUB (WITH BRAKES)
15. CIRCLIP 20. INNER BEARING
16. OUTER BEARING 21. CARTRIDGE SEALING RING

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Assembly
Adjusting the wheel bearing STEP 3
The components of the wheel hub alignment are
based on extremely small tolerances and therefore
require no adjustment. Before fitting, check that 20
components’ dimensions are within tolerance. Parts
which are out of tolerance must be replaced.

SD01M128

Slide the inner ring of the bearing onto the king pin
housing.
STEP 4
SS01M131
13
A = 17.950 - 18.000 mm
B = 64.275 - 64.325 mm
C = 23.070 - 23.172 mm
STEP 1

13
SD01M129

Premount the centre pins (item 13) into the support

frame carrier. Allow the two opposite centre pins to
stick out slightly for later assembly.

SD01M126 STEP 5
Drive the outer rings of the tapered roller bearings into
the wheel hub using a suitable insertion tool.
STEP 2

15

SS01M130

Mount the internal geared wheel onto the support

frame carrier. Fit the circlip (item 15).

SD01M127

Insert a new cartridge sealing ring (item 21) into the

wheel hub using insertion tool 380001489.

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 5007-33

STEP 6 STEP 9

16

SD01M134

Drive in all remaining centre pins using a suitable

SD01M131
insertion tool. Then attach all fixing screws and tighten
Fit the pre-assembled wheel hub. Insert the outer them.
bearing (item 16). Tightening torque........................................ 230 Nm
,03257$17 When fitting the wheel hub, moisten STEP 10
the inner surface of the cartridge sealing ring with a
mixture of white spirits and water.
The seat area for the cartridge seal ring at the kingpin
housing must be free of oil and grease.
STEP 7

17

SD01M027

Attach a new ‘O’ ring (item 17) onto the wheel hub.
14
STEP 11
SD01M132

Mount the support frame carrier (item 14) together

with the preassembled internal geared wheel onto the

axle stub housing.

127( When doing this, use the two protruding 
sleeves for centering the support frame carrier.
STEP 8

12

66'

Fit the washers (items 92 and 91) and the circlip

(item 90).
127( Observe the correct mounting order!
,03257$17 Fit the washer (item 91) with the collar
to the circlip.
SD01M133

Fix the support frame carrier using two screws

(item 12) onto the two protruding sleeves.

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5007-34

TORSION BAR
NOTE: The following points must be observed prior to removing the torsion bar:
• Put the tractor on firm, level ground, apply the parking brake and fully lower the front axle onto its lowest
mechanical limit (if necessary, open the discharge valve at the hydraulic control unit – refer to Chapter 5002).
Switch the engine OFF and remove the ignition key.
• Place chocks in front of and behind the rear wheels.

Removal
STEP 1 STEP 4

25

SD01M039 SD01M042

With the axle dismounted, secure the kingpin housing Screw out the adjusting screw (item 25) until the
to the uppermost position using a lifting device. torsion bar is no longer pre-tensioned.
STEP 2 STEP 5

22 23

SD01M040 SD01M043

Remove the cover (items 22 and 35) from the flanges. Remove the circlip (item 23).
STEP 3 STEP 6
Remove the three fixing screws (item 26) and the
26 three sleeves (item 27). Remove the rear flange.
WARNING: Before disassembling the rear flange, the
torsion bar must be loosened (see step 4).

24

SD01M041

Slightly loosen the three securing screws (item 26)

from the rear flange. Loosen the lock nut (item 24) of
the adjusting screw.

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 5007-35

STEP 7 STEP 10

30

29

SD01M046 SD01M049

Check the ’O’ ring (item 29) and replace if required. Pull out the front flange with the torsion bar (item 30)
from the axle housing.
STEP 8
STEP 11

37

SD01M047

SD01M050
Remove the three fixing screws (item 37) from the
front flange. Drive out the torsion bar through the front flange using
a soft hammer.
STEP 9
STEP 12
X

SD01M048 
66'
Pull out the front flange by screwing a screw into the
threaded hole X. Remove the O-ring (item 31) from the front flange.
127( 5HSODFHWKH2ULQJ

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STEP 13 STEP 14

36

34

SD01M051 SD01M052

If necessary, drive out the two centre pins (item 36) Remove the circlip (item 34).
from the front flange using a soft hammer and an
insertion tool.





 

 






SS03D062





22. COVER 30. TORSION BAR

23. CIRCLIP 31. SEALING RING
24. NUT 32. FLANGE
25. ADJUSTING SCREW 33. SECURING BOLT
26. SECURING BOLT 34. CIRCLIP
27. SLEEVE 35. COVER
28. FLANGE 36. SLEEVE
29. ’O’ RING 37. SECURING BOLT

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 5007-37

Fitting
STEP 1 STEP 4





66' SD01M112

Use grease to fit the new O-Ring (item 31) on the front Screw in the screws (items 33 and 37) of the front
flange (item 32). flange and tighten them.
127( Insert the sealing ring with the spring pointing 127( Observe the correct screw lengths! Secure
towards the flange. the screws with Loctite 542.
STEP 2 Tightening torque...........................................95 Nm
STEP 5

SD01M110

Position the front flange at the lower swinging arm and SD01M039
insert using a soft hammer.
With the axle dismounted, lift up the kingpin housing
127( 'R QRW GDPDJH WKH 2ULQJV LWHPV  DQG to the uppermost position using a lifting device.
6HLWH
127( The uppermost point of the spring travel has
STEP 3 been reached when the piston is moved in the
hydraulic cylinder up to the stop.
STEP 6

36

SD01M111

Drive the centre pins (item 36) into the front flange
using a suitable insertion tool. SD01M115

Grease the profile of the front flange.

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5007-38

STEP 7 STEP 10

29

SD01M116 SD01M046

Before inserting the torsion bar, observe the labelling: Grease the new ’O’ ring (item 29) and insert into the
sx = left torsion bar, dx = right torsion bar. rear flange (item 28).
The arrow shows the direction of rotation in which the STEP 11
torsion bar is pre-tensioned.
,03257$17 The labelling "dx" or "sx" must be on
the side of the pinion shaft (drive flange).
STEP 8

25
24

SD01M118

Pre-mount the adjusting screw (item 25) with the lock

nut (item 24) into the rear flange. Screw in the
adjusting screw to shortly before the limit position.
SD01M117
STEP 12
Insert the torsion bar.
STEP 9
26
27

28
34
SD01M045

Fit the rear flange (item 28). Screw in the fixing screws
SD01M114
(item 26) with their sleeves (item 27) but do not yet
tighten them.
Fit the circlip (item 34).
127( Only tighten the fixing screws of the rear
flange after the torsion bar has been set.

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 5007-39

Setting the torsion bar

STEP 1 STEP 4

23

SS01M129 SD01M043

• With the axle dismounted, lift up both kingpin Insert the circlip (item 23) of the torsion bar at the rear
housings to the uppermost position. flange.
• With the axle inserted, lower this to the stop
position. STEP 5
STEP 2

25

SD01M042

SD01M045
Turn the adjusting screw (25) into the rear flange, until
it sits on the axle housing.
Turn the lower flange at the left (as shown in the Then turn the adjusting screw in another 7.5 turns, in
picture) anticlockwise until it reaches its final stop order to achieve the correct pre-tension of the torsion
position. bar.
Turn the lower flange at the right clockwise until it
reaches its final stop position. STEP 6
STEP 3
26

34

SD01M122

SD01M119
Tighten the securing screws (item 26) of the rear
flange.
Insert the torsion bar into the profile of the front and Tightening torque.........................................145 Nm
rear flange until the circlip (item 34) is in its stop
position.

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5007-40

STEP 7

SD01M123

Tighten the lock nut (item 24) of the adjusting screw.

Tightening torque ..........................................45 Nm
STEP 8
Mount both covers (items 22 and 35).

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 5007-41

KING PIN HOUSING

127( Before the king pin housing can be removed, the following work must be carried out:
• Remove the planetary gear unit (see page 19)
• Remove the pressure plate and the brake disc when equipped (see page 23)
• Remove the wheel hub (see page 30)
• Remove the torsion bar (see page 34)

Removal
STEP 1 STEP 4

 

SD01M054 66'

Screwan eye screw into the kingpin housing and
secure it with a lifting device.
STEP 2
Pull out the centre pin (item 42) using a standard
extractor (M8x1 thread) from the fork holder.
127( Check the ’O’ ring (item 45) and replace if
required.
STEP 5

46

SD01M055

Loosen the locking nut and slightly unscrew the fixing

screw of the bearing bolt (item 46). SS01M018

STEP 3 Pull out the bearing bolt (item 46) using a standard
extractor (M8x1 thread) from the fork holder or from
 the protective sleeve (item 106).
127( If necessary, lift up the protective sleeve
slightly by the drive shaft to ease removal of the
 bearing bolt.

6''

Remove the circlip (item 41) from the fork holder. Un-
screw the lubrication nipple (item 40) from the cen-
tering bush.

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5007-42

STEP 6 STEP 9

SD01M057 SD01M060

Secure the lower swinging arm using a lifting device Remove the hexagonal nut (item 50) of the upper
until disassembly is completed. knuckle joint.
STEP 7 STEP 10

71

SD01M058 SD01M061

Unscrew both the securing screws (item 71) of the Remove the hexagonal nut (item 63) of the lower
lower bolt of the hydraulic cylinder. knuckle joint.
STEP 8 STEP 11

61

62
69
SD01M059 SS01M019

Pull out the bearing bolts (item 69). If necessary, lift up
the protective sleeve slightly to ease removal of the
bearing bolt. Remove he spacers and disk springs
from the lower side of the hydraulic cylinder.
127( There are two threads for thrust screws in the
bearing bolt. The threads are closed by plastic caps.
Unscrew the securing screws (item 62) of the lower
flange. Pull out the lower flange (item 61).
127( If the knuckle joint sticks in the flange,
unscrew the nut and place it flush to the end of the
spigot. Using a lever, press between the kingpin
housing and the swinging arm and simultaneously
remove the knuckle joint from the flange using a soft
hammer.
,03257$ 17 Always replace the nuts and the
knuckle joints.

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 5007-43

STEP 12 STEP 15

52

53

55

56
SD01M062 SS01M020

Slowly lower the kingpin housing until the lower Screw off the hexagonal nut (item 56) of the upper
swinging arm is free. knuckle joint and remove the washer (item 55). Pullout
the upper knuckle joint (item 52) or, when necessary,
127( Do not damage the thread of the knuckle
drive it out using a suitable extraction tool.« To do this,
joint.
screw on the nut and place it flush to the end of the
STEP 13 spigot. If the sleeve has to be replaced (item 53) then
drive it out or press it out using a suitable extraction
tool.
127( Check the upper and the lower knuckle joint
for wear and check their sealings for tightness. If
necessary, replace the knuckle joint.
STEP 16

58
SD01M063

Swing up the swinging arm together with the fork

holder.
:$ 51,1* With the axle mounted, secure the
swinging arm in its upwards position!
STEP 14 SD01M066

Drive out the shaft sealing ring (item 58) using a

suitable extractor. If necessary, drive out the bearing
bush (item 57) using a suitable extractor.

SD01M064

Slowly lower the kingpin housing and simultaneously

swing it outwards and upwards. Remove the king pin
housing from the drive shaft.
127( Do not damage the thread of the knuckle
joint.

