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John Deere 544K 4WD Loader Engine 6068HDW84 (iT4) Operation & Test Manual TM12097 – PDF DOWNLOAD
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John Deere 544K 4WD Loader Engine 6068HDW84 (iT4) Operation & Test Manual TM12097 – PDF DOWNLOAD
Description
John Deere 544K 4WD Loader Engine 6068HDW84 (iT4) Operation & Test Manual TM12097 – PDF DOWNLOAD
FILE DETAILS:
John Deere 544K 4WD Loader Engine 6068HDW84 (iT4) Operation & Test Manual TM12097 – PDF DOWNLOAD
Language : English
Pages : 1370
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere 544K 4WD Loader Engine 6068HDW84 (iT4) Operation & Test Manual TM12097 – PDF DOWNLOAD
- This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.
- Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
- Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and test sections help to quickly identify the majority of routine failures quickly.
- Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.
- Technical manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.
- Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.
TABLE OF CONTENTS:
John Deere 544K 4WD Loader Engine 6068HDW84 (iT4) Operation & Test Manual TM12097 – PDF DOWNLOAD
Contents........................................................................................................................ 5 General Information......................................................................................................... 7 Safety.................................................................................................................. 9 Recognize Safety Information........................................................................................ 9 Follow Safety Instructions.......................................................................................... 9 Operate Only If Qualified........................................................................................... 9 Wear Protective Equipment........................................................................................... 10 Avoid Unauthorized Machine Modifications............................................................................ 10 Add Cab Guarding for Special Uses................................................................................... 10 Inspect Machine..................................................................................................... 11 Stay Clear of Moving Parts.......................................................................................... 11 Avoid High-Pressure Fluids.......................................................................................... 11 Avoid High-Pressure Oils............................................................................................ 12 Work In Ventilated Area............................................................................................. 12 Prevent Fires....................................................................................................... 13 Clean Debris from Machine........................................................................................... 13 Prevent Battery Explosions.......................................................................................... 14 Handle Chemical Products Safely..................................................................................... 14 Decommissioning — Proper Recycling and Disposal of Fluids and Components............................................ 15 Exhaust Filter Ash Handling and Disposal............................................................................ 15 Prepare for Emergencies............................................................................................. 15 Use Steps and Handholds Correctly................................................................................... 16 Start Only From Operator's Seat..................................................................................... 16 Use and Maintain Seat Belt.......................................................................................... 16 Prevent Unintended Machine Movement................................................................................. 17 Avoid Work Site Hazards............................................................................................. 18 Use Special Care When Operating Loader.............................................................................. 19 Keep Riders Off Machine............................................................................................. 19 Avoid Backover Accidents............................................................................................ 19 Avoid Machine Tip Over.............................................................................................. 20 Operating on Slopes................................................................................................. 20 Operating or Traveling On Public Roads.............................................................................. 21 Inspect and Maintain ROPS........................................................................................... 21 Add and Operate Attachments Safely.................................................................................. 21 Park and Prepare for Service Safely................................................................................. 22 Clean Exhaust Filter Safely......................................................................................... 23 Service Cooling System Safely....................................................................................... 24 Service Tires Safely................................................................................................ 24 Remove Paint Before Welding or Heating.............................................................................. 25 Make Welding Repairs Safely......................................................................................... 25 Drive Metal Pins Safely............................................................................................. 25 Diagnostics................................................................................................................. 43 Engine Control Unit (ECU) Diagnostic Trouble Codes...................................................................... 45 Engine Control Unit (ECU) Diagnostic Trouble Codes.................................................................. 45 000091.03 — Engine Throttle Short to Power.......................................................................... 45 Engine Throttle Short to Power Diagnostic Procedure............................................................. 45 000091.04 — Engine Throttle Open or Short........................................................................... 46 Engine Throttle Open or Short Diagnostic Procedure.............................................................. 46 000111.07 — Engine Coolant Out of Range............................................................................. 48 Engine Coolant Out of Range Diagnostic Procedure................................................................ 48 000111.17 — Engine Coolant Low Level................................................................................ 48 Engine Coolant Low Level Diagnostic Procedure................................................................... 48 000168.01 — Engine Control Unit (ECU) Battery Voltage Low........................................................... 49 Engine Control Unit (ECU) Battery Voltage Low Diagnostic Procedure.............................................. 49 000237.31 — Invalid Vehicle Identification Number (VIN)............................................................. 50 Invalid VIN Diagnostic Procedure................................................................................ 50 001321.05 — Starter Relay Open Circuit.............................................................................. 51 Starter Relay Open Circuit Diagnostic Procedure................................................................. 51 001321.06 — Starter Relay High Current.............................................................................. 52 Starter Relay High Current Diagnostic Procedure................................................................. 52 001321.09 — Starter Signal Invalid.................................................................................. 