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5007-44

50
51

46
45
44
43
42
41 81
40 80
79
40 78
52 49 77
53 48 76
82 47 75

54 55
68
56
67
66
74
71 73
57 72
58
70
69

65

59
83
64
60
61
62 SS03D065

63

40. GREASE NIPPLE 55. WASHER 70. GREASE NIPPLE

41. CIRCLIP 56. HEXAGONAL NUT 71. FIXING SCREW
42. CENTRE PIN 57. SLEEVE 72. DISK SPRING
43. WASHER 58. SHAFT SEAL 73. SPACERS
44. BEARING BUSHES 59. STOP SCREW 74. SCREWED JOINT
45. SEALING RING 60. NUT 75. SPACERS
46. BEARING BOLTS 61. FLANGE 76. HYDRAULIC CYLINDER
47. SEALING RING 62. SECURING BOLT 77. GREASE NIPPLE
48. BEARING BUSHES 63. HEXAGONAL NUT 78. DISK SPRING
49. WASHER 64. SWINGING ARM 79. SPACERS
50. HEXAGONAL NUT 65. KNUCKLE JOINT 80. WASHER
51. SWINGING ARM 66. HEXAGONAL NUT 81. CIRCLIP
52. KNUCKLE JOINT 67. SPACERS 82. BLEED SCREW
53. SLEEVE 68. DISK SPRING 83. WASHER
54. KING PIN HOUSING 69. BEARING BOLTS

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 5007-45

Fitting
67(3 STEP 3

 53




66' SS01M125

Fit the stop screw (item 59) together with the nut (item
60) and the washer (item 83).
Tightening torque Nut ..................................450 Nm
127( $GMXVWWKHVWRSVFUHZVRWKDWWKHW\UHVPXG
JXDUGVGRQRWFROOLGHZLWKWKHFKDVVLVRQUHDFKLQJWKH
PD[LPXPVWHHULQJDQJOHDQGUDQJHRIPRYHPHQW
Drive in or press in the sleeve (item 53) into the
kingpin housing using a suitable insertion tool.
127( To ease assembly, cool the sleeve using dry
ice.
STEP 4

STEP 2 52

53

55

56
SS01M020

Insert the knuckle joint (item 52) into the sleeve

SD01M102
Drive in a new bearing sleeve (item 57) using special
tool 380000024. Attach a new sealing ring (item 58)
using special tool 380000032.
127( Insert the sealing ring with the lip seals
pointing towards the bearing bush.
(item 53) in the kingpin housing. Fix the knuckle joint
using a washer (item 55) and a new hexagonal nut
(item 56).
Tightening torque.........................................250 Nm
STEP 5

SD01M057

Lift and secure the upper swinging arm.

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5007-46

STEP 6 STEP 9

SD01M054 SD01M105

Screw in an eye screw into the holes in the kingpin Slowly lower the upper swinging arm, simultaneously
housing and hang the kingpin housing onto a lifting inserting the knuckle joint.
device. 127( Make sure that the thread of the knuckle joint
STEP 7 is not damaged.
STEP 10

61

62
SD01M103

Push sliplock 380000034 onto the profile of the drive SS01M019

shaft to protect the shaft sealing ring from damage Insert the flange (item 61) into the lower swinging arm.
(item 58). Lift up and position the kingpin housing. Fit Screw in and tighten the three screws (item 62).
the drive shaft into the kingpin housing.
Tightening torque ........................................ 169 Nm
127( Grease the sealing lip of the shaft sealing ring
before assembly.
STEP 11

STEP 8

SD01M061

Attach a new hexagonal nut to the lower knuckle joint

SD01M104
and tighten.
Slowly lift the kingpin housing and simultaneously fit it Tightening torque ........................................ 250 Nm
into the lower knuckle joint.
127( Make sure that the thread of the knuckle joint
is not damaged during insertion.

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STEP 12 STEP 15

46 147
SD01M060 106
SS01M126
Attach a new hexagonal nut to the upper knuckle joint
and tighten. Grease the sleeve in the fork holder (item 147) suf-
Tightening torque ........................................ 250 Nm ficiently and align it to the hole in the protective sleeve
(item 106). Grease the bolt (item 46) and push it in.
STEP 13
127( Align the nut in the bolt to the threaded hole
of the fixing screw (item 107).
STEP 16
Screw the fixing screw (item 107) into the protective
sleeve until the nut grips onto the bolt.
STEP 17

SD01M106

Make sure that there is one disk spring (items 68

and 72) on each side of the hydraulic cylinder as well
as a spacer for each (items 67 and 73). Align the holes 45
in the lower swinging arm and in the hydraulic cylinder
and push in the bolts.
127( Grease the disk springs, spacers, bolts and SS01M127
holes. Always grease the upper and lower bearings
after mounting the cylinder. insert a new sealing ring (item 45) into the centre pin
using insertion tool 380000031. Grease the sealing
STEP 14 ring and the centre pin sufficiently.
STEP 18

71

SD01M058

Attach the securing screws (item 71) of the lower bolt 42

SS01M128
and tighten them.
Tightening torque .......................................... 95 Nm Insert the centre pin (item 42) into the fork holder.

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STEP 19

SD01M107

Insert the circlip (item 41).

STEP 20

SD01M108

Screw the lubrication nipple (item 40) into the removal

hole in the centering bush.
STEP 21

SD01M109

Tighten the centre pin (item 107) to secure the bearing

bolt (item 46) in the fork holder.
127( Secure the fixing screw with Loctite 542.
Tightening torque ........................................135 Nm
Tighten the lock nut (item 108) of the fixing screw.
Tightening torque ..........................................70 Nm

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HYDRAULIC CYLINDER
127( The following points must be observed prior to removing the hydraulic cylinder:
• Remove the torsion bar (see page 34)
• Swing up the upper swinging arm (see page 41)

Removal
STEP 1 STEP 4

78

79

80
81
71

SD01M058 SD01M074

Unscrew both securing screws (item 71) of the lower Remove the circlip (item 81) from the upper bolts.
bearing bolt. Remove the washer (item 80), the spacers (item 79)
and the disk springs (item 78).
STEP 2
STEP 5

69
SD01M059

Lift the swinging arm to unload the bearing bolt. Pull
out the bearing bolts (item 69) or press out with two
screws. Remove the spacers (items 67 and 73) and
the disk springs (items 68 and 72) from under the
hydraulic cylinder.
STEP 3
64
SD01M075
Pull out the hydraulic cylinder from the upper bolt and
the remove the spacer (item 75) behind it.
Check all parts of the cylinder fixing including the
bearing bolts and replace as necessary. Check
tightness and easy accessibility of the cylinder. Check
the condition of the piston surface.
127( A sealing set is available for the hydraulic
cylinder.

SD01M067

Swing the lower swinging arm (item 64) downwards

until the hydraulic cylinder is free.

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Fitting
STEP 1 STEP 4
75

74

69
SD01M091 SD01M106

Attach the spacer ring (item 75) at the upper hole with Grease the holes of the swinging arm and the
the chamfer pointing towards the housing. Position hydraulic cylinder as well as the bearing bolts
the hydraulic cylinder at the upper bolt and mount it (item 69). Align the holes and push in the bearing
using a suitable insertion tool. bolts.
,03257$17 Before mounting the cylinder, check
STEP 5
the position of the screwed joint (item 74). The
threading must be tilted forwards by 8° (in driving
direction).
STEP 2

78

79
71
80

81 SD01M058

Screw in and tighten the screws (item 71).

Tightening torque ..........................................95 Nm
SD01M092 Fit the stopper plugs into the pressure thread of the
Fit the spring disks (item 78), the spacer ring bearing bolt.
(item 79), the washer (item 80) and the circlip STEP 6
(item 81).
Grease both bearings of the hydraulic cylinder using
STEP 3 a grease gun.

68
67 73
72

SS01M025

Attach the spring disks (items 68 and 72) and the

spacer rings (items 67 and 73) by greasing them onto
the cylinder.
127( Attach all spring disks in such a way that the
outer diameter is on the cylinder.

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DRIVE SHAFT
127( The following points must be observed prior to removing the drive shaft:
• Remove the planetary gear unit (see page 19)
• Remove the pressure plate and the brake disc when equipped (see page 23)
• Remove the torsion bar (see page 34)
• Remove the kingpin housing together with the wheel hub (see page 41)

Removal
STEP 1 STEP 3

42 45

SD01M055 SS01M017

Loosen the locking nut (item 108) and the fixing screw
(item 107) of the baring bolt in the protective sleeve
(item 106).
STEP 2
Pull out the centre pin (item 42) from the fork holder
using a standard extractor (M8x1 thread).
127( Check the ’O’ ring (item 45) and replace if
required.


STEP 4



46

6'0

Unscrew the lubrication nipple (item 40) from the cen-
tering bush. Remove the circlip (item 41) from the fork
holder.
SS01M018
Pull out the bearing bolt (item 46) using a standard
extractor (M8 thread).
127( If necessary, lift up the protective sleeve by
the drive shaft to ease removal of the bearing bolt.

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STEP 5 STEP 8

64

SD01M067 SD01M069

Swing the lower swinging arm (item 64) downwards. Turn the locking nut (item 190) and the fixing screw
Swing the hydraulic cylinder upwards. (item 191) of the centre pin (item 114) of the inner
drive shaft several times. Do exactly the same with
STEP 6 the fixing screw (item 179) on the opposite side of the
axle housing.
STEP 9
106

SD01M068
106
Remove the outer drive shaft from the protective
sleeve (item 106).
SD01M070

STEP 7 Remove the protective sleeve (item 106) with the

inner drive shaft from the axle housing.
STEP 10

110

100

109 105
SS01M021

Remove both sealing rings (item 110) as well as the

bearing (item 109) from the protective sleeve.
SD01M071

127( Check the sealing rings and the bearing

Dismount the drive shaft from the protective sleeve.
Always replace the sealing rings.
• Carefully plug the protective sleeve together with
the drive shaft into a vice.
• Screw out the fixing screw (item 105).
• Remove the circlip (item 100) from the protective
sleeve.
,03257$ 17 Do not drive out the drive shaft
through the protective sleeve, but remove it via the
fork of the universal joint shaft using a soft hammer.

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STEP 11 STEP 14

104 103 102 101

115

SD01M072 SS01M024

Pull out the inner drive shaft together with the bearing • Remove the circlip (item 104) from the drive shaft
and the sealing rings from the protective sleeve. (wheel side).
Remove the ’O’ rings (item 115). • Pull off the bearing (item 103).
• Pull off the sleeve (item 102) together with both
STEP 12 sealing rings (item 101).
• Remove both sealing rings (item 101) from the
sleeve (item 102).
127( Check all parts of the inner and outer drive
shaft (joints, drive profile, teeth of the sun gear,
bearing, running surfaces of sealing rings, surfaces
of bearings and sealing rings in the protective sleeve
and in the centre pin) for wear. Replace worn parts.
114 112 111

SS01M022

Remove both circlips (items 111 and 112) from the

end of the drive shaft (differential side). Pull out the
centre pin (item 114) using a standard extractor,
together with the bearing and the sealing ring.
STEP 13

116

113

SS01M023

Remove the sealing ring (item 116) from the centre

pin Drive out the bearing (item 113) from the centre
pin using an extraction tool.

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97

96
95
94

93

92 98
91
90

99
100
101
102
103
104
105
106
107
108
111
109 112
113
110
114

115
116

SS01M164

90. CIRCLIP 99. SLIDING PIECE WITH FORK 108. NUT

91. THRUST WASHER 100. CIRCLIP 109. NEEDLE BEARING
92. THRUST WASHER 101. SEALING RING 110. SEALING RING
93. SHAFT WITH FORK 102. SLEEVE 111. CIRCLIP
94. CROSSED SPIGOT, COMPLETE 103. BEARING 112. CIRCLIP
95. CIRCLIP 104. CIRCLIP 113. BEARING
96. DOUBLE-JOINTED FORK 105. FIXING SCREW 114. SLEEVE
97. SHAFT WITH FORK 106. PROTECTIVE SLEEVE 115. ’O’ RING
98. SHAFT WITH FORK 107. FIXING SCREW 116. CARTRIDGE SEALING RING

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Fitting
127( The following units must already be mounted prior to inserting the drive shaft:
• The differential carrier in the axle housing (see page 92)
• The lower swinging arm (see page 61)

STEP 1 STEP 3

114
102
116

113
101

SS01M023
SS01M120
Fit the bearing (item 113) and the circlip (item 112).
Insert two new sealing rings (item 101) into the sleeve Insert a new cartridge sealing ring (item 116) into the
(item 102) up to the stop using insertion sleeve (item 114) up to the stop using a suitable
tool 380000444. The grease the sealing rings. insertion tool.
,03257$17 Insert both sealing rings with the lip STEP 4
seals pointing towards the universal joint shaft. When
later filling the protective sleeve with grease, the
grease must be able to exit via the sealing ring. 103

STEP 2

102 102

100 100

SS01M121
114
Place the circlip (item 100) (which will be required
SD01M122
later) onto the drive shaft. Push the sleeve (item 102)
onto the drive shaft together with the sealing rings. Fit the bearing (item 103) and the sleeve (item 114)
onto the drive shaft.
127( To ensure that the sealing rings are not
damaged when pushing them on, attach insulating
tape at the edge X. Remove the insulting tape after
assembly.
,03257$17 Fit the sleeve (item 102) so that the
sealing lips are facing towards the universal joint
shaft.

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STEP 5 STEP 7

105
116

104
111

115 105

SD01M093

SD01M095
Fit the circlip (items 104 and 111). Attach a new
‘O’ ring (item 115) onto the sleeve. 127( The opening of the circlip must be at the
STEP 6 fixing screw (item 105).
STEP 8

100

102

106

SD01M096
380000398
Cover the thread of the fixing screw (item 105) with
Loctite 542. Screw in the fixing screw and tighten it.
127( The fixing screw secures the sleeve
SS01M124 (item 102) against turning in the protective sleeve.

Carefully plug the protective sleeve (item 106) of the STEP 9

drive shaft into a vice. Cover the sleeve (item 102)
seating with Loctite 542. Grease the profile of the
sliding piece of the inner drive shaft.
Insert the inner drive shaft into the protective sleeve
using special tool 380000398.
110
127( To insert the sleeve (item 102) correctly,
proceed as follows:
• Insert the u-shaped, special tool 380000398
between the sleeve and the universal joint shaft.
• Fit the drive shaft into the protective sleeve. 109
• Hit the shaft end with a soft hammer until the
SS01M021
sleeve is flush with the protective sleeve. Remove
special tool 380000398. Drive the roller bearing (item 109) into the protective
• Drive in the shaft until the bearing (item 103) sleeve using insertion tool 380000448 (NH 294165-
reaches the stop. Adjust the sleeve with a suitable 6). Drive the two new sealing rings (item 110) into the
insertion tool until the safety ring (item 100) can protective sleeve using insertion tool 380000443.
be inserted. (see next step)
127( The sealing lips of both sealing rings
(item 101) must point outwards (to the joint).

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STEP 10 STEP 13

114
115

SD01M097
SD01M101

Grease the ’O’ ring (item 115) at the centre pin
(item 114). Insert the drive shaft group with the centre
pin into the axle housing up to the stop.
127( Facilitate fitting of the profile by slightly
turning the shaft.
STEP 11
Replace the screw plug (see arrow) in the protective
sleeve by a lubricating nipple. Using a manually
operated grease gun, press in some grease
(POLYMER 400 or equivalent) until it is pressed out at
the sealing rings at the ends of the protective sleeve.
Remove the lubricating nipple and screw in the screw
plug (covered with Loctite 542).
127( The screw plug must not be screwed in
deeper than the surface of the protective sleeve.

SD01M099

Fix the centre pin using fixing screws (items 179

and 191). Tighten the lock nuts.
Tightening torque – fixing screw ................... 30 Nm
Tightening torque – lock nut.......................... 80 Nm
STEP 12

106

SD01M100

Grease the drive profile of the outer drive shaft. Insert

the shaft, turning slightly, until it reaches the stop in the
protective sleeve (item 106).
127( The drive profile must not damage the
sealing rings in the process.

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SENSORS
Removal
STEP 1 STEP 4

126

SD01M006 SD01M009

Tighten the securing screws (item 122) of the sensor Remove the sensor (item 126).
cover.
STEP 5
STEP 2
127
123
120

127
126

SD01M010

Unscrew the fixing screws (item 123) and the holder

SD01M007
(item 127) and then remove the holder.
Remove the cover (item 120). Unlock the plug and
pull it off from the sensor (item 126).
STEP 6

STEP 3 128

127

SD01M011

Remove the rubber disk (item 128).

SD01M008
127( Check the condition of the rubber disk
Unscrew the nuts from the sensor fixing and remove (sensor shaft drive) and replace if required.
the washers.
127( The sensor can also be dismounted together
with its holder (item 127; see step 5).

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Fitting
STEP 1 STEP 4
129

128

126

SD01M150 SD01M153

If the holding ring (item 129) has been removed, cover Attach the sensor (item 126) to the holder. Push the
its circumference with LOCTITE 542 and insert it into sensor shaft into the rubber disk.
the bearing bolt.
STEP 5
127( The groove of the holding ring must be flush
with the fixing screw of the bearing bolt of the upper
swinging arm. 127
STEP 2

123
128

SD01M008

Attach the washers and the nuts of the sensors.

STEP 6
SD01M151
Centre the sensor shaft in the rubber disk by shifting
Insert the rubber disk (item 128) in such a way that its the holder (item 127). Tighten the securing screws
nose grips into the groove of the holding ring (item 123) of the holder.
(item 129). The “OUTSIDE" mark must point Tightening torque ..........................................13 Nm
outwards.
STEP 3

127

SD01M152

Position the holder (item 127) onto the upper swinging

arm. Screw in the screws, but only tighten them
slightly to start with.

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STEP 7 STEP 9
121
Adjusting the Sensors
127( The sensors can be set either with the axle
inserted or removed. To set the inserted axle, refer to 122
chapter 5002.

Setting the removed axle:

127( Before setting the sensor, the torsion bars
must be fitted and tightened (see page 39). The axle
stubs must be in the topmost position. (hydraulic
cylinder is driven up to the stop) SD01M156

Clean the sealing surfaces on the swinging arm and

on the cover. Cover the sealing surface of the cover
with Loctite 518.
Mount the cover with the fixing screws (item 122).
Tightening torque ..........................................13 Nm
127( Make sure that the stop plug (item 121) is in
the cover.

SSO2A053

1. Connect a multimeter and a 12V battery as shown

in the diagram. If available, Y-adapter 380000070
can be used.
2. By turning, set the sensor in such a way that a
signal current of 7.8 mA ±0.5 is achieved.
3. Tighten the fixing nuts.
Tightening torque ............................................ 4 Nm
127( Supply the sensor with 12 volts DC.
STEP 8

SD01M154

Connect the sensor line.

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SWINGING ARM
127( Before the swinging arm can be removed, the following work must be carried out:
• Remove the sensor (see page 58)
• Remove the torsion bar (see page 34)
• Remove the planetary gear unit (see page 19)
• Remove the pressure plate and the brake disc when equipped (see page 23)
• Remove the lower bolts of the hydraulic cylinder (see page 49)
• Remove the king pin housing (see page 41)
,03257$17 If only the upper swinging arm is removed, then from he work listed above, only the sensor has to be
removed! As preparatory work, steps 2 - 5 and step 9 have to be carried out as listed in the chapter on removing the
kingpin housing (see page 41).

Removing the upper swinging arm

STEP 1 STEP 3
176

153

SD01M076 SD01M077

Loosen the nut locks. Screw out the fixing screw of the
bolt (item 176) of the upper swinging arm. Screw out
the fixing screws of the cover (item 153).
STEP 2
Secure the swinging arm with a lifting device. Drive
out the bolts (item 132) using a soft mandrel.
STEP 4

 131
 132

133

 SS01M027
66'
Remove the O-ring (item 131) and the thrust washer
Remove the cover (item 151) with the O-ring (item (item 133).
152) and the thrust washer (item 150).
127( &KHFN WKH EROW 2ULQJV DQGWKUXVW ZDVKHUV
UHSODFHDVUHTXLUHG

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STEP 5 STEP 8

149






SS01M028 660

Pull out the sleeve (item 149) from its seating and Unscrew the lubrication nipple (item 142) from the
remove the swinging arm. centering bush (item 140). Remove the circlip (item
141).
STEP 6
STEP 9
134

148

135 137
SS01M029 140
SS01M031
Remove the sealing rings (item 135). Drive out the
sleeves (items 134 ad 138) using a suitable extractor. Pull out the centre pin (item 140) from the swinging
arm using a standard extractor (M8x1 thread).
127( Check the sealing rings and the sleeves;
replace if necessary. 127( Check the sealing ring (item 137) and the
bearing bush (item 138) in the centre pin and replace
STEP 7 them if necessary.
STEP 10

SD01M078

Drive out the clamping sleeve (item 143).

136
SS01M032

Pull out the bearing bolt (item 136) using a standard

extractor (M8 thread).

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 5007-63

STEP 11 STEP 12
146

48

SD01M086 47

When necessary, replace the sealing ring (item 146) SS01M033

and the bearing bush (item 145) in the upper swinging
arm. When necessary, replace the sealing ring (item 47)
and the bearing bush (item 48) in the fork holder.

Removing the lower swinging arm

STEP 1 STEP 3

SD01M080 157
Unscrew the castellated nut (item 165) using nut key SS01M036

380000041 and then remove it.
127( When necessary, hold the opposite side of
the shaft using a suitable tool.
STEP 2
Relieve the swinging arm and drive out the shaft
(item 157) using a soft mandrel.
STEP 4

  161

SS01M037

Pullout the cover (item 161) and remove the swinging

66' arm.
Remove the ring (item 164) and the O-ring (item 166). 127( Check the shaft (item 157) and the sleeve
(item 161) and replace them if necessary.

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STEP 5 STEP 7

162


 159

SS01M039
66'
Drive out the sleeves (items 159 and 162) using a
Remove the washer (item 167) with the O-ring (item suitable extractor.
156).
127( Check the sleeves; replace if necessary.
127( &KHFN WKH VHDOLQJ ULQJV DQG WKH ZDVKHUV
UHSODFHDVUHTXLUHG STEP 8
STEP 6 66

163

158
65

156 154
154
SS01M040
160
SS01M038 Loosen the hexagonal nut (item 66). Dismount the
universal joint (item 65) from the lower swinging arm.
Remove the sealing rings (items 156 and 160) and If necessary, dismount the stop (item 154).
the thrust washers (items 158 and 163).
127( Check the universal joint; replace if
127( Check the sealing rings and the thrust necessary.
washers; replace if necessary.
127( Secure the fixing screws (Item 155) with
Loctite 542.

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 5007-65


 







 
 

 



 






 





 
 

 



 








SS03D063


51. UPPER SWINGING ARM 131. ’O’ RING 144. WASHER 157. SHAFT
64. LOWER SWINGING ARM 132. BEARING BOLTS 145. BEARING BUSHES 158. THRUST WASHER
120. COVER 133. THRUST WASHER 146. SEALING RING 159. SLEEVE
121. PLUG 134. SLEEVE 147. FORK HOLDER 160. SEALING RING
122. BOLT 135. SEALING RING 148. SLEEVE 161. SLEEVE
123. BOLT 136. BEARING BOLTS 149. SLEEVE 162. SLEEVE
124. WASHER 137. SEALING RING 150. THRUST WASHER 163. THRUST WASHER
125. NUT 138. BEARING BUSHES 151. COVER 164. ’O’ RING
126. SENSOR 139. WASHER 152. ’O’ RING 165. SLOTTED ROUND NUT
127. HOLDER 140. CENTRE PIN 153. CYLINDER SCREW 166. ’O’ RING
128. RUBBER DISK 141. CIRCLIP 154. STOP 167. WASHER
129. HOLDING RING 142. GREASE NIPPLE 155. BOLT
130. SENSOR LINE 143. CLAMPING SLEEVE 156. ’O’ RING

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5007-66

Installing the lower swinging arm

STEP 1 STEP 3
162

159

SS01M092 SS01M094

Drive the sleeves (items 159 and 162) flush into the Position the lower swinging arm at the axle housing in
swinging arm using insertion tool 380000447. such a way that the sleeves in the swinging arm are
flush with the hole in the axle housing.
STEP 2
STEP 4







66'

Grease the sealing rings (item 160) and the thrust wa-
sher (item 158) sufficiently. Insert both sealing rings
(item 160) into the swinging arm using insertion tool
380001512.
127( 7KH VHDOLQJ ULQJV PXVW EH LQVHUWHG ZLWK WKH
VSULQJSRLQWLQJLQZDUGV
66'
Heat the washer (item 167) up to approx. 120 °C and
fit it on the shaft (item 157). Fit the O-ring (item 156)
on the washer.
127( $OVRJOXHWKHZDVKHUXVLQJ/RFWLWH

Insert the thrust washer (item 158). 127( )LW WKH ZDVKHU ZLWK WKH JURRYH SRLQWLQJ
WRZDUGVWKHVZLQJLQJDUP
127( 7KH WKUXVW ZDVKHU PXVW EH LQVHUWHG ZLWK
´3,76´SRLQWLQJRXWZDUGV





66'

Sva 6-51651 EN Edition 04-2004

 5007-67

STEP 5 Grease and insert the ring (item 164).

127( The ring must be inserted with the chamfer
pointing towards the thrust washer.
STEP 8

157

SS01M106

Drive in the shaft (item 157) with a soft hammer. (with

SD01M085
tread pointing in the driving direction)
127( Do not damage the sealing rings, sleeves
and thrust washer.
,03257$17 Before assembling the shaft, make
sure that the sealing rings, thrust washers and
sleeves, as well as the shaft, are all sufficiently
greased.
STEP 6
SS01M109
161
Screw on and tighten the castellated nut using nut key
380000041.
When necessary, hold the opposite side of the shaft
using a suitable tool.
Tightening torque........................................ 600 Nm
127( The swinging arm must be able to move
SS01M107 freely after tightening the castellated nut.

Drive in the sleeve (item 161) using insertion tool

STEP 9
380001512. 66
127( The sleeve must be driven in to the stop in
the axle housing.
STEP 7
164
163

65

SS01M110

Insert the knuckle joint (item 65) with a new hexagonal

nut (item 66) into the swinging arm and tighten.
Tightening torque........................................ 250 Nm
SS01M108
127( Use a new hexagon nut (item 66)!
Grease and insert the thrust washer (item 163).
127( *UHDVH WKH EHDULQJ SRLQWV RQ WKH VZLQJLQJ
127( 7KH WKUXVW ZDVKHU PXVW EH LQVHUWHG ZLWK DUPVHH6HLWH
´3,76´SRLQWLQJRXWZDUGV

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5007-68

Installing the upper swinging arm

STEP 1 STEP 4

137

47
SS01M033 SS01M112

Grease the new sealing ring (item 47) and insert it into
the fork holder using insertion tool 380000031 (with
sealing lip pointing towards the insertion tool).
STEP 2
Grease the new sealing ring (item 137) and insert it
into the centre pin (item 140) using insertion
tool 380000031 (with sealing lip pointing towards the
insertion tool).
STEP 5

SD01M086 SD01M087

Grease the new sealing ring (item 137) and insert it
into the swinging arm using insertion tool 380000031
(with sealing lip pointing towards the swinging arm).
STEP 3
Grease the bearing bush in the centre pin sufficiently.
Insert the centre pin into the swinging arm.
STEP 6



136 147 66'

SS01M111
Insert the circlip (item 141). Screw in the lubrication
Position the fork holder (item 147) in the swinging nipple (item 142).
arm and insert the bearing bolt (item 136). (Grease
the bearing bolt)
127( Align the hole X in the bearing bolt to the hole
in the fork holder. The threaded hole in the bearing
bolt must point towards the centre pin.

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 5007-69

STEP 7 STEP 9

SD01M088 SS01M115

Insert the clamping sleeve (item 143) into the fork Position the upper swinging arm at the axle housing
holder. using a lifting device.
STEP 8 STEP 10
134

133

148 135
150
SS01M114 SS01M116

Grease the thrust washers (items 133 and 150) and

insert them into the swinging arm.
127( 7KH WKUXVW ZDVKHUV PXVW EH LQVHUWHG ZLWK
´3,76´SRLQWLQJRXWZDUGV
STEP 11

132

66'

Insert the sleeves (items 134 and 148) into the upper
swinging arm using insertion tool 380000445. Grease
the new sealing rings (item 135) and insert them into
the swinging arm using insertion tool 380001488. (see
SD01M089
figure)
Fit the O-ring (item 131) on the bolt. Insert the bolt,
thereby aligning the groove to the threaded hole of the
fixing screw (item 176). Drive the bolt in until it comes
to rest using a soft hammer. Turn the fixing screw until
it comes to rest.
,03257$17 6XIILFLHQWO\JUHDVHWKHWKUXVWZDVKHUV
VOHHYHVEROWDQGWKH2ULQJ

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5007-70

STEP 12 STEP 14
176

149 SD01M090

SS01M117 Tighten the fixing screw (item 176).

Grease the sleeve (item 149) and insert it with the
chamfer facing towards the axle housing.
127( Do not fully insert the sleeve. It will be used
as a guide later when assembling the cover
(item 151).
STEP 13
Tightening torque ........................................ 135 Nm
Tighten the lock nut (item 177).
Tightening torque .......................................... 70 Nm
,03257$17 The swinging arm must be able to
move freely.
6&+5,77
/8%5,&$7,2132,1766

/8%5,&$7(817,/*5($6(&20(6287

$77+(32,1766+2:1





 66'

Fir a new O-ring (item 152) on the cover (item 151).

Grease the cover with the O-ring and position the co-
ver on the protruding sleeve. Use a soft-faced hammer
to drive in the cover and sleeve until they come to rest.
Screw in and tighten the three fixing screws (item
153).
Tightening torqueTightening torque...............50 Nm
66'
,03257$17 Repeat the tightening procedure for
the fixing screws (item 153) several times. Grease all lubrication points on the swinging arms.

127( Secure the fixing screws (Item 153) with

Loctite 243.

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 5007-71

STEERING CYLINDER
Removal
STEP 1 STEP 4

171

172

SD01M012 SD01M015

Loosen the lock nut (item 172). Unscrew the (item 171) track rod.
STEP 2 STEP 5

170

SD01M013

SD01M016
Loosen the nut (item 170).
Dismount the screw-in fitting for the hydraulic line.
STEP 3
STEP 6

174

170

SD01M014

SD01M017
Align the nut (item 170) flush to the spigot of the
steering knuckle arm (track rod arm). Disconnect the Loosen the securing screws (items 174) of the
steering knuckle arm from the kingpin housing using steering cylinder.
a soft hammer.

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STEP 7 STEP 10

SD01M018
SD01M021
Pull out the steering cylinder from the axle housing.
Disassemble the seals of the cylinder pipe. Check the
STEP 8 cylinder pipe and replace it as required.
STEP 11

SD01M019

Check the steering cylinder after removing it. Unscrew

both knuckle joints (item 173) from the piston rod. SD01M022

Disconnect the cover from the steering cylinder and

Dismount the sealing rings and the washer bushings
pull out the piston rod.
from the piston rod. Check the piston rod and replace
127( Check both knuckle joints and both steering it as required.
knuckle heads for wear and replace as required.
STEP 9

SD01M020

Remove the cover from the piston rod. Disassemble

the sealing rings.

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 5007-73

Fitting
STEP 1 STEP 4

SD01M020 SD01M142

Grease the new sealing rings and insert them into the Push the pre-assembled piston rod into the steering
cover. cylinder and mount the steering cylinder head.
STEP 2 STEP 5

SD01M201
SD01M021
Push the steering cylinder into the bores (attachment
Grease the new sealing rings and insert them into the holes) of the axle housing.
cylinder pipe.
STEP 3 STEP 6

173
173
SD01M143
SD01M022
Screw the knuckle joints (item 173) of the track rods
Insert the new sealing rings on the piston rod. onto the ends of the piston rod.
127( Grease the sealing rings before mounting Tightening torque ........................................ 300 Nm
them.

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5007-74

STEP 7 STEP 9
174

170

SD01M144 SD01M146

Screw in the securing screws (items 174) of the Insert the knuckle joints of both track rods into their
steering cylinder. appropriate seatings in the kingpin housing and screw
Tightening torque ........................................120 Nm on the nuts (item 170).

STEP 8 127( The nuts must be replaced.

171 STEP 10

172

SD01M145

If track rods have been removed (item 171) then screw SD01M147

them back onto the knuckle joints. While holding on to Tighten the nuts.
the track rod, tighten the lock nuts (item 172).
Tightening torque ........................................ 220 Nm
Tightening torque ........................................250 Nm

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 5007-75

174

170
171
172
173

175

173
172
176 176 197
170
177

180 185 186

179 184
181
178 183
182
187

188

190
179
191
176
178

177
197

187
192 189
193
188 194 190
195 191 SS01M192
196

170. NUT 180. VENT 190. COUNTER LOCKING NUT

171. LEFT TRACK ROD 181. COVER 191. FIXING SCREW
172. COUNTER LOCKING NUT 182. FILLER PLUG 192. THRUST WASHER
173. KNUCKLE JOINT 183. THRUST WASHER 193. SLEEVE
174. SECURING BOLT 184. SLEEVE 194. ’O’ RING
175. STEERING CYLINDER 185. SLEEVE 195. SLEEVE
176. FIXING SCREW 186. FRONT BEARING BLOCK 196. REAR BEARING BLOCK
177. COUNTER LOCKING NUT 187. RETAINING SCREW 197. SLEEVE (4)
178. COUNTER LOCKING NUT 188. GREASE NIPPLE
179. FIXING SCREW 189. HOUSING

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4-WHEEL DRIVE AXLE

Removing and Fitting
127( The parts are numbered in order of removal. Re-fit parts in the same manner but in the reverse order.
Before the 4-wheel drive axle can be removed, the following preparatory work must be carried out:
• Put the tractor on firm, level ground, apply the parking brake and use the switch RAISE/LOWER to fully lower the
front axle to its lowest limit. Switch the engine OFF and remove the ignition key.
• Place chocks in front of and behind the rear wheels.
• Disconnect the battery (negative pole first).
127( When re-connecting, connect the positive (+) pole(s) first.
127( Steps 1 to 4 must only be carried out, if the tractor is fitted with the front hitch option.

STEP 1 STEP 3

SD00B017 SD00B019

Remove the brackets for the hydraulic lines on the
outside of the support frame (left and right). Discon-
nect the hydraulic hoses from the pipelines that run in
the support frame.
Seal the hydraulic hoses.
:$51,1* If the tractor is equipped with a free
return to the front, then this line must be sealed. If the
line is not sealed, hydraulic oil will run out!
STEP 2
Loosen the lock nut of the adjusting screw (at the
support frames). Turn out the adjusting screws by two
turns.
127( :KHQ UHDVVHPEOLQJ SUHWLJKWHQ WKH DGMX
VWLQJVFUHZVWR1P7KHQWLJKWHQWKHPDOWHUQDWHO\
XSWRDWRUTXHRI1P6HFXUHWKHDGMXVWLQJVFUHZV
E\PHDQVRIORFNQXWV
STEP 4

SD00B020
SD00B018

Place a hydraulic jack under the support frame and
remove the securing bolts.
Loosen the front fixing screws on the support frame.
Remove the supporting frames.
127( When reassembling, secure screws with
Loctite 242 sichern and tighten them to a torque of
200 Nm!

Sva 6-51651 EN Edition 04-2004


STEP 5
127( For tractors fitted with front hitch, the shaft
protector for the 4-wheel drive shaft must first be
removed.
Place a hydraulic jack under the centre of the axle and
raise the tractor. Lower the front of the tractor onto
suitable support trestles and remove the front wheels.
127( When re-fitting, tighten the wheel nuts of the
front wheels.
Tightening torque – braked axle.................. 570 Nm
Tightening torque – unbraked axle.............. 425 Nm
STEP 6
SS02A054
Place a container, with a capacity of at least 5.5 litres
under the oil drain plug, screw the oil drain plug out
and drain the oil.
127( When re-fitting, tighten the drain plug to a
torque of 60 Nm. Screw the filler plug out and fill oil to
the recommended level; refer to the Technical Data.
Tighten the filling screws to a torque of 60 Nm.
STEP 7
SD00B021
Remove the fixing screws of the console for the front
wheel mudguard.
Sva 6-51651 EN
5007-77
STEP 8
Mark the position of the hydraulic hoses to the steering
cylinder, disconnect them and fit protective caps. Mark
the hydraulic hoses to position of the axle cylinders,
disconnect them and fit protective caps. Disconnect
the hydraulic hose to the differential lock, the front
PTO shaft and the brakes (if fitted) and fit with
protective caps.
,032 5 7$ 17 I n or d er to p re v en t the l os s of
hydraulic oil, the hydraulic hoses must be securely
tied with the open ends upwards (towards the cab).
STEP 9
120
122
SD02A028
Loosen the fixing screws (item 122) and remove the
cover (item 120).
127( When assembling, seal the cover with
Loctite 518. Tighten the securing screws (item 122) to
a torque of 13 Nm.
STEP 10
SD01M154
Mark the connectors at the sensors and disconnect
them.
STEP 11
Remove the 4-wheel drive shaft from the front flange.
127( When assembling, tighten the fixing screws
of the 4-wheel drive shaft to 60 Nm.
Edition 04-2004
5007-78

STEP 12 STEP 14

SD00B026 SD00B028

Place a hydraulic jack under the centre of the front Lower the front axle by means of the hydraulic jack
axle. Loosen the fixing screws on front bearing block. and remove the jack.
STEP 13

SD00B027

Loosen the fixing screws on rear bearing block.

127( The rear bearing block is fitted with two
sleeves (see page 25).
127( When reassembling, lightly coat the securing
bolts of the front and rear bearing blocks with
LOCTITE 243 and tighten them to a torque of
540 Nm.

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PIVOTED BEARING
127( To assemble and to disassemble the swing bearing, the axle must first be removed. (see page 76)

Removal
STEP 1 STEP 4

195

196
SD01M001
187
SD01M004

Remove the rear bearing block (item 196). Unscrewthe fixing screw (item 187) of the bearing
STEP 2 bush (item 195) at the rear bearing block. Remove the
‘O’ ring and the bearing bush. Check all components
and replace as required.
STEP 5

186
SD01M002
197

Remove the front bearing block (item 186).

STEP 3 SD01M005

185 Check centre pin (item 197) of the front and rear
bearing block and replace if required.

187
SD01M003

Unscrewthe fixing screws (item 187) of the bearing

bush (item 185) at the front bearing block. Check all
components and replace as required.

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5007-80

Fitting
127( The differential carrier must already be mounted in the axle housing prior to inserting the swivel bearing.
STEP 1 STEP 4

187

185 SD01M159
SD01M157

Push the bearing bush (item 185) into the front If required, replace the centre pin (item 197) of the
bearing block. front and rear bearing block. Cover the centre pin with
LOCTITE 638 before inserting it.
127( Align the hole for the retaining screw to the
hole in the bearing block. STEP 5
STEP 2



6''

SD01M158
Screw in and tighten the retaining screw (item 187) of
the bearing bush.
Tightening torque ........................................ 200 Nm
Check the lubricating nipple and replace if necessary.
Tightening torque ............................................ 8 Nm
Attach a new ‘O’ ring (item 194) into the bearing bush
of the rear bearing block. Insert the bearing bush into
the rear bearing block.
127( Align the hole for the retaining screw to the
hole in the bearing block.
STEP 6

STEP 3

SD01M161

Screw in and tighten the retaining screw (item 187) of

SD01M002
the bearing bush.
Attachthe front bearing block to the axle housing. Tightening torque ........................................200 Nm
Check the lubricating nipple and replace if necessary.
Tightening torque ............................................8 Nm

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 5007-81

STEP 7

SD01M001

Attach the rear bearing block to the differential carrier.

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DIFFERENTIAL
127( The axle must be removed before removing the differential carrier. (see page 76)

Removal
STEP 1 STEP 3

201
216

229

200

SS01M041 SS01M044

127( Secure the differential carrier (item 201) with Unscrew the lock nut on the left (item 229) using nut
a lifting device before removing it. key 380000406.
Unscrew the lock nut on the right (item 216) using nut
Loosen all fixing screws (item 200) and remove the
key 380000441.
differential carrier.
127( The lock nuts on the left and the right differ
STEP 2 from each other.
STEP 4

219
220A
220
230
217 221

SS01M042

Loosen the fixing screws (item 218) and remove the

SS01M045
lock nuts (items 230 and 217).
Unscrew the fixing screws (item 219) and remove both
127( Mark the position of the adjusting nuts (lock
bearing covers (items 220 and 220 A). If necessary,
nuts) relative to the differential carrier.
remove the centre pins (item 221) from the bearing
covers.

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 5007-83

STEP 5 STEP 6

227 224 226

225

227 228

SS01M046 SS01M047

Remove the outer sealing ring (item 227), the ring
(item 228) and the inner sealing ring (item 227) as well
the disk (item 224).
127( Check the sealing rings and replace as
required.
Remove the differential and the outer rings from the
differential carrier. Remove the support ring (item 226)
and the ’O’ ring (item 225).
,03257$17 Do not swap the two outer bearing
rings when they are re-installed.

Removing the Pinion Shaft

STEP 1 STEP 3

208
207 210
209

SS01M048 SS01M050

Plug the differential carrier into a vice. Remove the Remove both castellated nuts (item 209) and the disk
drive flange (item 207) and the cartridge sealing (item 210).
ring (item 208).
STEP 2

209

SS01M049

Unscrew the castellated nut (item 209) using nut key

380000021 and dolly 380000020.

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5007-84

STEP 4 STEP 7

202
211
212
211
209
212

SS01M051 SD01M081

Press the pinion shaft out of the housing using a
hydraulic press. Remove the disks (item 211), the
spring collet (item 212) and the bearing (item 202).
127( Catch the pinion shaft when dismounting it.
STEP 5
Check the condition of all parts.
,03257$17 The pinion shaft and master gear may
only be replaced in pairs.
127( The castellated nut (item 209) and the spring
collet (item 212) must always be replaced.

SS01M052

Drive out the tapered roller bearing using a suitable

mandrel.
STEP 6

214

SS01M053

Remove the bearing (item 213) from the pinion shaft

using a bearing puller. Remove the packing ring
(item 214).

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 5007-85

229
218 227
228
227
230
224
223

219
220A

226 220
221
225 222

210
209 218
208
207
206 223
215
214 217
213
216
211
212
205 211

200

201

SS01M162

202 203 204

200. SECURING BOLT 211. WASHER 221. SLEEVE

201. DIFFERENTIAL CARRIER 212. SPRING COLLET 222. DIFFERENTIAL
202. BEARING 213. BEARING 223. BEARING
203. DRAIN PLUG 214. WASHER 224. WASHER
204. ALIGNMENT PIN 215. PINION SHAFT 225. ’O’ RING
205. CLAMPING SCREW 216. ADJUSTING NUT, RIGHT 226. SUPPORT RING
206. NUT 217. SECURING PIN, RIGHT 227. SEALING RING
207. FLANGE 218. SECURING BOLT 228. ’O’ RING
208. CARTRIDGE SEALING RING 219. SECURING BOLT 229. ADJUSTING NUT, LEFT
209. SLOTTED ROUND NUT 220. BEARING COVER, RIGHT 230. SECURING PIN, LEFT
210. WASHER 220A.BEARING COVER, LEFT

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DIFFERENTIAL UNIT
Disassembling
STEP 1 STEP 4

243
SS01M059 SS01M055

Remove the inner bearing rings from the differential Remove all outer and inner disks, the disk (item 243)
housing and from the cover using a bearing puller. and the axle bevel wheel (item 244).
STEP 2 STEP 5

248

235 SS01M063

Tilt the differential housing with its open side forwards.

Keep tilting until the three pins (item 248) used for
SD02A001
securing the bearing bolts fall out of their holes.
Plug the differential unit into a vice. Unscrew the
securing screws (item 235) and remove the master STEP 6
gear.
STEP 3 247

239

253

247
236 SS01M057
237
238 Remove the bearing bolts (items 247 and 253) from
240 the differential housing.
SS01M054

Remove the cover (item 236) from the differential

housing. Remove the piston (item 239) from the
differential housing. Replace the ’O’ rings (items 237,
238 and 240).

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 5007-87

STEP 7 Remove the thrust washers (item 245), the differential

bevel gears (item 246) and the cross piece (item 254).
245 Remove the axle bevel wheel (item 249) and the thrust
249
washer (item 250). Clean all components thoroughly
246 250 and check their condition; replace if necessary.
254 127( When re-using parts, always connect them at
the same location as previously. (bearing bolts, thrust
washers and rings and differential bevel gears.

SS01M058

242
242
242
242 243
242 244
245
246
247
248
249
250
241 251
241 252
241
241
241 254

253

235
236 SS01M193

237
238
239
240

235. SECURING BOLT 245. THRUST WASHER (4)

236. COVER 246. DIFFERENTIAL BEVEL GEAR (4)
237. ’O’ RING 247. BEARING BOLTS (2)
238. ’O’ RING 248. PIN (3)
239. PISTON 249. AXLE BEVEL GEAR
240. ’O’ RING 250. THRUST WASHER
241. OUTER DISK (8) 251. DIFFERENTIAL HOUSING
242. INNER DISK (7) 252. DIFFERENTIAL MASTER GEAR
243. WASHER 253. BEARING BOLTS
244. AXLE BEVEL GEAR (LOCKING SIDE) 254. CROSS PIECE

Sva 6-51651 EN Edition 04-2004

5007-88

Assembly
STEP 1 STEP 4

244

243
SS01M061 SS01M064

Clean all parts of the differential unit thoroughly, check Insert the axle bevel wheel (item 244) and the disk
for wear or damage and then assemble as shown in (item 243) into the differential housing. Alternately
the diagram. insert an outer disk and an inner disk (as shown in the
diagram) into the differential housing. The outermost
STEP 2
disk is an outer disk.
STEP 5
247

239

253

247 236
SS01M062 237
238
Place the differential housing vertically (with its 240
SS01M065
opening upwards). Insert the long bearing bolt
(item 253) from the outside. When doing so, insert the Grease the new ’O’ rings (items 237, 238 and 240) and
thrust washer, the differential bevel gear and the cross insert them into the piston nuts (item 239) and the
piece. cover (item 236). Insert the piston and the cover into
Then insert the two short bearing bolts (item 247) with the differential housing.
thrust washers and differential bevel gear.
127( Observe the correct positioning of the piston
STEP 3 (item 239)!

248

SS01M063

Insert the three pins (item 248) to secure the bearing

bolts.
127( The pins (item 248) are held in position by the
disk (item 243).

Sva 6-51651 EN Edition 04-2004

 5007-89

STEP 6 STEP 7

235 SS01M060

127( Both differential bearings are identical.

SD02A001 Warm the new bearing up to 80 °C and push it onto the
Position the master gear at the differential housing. differential housing and the cover. Adjust with a
Cover the fixing screws (item 235) with Loctite 270 suitable insertion tool until the bearings are plane.
and screw them in.
Tightening torque...........................................70 Nm
127( When assembling a new cover (item 236),
check that the oil bore hole (X) is closed.

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5007-90

Adjusting the Pinion Shaft

STEP 1 STEP 4

SS01M066 SS01M069

Insert the outer rings of the new bearing using a
suitable insertion tool.
127( Make sure that the bearing rings seat
correctly against the shoulders.
STEP 2
Measure distance "X" between the differential bearing
and the surface of the inner bearing ring using a depth
gauge and note the result.
STEP 5

SS01M071

SS01M067 Calculate the packing ring required for setting the

Using the clamping device 380000018, the gauge correct meshing as follows:
380000440 + gauge disks 380000439, measure the S= X-V
dimensions of the housing and note the results. S = Gauge – packing ring
X = size of housing (measured from the middle of the
STEP 3
differential to the flush of the bearing)
V = pinion dimension (etched into the end of the
pinion shaft)
220A
220
Example:
X = ......................................................... 118.60 mm
V = ....................................................... - 115.90 mm
S = ........................................................... 2.70 mm

Shim thickness required = 2.70 mm

SS01M068 ,03257$17 Shims are available in a thickness of
2.5 mm to 3.4 mm (in increments of 0.1 mm). If the
Using the clamping device 380000018 insert the new
calculated thickness of the shim is less than 2.5 mm
inner bearing rings into the housing. Tighten the
or more than 3.4 mm, repeat STEP 1 to STEP 5 in
clamping device until there is an initial bearing tension.
order to eliminate a measurement error.
Insert gauge 380000440 together with gauge disks
380000439 into the bearing seating of the differential
carrier. Attach and screw on the bearing covers
(items 220 and 220 A).

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 5007-91

STEP 6 STEP 8
211
212
211

SS01M073 SS01M075

Push the packing ring that has been calculated "S" Tighten the castellated nut using nut key (380000021)
onto the pinion shaft. and dolly (380000020) until the pinion shaft is free of
play.
,03257$17 Fit the packing ring with the chamfer
pointing towards the pinion. 127( The adjustment is made by turning the
castellated nut in steps. Make sure that the
Heat up the new inner bearing to 80 °C and place it on
prescribed rolling resistance is not exceeded.
the pinion shaft.
127( Before checking the rolling resistance, lightly
127( Make sure that the inner bearing ring is in
tap on both ends of the pinion shaft with a soft
contact with the shim (packing ring) (S).
hammer to ensure that the bearings sit correctly.
Attach the disks (item 211) and a new clamping sleeve
(item 212). STEP 9
,03257$17 The clamping sleeve (item 212) must
be replaced after every disassembly.
STEP 7

210
209

SS01M076

,03257$17 Rooling resistance “P" is measured

without a sealing ring (item 208).

SS01M074
Insert the pre-assembled pinion shaft into the
differential carrier. Heat up the second inner bearing
ring to 80 °C and fit it. Attach the disk (item 210) and a
new castellated nut (item 209).
127( Oil the bearing.
Tie a piece of string to the pinion shaft and wind the
string, without overlapping it, around the pinion shaft.
Tie a spring balance to the end of the string and
measure the rolling resistance.
Tighten the castellated nut until the rolling resistance
of the pinion shaft is between 92 and138 N (Newton).
P = 92 - 138 N
P = pinion (pinion shaft)
Note the value displayed for the rolling resistance.
127( If the castellated nut is overtightened and the
rolling resistance is thereby out of tolerance, the
spring collet ([clamping bush] item 212) must be
replaced.
STEP 10
Secure the nut with a suitable mandrel when the
prescribed rolling moment has been reached.

Sva 6-51651 EN Edition 04-2004

5007-92

Assembling the differential

127( The pinion shaft must be attached and the bearing must be set. The sealing ring (item 208) must not be
fitted

STEP 1 Push the pre-assembled spacer ring (item 228)

carefully onto the differential housing (master gear
side).
,03257$17 Do not damage the sealing rings
226 (item 227) when pressing on!
225 Insert the entire differential unit into the differential
carrier.
STEP 3

220

SS01M077
220A
Insert the new ’O’ ring (item 225) and the support ring 221
(item 226) into the oil bore hole (bearing seating on
the master gear side) in the differential carrier. Place
on the outer ring.
STEP 2
228
224
SS01M079

Insert the four centre pins (item 221) into the bearing
covers. Attach both bearing covers (items 220
227 and 220 A) and screw them in manually using the
appropriate screws.
STEP 4

227 224 216

229
229

226
228
225
SS01M078
Place the disk (item 224) with its stepped side
pointing towards the bearing onto the outer bearing
ring. Pre-assemble the sealing rings (item 227) in the
spacer ring (item 228).
127( Use new sealing rings (item 227)! Oil the
sealing rings thoroughly before mounting them.
SS01M080
Screw the castellated nuts (items 229 and 216) into
differential carrier.
Tighten both castellated nuts until the differential
carriers are slightly pre-tensioned. Tap lightly with a
soft hammer to ensure the bearing sits correctly.
127( Make sure that there is always tooth flank
play during this procedure

Sva 6-51651 EN Edition 04-2004


STEP 5
SS01M081
Set tooth flank play to between 0.20 and 0.28 mm
STEP 6
SS01M083
Set tooth flank play as follows:
• If the measured play is smaller than the
indicated tolerance range then loosen the
castellated nut on the master gear side slightly
and screw in the opposite castellated nut
correspondingly.
• If the measured play is larger than the indicated
tolerance range then loosen the castellated nut
opposite the master gear slightly and screw in the
castellated nut on the master gear side
accordingly.
127( After setting the tooth flank play, you must
also make sure that the tapered roller bearings of the
differential bearing is slightly tensioned. Setting the
bearing is described in the next work step.
Sva 6-51651 EN
5007-93
Setting the differential bearing
STEP 7
SS01M084
,03257$17 Rolling resistance “T" is measured
without a sealing ring (item 208).
Tie a piece of string to the pinion shaft and wind the
string, without overlapping it, around the pinion shaft.
Tie a spring balance to the end of the string and
measure rolling resistance "T".
Rolling moment "T" is calculated from the entire
bearing tension:
Bearing of the pinion shaft + differential bearing
P = pinion (pinion shaft)
T = Total
N = Newton (unit for power)
T = (P + 92) to (P + 107) N
If the total rolling moment "T" is too small then screw
in both castellated nuts by the same amount (angle of
rotation: clockwise).
127( The tooth flank play must not be altered.
If the total rolling moment "T" is too large then screw
out both castellated nuts by the same amount (angle
of rotation: anti-clockwise).
Turn the pinion shaft with the differential and tap lightly
with a soft hammer on the side of the differential
housing.
Check the rolling moment and the tooth flank play.
Edition 04-2004
5007-94

Correct meshing check

STEP 8 STEP 10

SS01M085 SS01M088

To check the teeth meshing, cover some of the teeth
on the master gear with red lead.
127( The meshing must always be checked on
BOTH tooth flanks of the teeth of the master gear.
When turning the pinion shaft, simultaneously brake
the master gear. (gives a real meshing)
STEP 9
Tighten the securing bolts on both bearing covers.
Tightening torque ........................................266 Nm
127( After tightening the screws, check the total
rolling moment "T". (see page 93)
STEP 11
230

217

SS01M089

SS01M086 After carrying out the settings and checks, mount the
left and the right securing pins (items 217 and 230)
OK: The position of the meshing is CORRECT. using the appropriate screws (item 218).
Z: Contact with the tooth is too much Tightening torque ..........................................13 Nm
OUTWARDS:
Decrease the distance of the pinion shaft to the
middle of the master gear.
X: Contact with the tooth is too much INWARDS:
Increase the distance of the pinion shaft to the
middle of the master gear.
127( This representation refers to the teeth of the
master gear.

Sva 6-51651 EN Edition 04-2004


STEP 12
208
207
SS01M090
Insert the cassette sealing ring (item 208) into the
differential carrier using insertion tool 380000022.
127( Moisten the inner surface of the cartridge
sealing ring with a mixture of white spirits and water.
Place the drive flange (item 207) on the pinion shaft
and fix using the clamping bolt (item 205).
Tightening torque- clamping bolt................... 57 Nm
STEP 13
204
204
SS01M091
Clean the sealing surfaces at the differential carrier
and at the axle housing. Apply a continuous, thin line
of LOCTITE 518 to the sealing surfaces. Fit the
differential carrier into the axle housing. Screw in and
tighten the appropriate screws.
Tightening torque ........................................ 169 Nm
127( The alignment pins (item 204) must be fitted
Sva 6-51651 EN
5007-95
STEP 14
Screw in and tighten the oil drain screw (item 203).
Tightening torque.......................................... 60 Nm
,03257$17 Fill the axle housing with oil.
Oiltype and filling level (see Technical Data, page 12)
127( You can fill the oil after fitting the inner drive
shafts (see page 51).
After filling the oil, screw in and tighten the oil filler plug
(item 182).
Tightening torque.......................................... 60 Nm
STEP 15
127( Check the vent of the axle housing (item 180)
for blockages:
• Clean the area around the vent.
• Screw out the vent and blow through with
compressed air. When doing so, make sure that
there are no blockages.
• Screw in the vent and tighten it.
Tightening torque.......................................... 10 Nm
Edition 04-2004
5007-96

TRACK ALIGNMENT

"A"

Driving direction

Axle in mid position

"B" SS02B101

127( Before aligning the track, check the tyre air pressure (see Operating Manual).

STEP 1 STEP 7
The front axle must be recalibrated before starting the
track alignment.
172
(see Chapter 5002)
STEP 2
Lower the front axle to the lower limit and then activate
the suspension. Once the axle is in the middle
position, switch 173
off the engine and apply the parking brake.
127( The front wheels must face straight ahead.
STEP 3
Make marks on the rear inside of the wheel rim (rim
flange), at the same height as the centre of the wheel SS00C121

hub.
Loosen the locking nuts (item 172). Extend or shorten
STEP 4 the track rods by turning the knuckle joints (item 173).
Measure the distance B between these marks and Repeat STEP 1 to STEP 5.
make a note of it. When the track has been aligned correctly, tighten the
locking nuts (item 172).
STEP 5
Tightening torque ........................................ 250 Nm
Drive the tractor forwards until the marks at the front
are level with the centre of the wheel hub.
STEP 6
Measure the distance (A) between these marks and
make a note of it. The track must be adjusted so that
value A is
0 to 4 mm smaller than value B.
6HWWLQJ
Axle in “mid-position“.................... 0 to +4 mm (toe-in)
127( If the value determined is outside the
prescribed setting, the track alignment must be
corrected in accordance with 67(3

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 6001
Chapter
6001

FUNCTIONAL DESCRIPTION OF TRANSMISSION

CNH Österreich GmbH Sva 6-51700 EN © 2006 CNH Österreich GmbH

Technical Documentation July 2006
A - 4300 St. Valentin, Steyrer Straße 32
 6001-3

7$%/(2)&217(176

Technical Data ...................................................................................................................................................... 5

Introduction ........................................................................................................................................................... 8

Description ............................................................................................................................................................ 9
Transmission layout ....................................................................................................................................... 11
Transmission plug-in unit (cartridge) .............................................................................................................. 12
Transmission schematic diagram .................................................................................................................. 13
Transmission unit layout ................................................................................................................................ 14

Functional description ......................................................................................................................................... 15

Functional description of power overlay ......................................................................................................... 16
Summing planetary gear ................................................................................................................................ 17
CVT / CVX speed diagram ............................................................................................................................. 18
Ratio 1 / standstill control ............................................................................................................................... 18
Standstill control ........................................................................................................................................ 19
Ratio 1 ...................................................................................................................................................... 20
Ratio 2 ............................................................................................................................................................ 21
Ratio 3 ............................................................................................................................................................ 22
Ratio 4 ............................................................................................................................................................ 23
Forward / reverse ........................................................................................................................................... 24

Claw couplings .................................................................................................................................................... 25

Transmission hydraulics ...................................................................................................................................... 26

Test connections ............................................................................................................................................ 27

Circuit diagram of transmission hydraulics .......................................................................................................... 29

Rear axle and PTO shaft ..................................................................................................................................... 31

Tyres ......................................................................................................................................................... 31
Differential ................................................................................................................................................. 32
Working brake ........................................................................................................................................... 32
Auxiliary brake .......................................................................................................................................... 32
PTO shaft drive ......................................................................................................................................... 32
Power output – PTO shaft gearbox ........................................................................................................... 32
Power transfer – PTO shaft spline ............................................................................................................ 32
PTO shaft output stub ............................................................................................................................... 32

Parking interlock .................................................................................................................................................. 33

Functional Description / Driving .......................................................................................................................... 35

Description of right-hand armrest / operating console ................................................................................... 37
Driving ............................................................................................................................................................ 38
Driving with the accelerator pedal (automatic mode) ................................................................................ 38
Overrun condition – downhill driving with trailer ........................................................................................ 39
Engine management potentiometer .......................................................................................................... 39
Accelerating .............................................................................................................................................. 39
Brakes ....................................................................................................................................................... 39
Brake cooling oil cut-off ............................................................................................................................. 40
Neutral shifting .......................................................................................................................................... 40

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6001-4
Permanent neutral shifting ........................................................................................................................ 40
PTO shaft operation (PTO mode) ............................................................................................................. 40
Cruise Control operation ........................................................................................................................... 41
Driving speed ranges ................................................................................................................................ 42
Manual mode ............................................................................................................................................ 42
Clutch pedal .............................................................................................................................................. 42
4-wheel drive ............................................................................................................................................. 42
Operation on inclines ................................................................................................................................ 42

Towing instructions .............................................................................................................................................. 43

Towing with engine operation ........................................................................................................................ 43
Towing without engine operation ................................................................................................................... 43

Maintenance ........................................................................................................................................................ 43
Oil filling .......................................................................................................................................................... 43
Oil filling in the case of a repair: ..................................................................................................................... 43

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 6001-5

Technical Data
Oil quantity, transmission, rear axle ..................................................................................................... approx. 60 l
Oil quantity, planetary gear, 135 HP / 145 HP ................................................................................................... 10 l
Oil quantity, planetary gear, 155 HP / 170 HP / 190 HP / 195 HP ..................................................................... 12 l
Quality, transmission, rear axle ...............................................................................................see operator manual
Quality, planetary gear ............................................................................... G (GL 5) SAE 85W-140, SAE 80W-90
Oil change, transmission, rear axle ......................................... every 1000 operating hours (at least after 2 years)
Oil change, planetary gear ......................... at 250 and every further 1000 operating hours (at least after 2 years)
Oil filter change, suction filter .................................................. every 1000 operating hours (at least after 2 years)
Oil filter change, pressure filter ............................................... every 1000 operating hours (at least after 2 years)

Max. forward/reverse inclination ........................................................................................................................ 35°

Max. lateral inclination........................................................................................................................................ 30°

Transmission
Ratio 1 ............................................................................................................................................................ 2.610
Ratio 2 .............................................................................................................................................. 2.610 to 1.428
Ratio 3 .............................................................................................................................................. 1.428 to 0.740
Ratio 4 .............................................................................................................................................. 0.740 to 0.384

Transmission hydraulics
Lubricating pressure pump (rotor pump) ......................................................... 35.2 cm³ 82 l/min 2100 rpm engine
System pressure variable pump (vane cell pump) ............................................. 30 cm³ 70 l/min 2100 rpm engine
Ratio of engine / system and lubricating pressure pumps ....................................... i = 1:1.121 engine / all pumps
Pressure limiting valve – oil cooler ............................................................................................................... 2.5 bar
Lubricating pressure limiting valve ............................................................................................................... 1.5 bar
Pressure limiting valve – brake cooling ........................................................................................................... 1 bar
Suction filter – by-pass sieve ......................................................................................................................... 125 µ
Suction filter ..................................................................................................................................................... 15 µ
Pressure filter ................................................................................................................................................... 10 µ
Pressure filter by-pass valve (pressure difference) ......................................................................................... 7 bar
Pressure filter test switch (pressure difference) .............................................................................................. 5 bar
Pressure reduction valve ............................................................................................................................... 20 bar

Ratio of engine / variable displacement pump ............................................................................................... 1.437

Variable axial piston pump (back to back) ................................................................................................... 55 cm3
Constant axial piston pump (back to back) ................................................................................................. 55 cm3
Pressure limiting valve - direction of rotation .............................................................................................. 430 bar
Pressure limiting valve + direction of rotation ............................................................................................. 430 bar
Opening pressure, scavenger valve ................................................................................................................ 7 bar
Oil quantity through scavenger valve ......................................................................................................... 10 l/min

3/2 directional control valves K1, K2, K3, K4, KR, KF, 4WD
Nominal voltage ........................................................................................................................................ 7.1 VDC
Resistance (20 °C) ................................................................................................................................... 2.5 ohms
Tightening torque ......................................................................................................................................... 30 Nm

4/3 directional control valve, parking interlock (double-coil solenoid)

Nominal voltage ......................................................................................................................................... 10 VDC
Resistance (20 °C) .................................................................................................................................... 10 ohms
Tightening torque ...................................................................................................................................... 27+1 Nm

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6001-6
Inductive speed sensor, engine (B24)
Overall length ............................................................................................................................................ 77.3 mm
Resistance (20 °C) ............................................................................................................................. 1050 +/- 100
Tightening torque (Loctite 243) .................................................................................................................... 50 Nm

Inductive speed sensor P1/P2 (B35)

Overall length ............................................................................................................................................ 77.3 mm
Resistance (20 °C) ............................................................................................................................. 1050 +/- 100
Tightening torque (Loctite 243) .................................................................................................................... 50 Nm

Inductive speed sensor, output speed 1 (B27)

Overall length ............................................................................................................................................ 99.1 mm
Resistance (20 °C) ............................................................................................................................. 1050 +/- 100
Tightening torque (Loctite 243) .................................................................................................................... 50 Nm

Inductive speed sensor, output speed 2 (B26)

Overall length ............................................................................................................................................ 99.1 mm
Resistance (20 °C) ............................................................................................................................. 1050 +/- 100
Tightening torque (Loctite 243) .................................................................................................................... 50 Nm

Inductive speed sensor P3/P4 (B25)

Overall length ............................................................................................................................................ 77.3 mm
Resistance (20 °C) ............................................................................................................................. 1050 +/- 100
Tightening torque (Loctite 243) .................................................................................................................... 50 Nm

Lubricating pressure sensor

Supply voltage ........................................................................................................................................... 5.0 VDC
Signal voltage at 0 bar ............................................................................................................................. 0.25 VDC
Signal voltage at 2 bar ............................................................................................................................. 0.70 VDC
Signal voltage at 20 bar ........................................................................................................................... 4.75 VDC
Tightening torque (Loctite 243) .................................................................................................................... 20 Nm

System pressure sensor

Supply voltage ........................................................................................................................................... 5.0 VDC
Signal voltage at 0 bar ............................................................................................................................. 0.25 VDC
Signal voltage at 30 bar ............................................................................................................................. 3.0 VDC
Signal voltage at 50 bar ........................................................................................................................... 4.75 VDC
Tightening torque (Loctite 243) .................................................................................................................... 20 Nm

Temperature sensor, transmission oil

Resistance (25 °C) ................................................................................................................................ 2000 ohms
Tightening torque (Loctite 243) .................................................................................................................... 30 Nm

Pressure filter service switch

Switching point (pressure difference) ............................................................................................................. 5 bar
Tightening torque (Loctite 243) .................................................................................................................... 30 Nm

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 6001-7
Rear axle 135 HP / 145 HP
No. of teeth, differential master gear ................................................................................................................... 59
No. of teeth, bevel pinion .................................................................................................................................... 17
Total transmission ratio ................................................................................................................................ 33.187
Bevel pinion / differential master gear transmission ratio ............................................................................... 3.470
Planetary gears transmission ratio ................................................................................................................. 9.562
No. of teeth, bevel pinion / four-wheel drive ........................................................................................... T 31/ T 49
100 % multi-disk lock (6 lining disks) ........................................................................................... electro-hydraulic
Flange dimension ..................................................................................................................................... 1890 mm

Rear axle 155 HP / 170 HP / 190 HP / 195 HP

No. of teeth, differential master gear ................................................................................................................... 58
No. of teeth, bevel pinion .................................................................................................................................... 16
Total transmission ratio ................................................................................................................................ 34,664
Bevel pinion / differential master gear transmission ratio ................................................................................. 3.63
Planetary gears transmission ratio ................................................................................................................. 9.562
No. of teeth, bevel pinion / four-wheel drive ........................................................................................... T 31/ T 51
100 % multi-disk lock (8 lining disks) ........................................................................................... electro-hydraulic
Flange dimension ..................................................................................................................................... 1890 mm

PTO-shaft
540 ................................................................................................................................ at 1870 rpm engine speed
540E .............................................................................................................................. at 1600 rpm engine speed
1000 .............................................................................................................................. at 1870 rpm engine speed
1000E ............................................................................................................................ at 1600 rpm engine speed
Piston diameter, PTO clutch 135/145 HP (up to DBD...)............................................................................. 120 mm
Piston diameter, PTO clutch 135/145 HP (from DBD...) ............................................................................. 130 mm
Piston diameter, PTO clutch 155/170/190/195 HP ..................................................................................... 130 mm
PTO shaft spline ................................................................................................... 1 3/8" DIN 96, Form 1 - 6 spline
.......................................................................................................................... 1 3/8" DIN 961, Form 2 - 21 spline
......................................................................................................................... 1 3/4" DIN 9611, Form 3 - 20 spline

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6001-8

Introduction
Ever increasing demands are made on tractors. Apart from performance and price, efficiency, environmental compa-
tibility and comfort are becoming increasingly important criteria in the selection of a product.

The complexity of the drive and transmission systems increased constantly in the past, due to high technical and
functional requirements. A high degree of driving ability and user knowledge became prerequisite to operating such
systems.

CNH Austria has set its aim at developing a drive train system, from the engine to the wheels, in which the optimum
operating status of the entire system is guaranteed in every driving situation without intervention by the driver.

The main element of this system is the continuously variable transmission. The basis of this is hydrostatic/mechanical
power splitting. The continuously variable transmission represents a completely new generation of transmissions,
which guarantees optimised customer usage through high functionality, very good overall efficiency and a modular
construction.

All gear levers have been dispensed with on vehicles with continuously variable transmission. Driving speed is con-
trolled by the accelerator pedal or the Cruise Control. The electronic control system regulates the engine and trans-
mission to achieve the desired driving speed.

The driver can concentrate on driving and operating the units and is not distracted by changing gears.

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 6001-9

Description
The main components of this transmission are:
● Hydrostatic unit
● Summing planetary gear
● Planetary trains (4 shift stages)
● Planetary unit (forwards / reverse)
● Transmission electronics (SGR)
● Transmission hydraulics
● Vehicle electronics (FMGR)
● Rear axle

Hydrostatic unit in the form of a swivel plate variable displacement pump with a fixed displacement motor, arranged
back-to-back.

A summing planetary gear in which the hydrostatic and mechanical power components are unified.

Planetary trains connected to the summing planetary gear, through which four transmission ratios are realised.
Greater transmission spread can be achieved through these ratio ranges. Shifting between the individual ratios is
done by the overlapped closing of claw couplings at synchronous speeds.

A forwards / reverse planetary unit with direct transmission for forwards travel and change of direction – by locking
the planet carrier against the housing – for reverse travel.

Transmission electronics (SGR) including transmission sensor technology to control and regulate internal trans-
mission functions.

Transmission hydraulics with integrated pressure and lubrication oil supply, pressure control valves, shifting valves
and oil filtering.

Vehicle electronics (FMGR) for processing signals from the operating elements. In addition, the vehicle controller
co-ordinates between the engine and transmission control systems.

Rear axle with electro-hydraulic operated multi-disk lock. Wet multi-disk brakes (driving and parking brakes). The
working brake is operated hydraulically, the parking brake mechanically. The wet PTO shaft clutch is electro-
hydraulically operated. Final drive with simple planetary drive. The 3-point hitch is shown in exploded view.

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6001-10

SS00B088
17
14

16
13
15

9
12
11
7
10
6
5
14

1
8

3
4

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 6001-11

Transmission layout
1 Hydraulic tank
2 Viewing glass hydraulic fluid
3 Input shaft (vibration damper)
4 Transmission plug-in unit (cartridge)
5 Summing planetary gears P1 and P2
6 Planetary train P3 and P4
7 Planetary train forwards / reverse F/R
8 Drive shaft for hydraulic pumps and PTO shaft
9 Rear axle
10 Multi-disk clutch 4-wheel drive
11 Parking interlock
12 Bevel gear compensation with 100 % multi-disk lock
13 Multi-disk clutch PTO shaft
14 Wheel brake cylinder
15 Rear axle lube-oil distributor, brake cooling oil distributor
16 Planetary gear with own oil supply
17 Lifting shaft with lifting arm

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6001-12

Transmission plug-in unit (cartridge)

6 7

SS00M054

8 5 4 3 2 10 9 1 1

1 Input shaft (drive for internal geared wheel 1, hydrostat, lubrication and system pressure pump,
PFC pump and PTO shaft).
2 Transmission plug-in unit
3 Transmission electronics (SGR)
4 Hydrostat electronics (Linde electronics box)
5 Suction filter lubrication pump / system pump 30 bar
6 System pump pressure 30 bar (vane-cell variable pump)
7 Lubricating pump (rotor pump)
8 Pressure filter
9 4-wheel clutch
10 Bevel pinion (power take-off)

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 6001-13

Transmission schematic diagram

1
2

3 4 5 SS00B091

1 Drive motor
2 Hydrostat (variable pump and fixed displacement motor)
3 Summing planetary gear P1, P2
4 Planetary train P3, P4 and couplings K1, K2, K3, K4
5 Planetary train forwards / reverse KF / KR
6 Output shaft bevel pinion

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6001-14

Transmission unit layout

8 6 7 5 3 4

2
20
17
19
18
15 SS00B089
11
14
16
12
9 13 10

List of components:
1 Drive, motor 11 Internal geared wheel 2 (H2),
output shaft stage 1
2 Mechanical power transmission,
internal geared wheel 1 (H1) 12 Planet carrier 1 (land 1)
3 Variable displacement pump drive 13 Planetary gear (short, engages in H1 and S1)
4 Drive for hydraulic pumps and PTO shaft 14 Planetary gear (long, engages in the short
planetary gear on P1 and in S2 and H2 on P2)
5 Hydrostat pump
15 Sun 2 (S2), output shaft stage 2 and 4
6 Hydrostat motor
16 Odometer wheel, land 1 (ST1)
7 Variable unit, hydrostat pump
17 Gear selector drum with P3 and P4
8 Driven gear wheel, hydraulic motor,
hydrostatic power transmission 18 Sun 3 (S3)
9 Drive gear wheel for sun 1 (S1) 19 Sun 4 (S4)
10 Internal geared wheel 1 (H1) 20 Output shaft for stage 3
(firmly connected to land 1)

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 6001-15

Functional description
The driving torque on the input shaft (1) drives, on the one hand, the internal geared wheel (H1) on the summing pla-
netary train (P1) via a spur wheel train, thereby ensuring purely mechanical power transmission, and on the other
hand, a variable hydrostat pump (5) via a further spur gear train (3) seated at the rear of the input shaft.

A fixed displacement motor (6), which is charged by the oil flow from the pump (5), is arranged back-to-back on this
hydrostat pump (5). Both the speed and the direction of rotation of the hydrostat motor can be altered by electro-
hydraulically adjusting (7) the swivel plate in the hydrostat pump. By swivelling the variable unit (7) on the pump, a
variable speed, between maximum negative and maximum positive, can thus be achieved on the hydrostat motor.

The hydrostat motor torque is transferred to the sun gear (S1), on the summing planetary gear (P1), via a spur gear
train (8/9).

In addition, four mechanical ratios (P2, P3, P4) are realised in the CVT transmission, in order to achieve sufficient
transmission spread and to keep the hydrostatic power component as small as possible.

Four claw couplings (K1, K2, K3, K4) enable driving in four ranges – in both forward (KF) and reverse (KR) travel.

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6001-16

Functional description of power overlay

The percentages relate to input or output speeds and not to power or torque.

0(&+$1,&$/ 0(&+$1,&$/ 0(&+$1,&$/

287387 287387

)520
2

3 3 3
SS03C019
1

+<'5$8/,& +<'5$8/,& +<'5$8/,&

The principle function of power overlay in the summing planetary gear P1, is shown in the diagram above, by three
distinctive points (stage 1).

The internal geared wheel (1) represents the mechanical part of the power transmission.
This internal geared wheel is driven by the engine and always rotates in the same direction according to the engine
speed.

The hydrostatic power component is transferred via the sun gear (2).
As this sun gear is driven by the hydrostat motor, the speed of the sun gear can be varied by adjusting the swivel plate
on the hydrostat pump from maximum opposing speed up to synchronisation with the internal geared wheel.

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 6001-17

Summing planetary gear

3
3

7
4
6

SS03C020
5
3
1
2

The summing planetary train (P1 / P2) is a 5-shaft planetary gear with two input shafts and three output shafts.
The internal geared wheel (1) is driven directly by the input shaft via a spur gear stage.
The sun gear (2) is driven by the hydrostat motor.
Two narrow planetary gears (3), which mesh with two wide planetary gears (4) and thus reverse the direction of rota-
tion, are arranged between the internal geared wheel and the sun gear.
The internal geared wheel (5) and the sun gear (7), via which power is taken off, engage in these wide planetary gears
on the output side.
Furthermore, power can be taken off via a shaft connected to the planet carrier (6). These three output options on the
summing planetary gear (internal geared wheel (5), sun gear (7) and land (6), allow four ratios to be realised, in con-
nection with the subsequent planetary trains (P3, P4). The required transmission spread for vehicles, with high draft
requirements and high top speed is achieved in this way.

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6001-18

CVT / CVX speed diagram

Planet carrier P3/P4 Planet carrier P1

Internal geared wheel P1 Sun gear P1
Internal geared wheel P2 sun gear P3 Sun gear P2/P4
Internal geared wheel P3 Internal geared wheel P4

SS03D054
DRIVING SPEED KM/H

The speed diagram displayed above shows the sequences in the four ratios of the continuously variable transmission
at a constant engine speed of 2100 rpm.
The speeds in both directions of rotation are shown on the ordinate, the driving speed is shown on the abscissa of
the diagram.
In the following descriptions of speeds in the individual ratios, it is assumed that the engine speed is kept constant
and the claw couplings for forward travel (KF) are closed.

Ratio 1 / standstill control

Transmission ratio: infinite to 2.610
The vehicle is operated from a standstill (active standstill control) up to reaching the first shifting point (at approx.
8 km/h, nominal engine speed 2100 rpm).
The following conditions exist during vehicle standstill (see speed diagram):

Internal geared wheel P1 (1) on input stage P1 rotates constantly at a speed of minus 2830 rpm.
The sun gear (2) for input stage P1, driven by the hydrostat motor, rotates at the same speed but in the opposite
direction (+2830 rpm), due to the hydrostat pump plate being swivelled fully (to minus).
The following speeds result, at vehicle standstill, on the three drive shafts of the summing planetary gear P2:

Internal geared wheel P2 (3) .................................................................... 0 rpm

Sun gear P2 (4) ................................................................................. -5075 rpm
Planet carrier P1 (5) .......................................................................... -1464 rpm
From this speed data, it is evident that there are no differential speeds between internal geared wheel P3 (7), plane-
tary train P3 and the transmission housing (8), when the vehicle (transmission output shaft standstill) and planet car-
rier P3/P4 (6) are stationary.
Claw coupling K1 can be closed under these conditions, which ensures active standstill control even with heavy trai-
lers and steep downhill or uphill gradients, through hydraulic motor counteraction. The torque which is required to
prevent the tractor from rolling is produced by the internal geared wheel P2 of the summing planetary gear via planet
carrier P3, P4 of the range transmission, directly to KF and the pinion shaft on the wheels.

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 6001-19
In stage 1 the drive is operated via the internal geared wheel H2; thus by arranging the corresponding speed ratios
in a particular way, the speed of the internal geared wheel H2 can be changed from zero (active standstill control) up
to the maximum speed independent of the engine speed when contra-rotating between the sun gear and the internal
geared wheel.
This standstill control makes it possible to hold the vehicle, even when burdened, as well as enabling gentle and jolt-
free drive off without Slip-Stick effects, even under the most difficult conditions.

Standstill control

1 3

4 7 8 6 SS00B096

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6001-20

Ratio 1
Output is by way of the internal geared wheel P2 of the summing planetary gear, via planet carrier P3, P4 for this ratio,
directly to KF and the pinion shaft.

2 3 7 6

5 4 SS00B095

To change the ratio, and thus accelerate the vehicle, the pump plate is swivelled and the speed of sun gear P1 (1) for
the summing planetary gear is continually reduced until the sun (1) comes to a standstill. In this state, with the angle
of swivel in the hydrostat pump at zero, the speed of the engine output is zero and therefore the speed of the sun
gear in the summing planetary gears is also zero. The drive power transfer initiated is purely mechanical at this ope-
rating point.
By turning the swivel plate in the hydrostat pump further, a change in the direction of rotation of the engine shaft takes
place and when swivelled fully, the speed of the sun gear (1) reaches that of the internal geared wheel (2) on P1.
This results in a continuous increase in the speed of internal geared wheel (3) P2, through which the power flow is
fed to the transmission output via planetary train P3 in the 1st range.
With internal geared wheel (2) P1 and sun gear (1) P2 at the same speed, the entire summing planetary train and
thus internal geared wheel (3) P2, sun gear (4) P2 and planet carrier (5) P1 all rotate at the same speed.
At this operating point, internal geared wheel (6) on planetary train P4 comes to a standstill, as a result of identical
planetary trains P3 and P4.
As the internal geared wheel (7) for planetary train P3 is also stationary, claw coupling K2 can be closed in addition
to the still engaged claw coupling K1, through which the internal geared wheel of planetary train P4 is also connected
to the transmission housing.
After engaging coupling K2, the torque on coupling K1 is transferred to coupling K2 by adjusting the swivel plate in
the hydrostat pump. Only then is coupling K1 disengaged.
This ensures that the power flow in the transmission is not interrupted at any time, during the shifting sequence.

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6001-21

Ratio 2

4 2

3 1

6 SS00B097

Transmission ratio ....................................................................... 2.610 to 1.428

The power flow in the above diagram is given after shifting from the 1st ratio to the 2nd ratio.
For tractors, this shifting point takes place at approx. 8 km/h.
In the 2nd ratio, the torque is transferred, from summing planetary train P1, via sun gear (1) P2 and the planet
carrier (2) of planetary train P4, to the drive shaft.
In reducing the speed of sun gear (3) P1 for the summing planetary gear, by swivelling the swivel plate in the hydrostat
variable displacement pump back, the speed of the sun gear (1) on the power output side of summing planetary train
P2 is constantly increased.
The increase in speed of the sun gear (1) on the power output side results from the sum of the differential speed added
to the speed of internal geared wheel P1, which comes about by reducing the input speed of sun (3) P1 against that
of internal geared wheel (4) P1. Transferred to the power output side of the sun gear (1) P2 , through the short pla-
netary gear (5) onto the long planetary gear (6) to sun (1) P2.
By swivelling the hydrostat pump back to zero, the speed of the sun (3) P1 is also zero. The synchronous speed on
claw coupling K3 is achieved by adjusting the angle of the swivel plate in the hydrostat pump to maximum, in the op-
posite direction.
Coupling K3 engages, a specific hydrostat swivel transfers the load from coupling K2 to coupling K3, whereupon cou-
pling K2 is disengaged.
For tractors, this shifting point takes place at approx. 14 km/h.

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Ratio 3

2
1
SS00B098
4

Transmission ratio: ...................................................................... 1.428 to 0.740

In the 3rd ratio, power is output via planet carrier (1) P1 of the summing planetary gear.
Again, the continual ratio change in the transmission is made by varying the output speed of the hydrostat motor (sun
gear P1) (2) by adjusting the swivel plate in the hydrostat pump.
The speed of sun gear P1 (2) is changed from the maximum counter rotation speed of internal geared wheel P1
(+2830 rpm) to the speed of internal geared wheel (3) P1 (-2830 rpm). In this way, block rotation in the summing pla-
netary train P1/P2 is achieved analogous to the shifting point from ratio 1 to ratio 2. In this operating status, synchro-
nous speed between planet carrier (1) P1 and sun gear (4) P2 is also achieved.
In this way, claw coupling K4 can be engaged and, analogous to the preceding shifts, claw coupling K3 can be dis-
engaged after successful load transfer.
For tractors, this shifting point takes place at approx. 28 km/h.

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Ratio 4

SS00B099

Transmission ratio: ...................................................................... 0.740 to 0.384

The following power flow is given after shifting into the 4th ratio:
Power is output via sun gear (1) P2 in the 4th ratio.

To achieve the maximum output speed, the direction of rotation and the speed of sun gear (2) P1 is changed, so that
the highest possible speed is finally achieved.

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Forward / reverse

SS00B100

F/R planetary train ratio: forward ....... i = 1.00

reverse ...... i = -1.11

A forward/reverse planetary train follows the continuously variable range in the transmission.
For forward motion, the power flow, between the output shaft of the continuously variable part and the transmission
output shaft, is transferred directly via claw coupling KF.
For reverse motion, the planet carrier (1) is connected to the housing by closing claw coupling KR, through which the
direction of rotation is reversed.
By shifting claw coupling KF (forwards) and claw coupling KR (reverse) in an overlapping manner, it is possible to
ensure that there are no interruptions in torque in the drive train during shifting from forward to reverse travel. In this
way, the drive train remains engaged at all times.

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Claw couplings
All couplings in the continuously variable transmission are claw couplings, which are engaged and held by means of
oil pressure, via ring pistons and are disengaged by the transferred torque and disk springs. Power flow is given
across the entire range of the transmission, through the overlapping shifting from one ratio to the next, as described
previously.
The use of disk springs is required to achieve short shifting times, when changing between ratios and when changing
over from forward to reverse travel. It is possible to keep the times for shifting from one ratio to the next to under
150 milliseconds by using a suitable control system. As a result of these short shifting times, ratio changes, during
vehicle acceleration, are no longer noticed by the driver .
Claw couplings are used in the CVT / CVX transmission instead of multi-disk clutches in order to keep frictional loss,
within the transmission, as low as possible. Practically no losses, resulting from high differential speeds, occur in the
disengaged state, which would not be the case if multi-disk clutches were used.

SD03C010

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Transmission hydraulics

19
3 15
2 16
14

12 10 9 5
11 7 8 6 13
17

23
SS00M051
22
21 20
1 Suction filter 11 4/3 directional control valve, parking interlock
2 Pressure filter 12 3/2 directional control valve, 4-wheel drive
3 Valve block 13 Pressure reduction valve, 20 bar
4 Pressure reservoir N 20 bar/20 °C 14 3/2 directional control valve, front PTO shaft
5 3/2 directional control valve, 15 Temperature sensor
coupling 1 16 System pressure sensor
6 3/2 directional control valve, 17 Lubricating pressure sensor
coupling 2
19 Differential pressure switch, 5 bar
7 3/2 directional control valve,
coupling 3 20 Measuring wheel – cartridge input speed sensor (B24)

8 3/2 directional control valve, 21 Measuring wheel – speed sensor P1/P2 (B35)
coupling 4 22 Measuring wheel – speed sensor P3/P4 (B25)
9 3/2 directional control valve, 23 Measuring wheel – output speed 1 / 2 (B26)
forwards coupling
10 3/2 directional control valve,
reverse coupling

The system pressure is raised by a vane-cell variable displacement pump. This hydraulic pump is located on the
transmission housing cover. It is driven by spur gearing on the drive shaft.
The 30 bar system pressure is fed to the valve plate (3) (for claw couplings, 4-wheel drive and parking interlock) and
20 bar is fed to consumers, like PTOs and the front / rear differential locks, through a pressure reduction valve. The
shifting valves (directional control valves), the claw couplings and the safety interlock (parking interlock) are located
in the valve plate, amongst others.
Drops in pressure, during coupling shifts, are kept within limits by a pressure reservoir (4).
Cooling is done by the lubricating circuit, the lubricating oil pump supplies a feed pressure of max. 5 bar.
There is transmission fluid in both circuits (system, lubrication).
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 Test connections

6 5 4 1 3 14 9 10 2

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