53 Starter Signal Invalid Diagnostic Procedure..................................................................... 53 001321.16 — Too Long to Start....................................................................................... 54 Too Long to Start Diagnostic Procedure.......................................................................... 55 001321.31 — Starter Solenoid Open Circuit........................................................................... 55 Starter Solenoid Open Circuit Diagnostic Procedure.............................................................. 55 002003.09 — Controller Area Network (CAN) Communication Lost For Transmission Control Unit (TCU).................... 56 Controller Area Network (CAN) Communication Lost For Transmission Control Unit (TCU) Diagnostic Procedure....... 56 002033.09 — Controller Area Network (CAN) Communication Lost For Vehicle Control Unit (VCU)......................... 57 Controller Area Network (CAN) Communication Lost For Vehicle Control Unit (VCU) Diagnostic Procedure............ 57 003353.31 — Alternator Excitation Condition Exists.................................................................. 60 Alternator Excitation Condition Exists Diagnostic Procedure..................................................... 60 004490.12 — Humidity Sensor Failure................................................................................. 61 Humidity Sensor Failure Diagnostic Procedure.................................................................... 61 Transmission Control Unit (TCU) Diagnostic Trouble Codes................................................................ 63 Transmission Control Unit (TCU) Diagnostic Trouble Codes............................................................ 63 000091.09 — Timeout EEC2 Message.................................................................................... 63 Timeout EEC2 Message Diagnostic Procedure....................................................................... 63 000513.02 — Percent Torque Invalid.................................................................................. 64 Percent Torque Invalid Diagnostic Procedure..................................................................... 64 000513.09 — Timeout EEC1 Message.................................................................................... 65 Timeout EEC1 Message Diagnostic Procedure....................................................................... 65 000514.02 — Friction Invalid........................................................................................ 66 Friction Invalid Diagnostic Procedure........................................................................... 66 000514.09 — Timeout EEC3 Message.................................................................................... 67 Time out EEC3 Message Diagnostic Procedure...................................................................... 67 000544.02 — Reference Torque Invalid................................................................................ 68 Reference Torque Invalid Diagnostic Procedure................................................................... 68 000544.09 — Timeout Engine Configuration Message.................................................................... 69 Timeout Engine Configuration Message Diagnostic Procedure....................................................... 69 000777.02 — Torque Converter Clutch Slippage........................................................................ 70 Torque Converter Clutch Slippage Diagnostic Procedure........................................................... 70 000777.03 — Torque Converter Lockup Solenoid Short to Power......................................................... 72 Torque Converter Lockup Solenoid Short to Power Diagnostic Procedure............................................ 72 000777.04 — Torque Converter Lockup Solenoid Short to Ground........................................................ 73 Torque Converter Lockup Solenoid Short to Ground Diagnostic Procedure........................................... 73 000777.05 — Torque Converter Lockup Solenoid Open Circuit........................................................... 74 Torque Converter Lockup Solenoid Open Circuit Diagnostic Procedure.............................................. 74 000928.03 — Axle Disconnect Solenoid Short to Power................................................................. 75 Axle Disconnect Solenoid Short to Power Diagnostic Procedure.................................................... 75 000928.04 — Axle Disconnect Solenoid High Current................................................................... 76 Axle Disconnect Solenoid High Current Diagnostic Procedure...................................................... 76 000928.05 — Axle Disconnect Solenoid Open Circuit................................................................... 77 Axle Disconnect Solenoid Open Circuit Diagnostic Procedure...................................................... 77 002033.09 — Controller Area Network (CAN) Communication Lost for Vehicle Control Unit (VCU)......................... 78 Controller Area Network (CAN) Communication Lost for Vehicle Control Unit (VCU) Diagnostic Procedure............ 78 002141.09 — Controller Area Network (CAN) Communication Lost for Sealed Switch Module (SSM)......................... 80 Controller Area network (CAN) Communication Lost for Sealed Switch Module (SSM) Diagnostic Procedure............ 81 522344.00 — Torque Converter Overtemperature........................................................................ 82 Torque Converter Overtemperature Diagnostic Procedure........................................................... 82 522350.15 — Transmission Input Torque Overload...................................................................... 83 Transmission Input Torque Overload Diagnostic Procedure......................................................... 83 522364.07 — Transmission Clutch Calibration Failed.................................................................. 84 Transmission Clutch Calibration Failed Diagnostic Procedure..................................................... 84 522364.13 — Transmission Clutch Calibration Fault................................................................... 85 Transmission Clutch Calibration Fault Diagnostic Procedure...................................................... 85 522365.13 — Limp Home Mode.......................................................................................... 86 Limp Home Mode Diagnostic Procedure............................................................................. 86 522366.13 — Application Invalid..................................................................................... 86 Application Invalid Diagnostic Procedure........................................................................ 87 522367.13 — Transmission Control Unit (TCU) Configuration Invalid................................................... 87 Transmission Control Unit (TCU) Configuration Invalid Diagnostic Procedure...................................... 87 522368.02 — Transmission Control Unit (TCU) Memory Failure.......................................................... 88 TCU Memory Failure Diagnostic Procedure......................................................................... 88 522369.03 — Remote Display Short to Power........................................................................... 89 Remote Display Short to Power Diagnostic Procedure.............................................................. 89 522370.02 — Transmission Control Unit (TCU) Valve Power Supply 2 Short Circuit...................................... 90 Transmission Control Unit (TCU) Valve Power Supply 2 Short Circuit Diagnostic Procedure......................... 90 522371.02 — Transmission Control Unit (TCU) Valve Power Supply 1 Short Circuit...................................... 91 Transmission Control Unit (TCU) Valve Power Supply 1 Short Circuit Diagnostic Procedure......................... 92 522373.03 — Power Supply High Voltage............................................................................... 92 Power Supply High Voltage Diagnostic Procedure.................................................................. 92 522373.04 — Power Supply Low Voltage................................................................................ 93 Power Supply Low Voltage Diagnostic Procedure................................................................... 93 522374.03 — Sensor Supply Short to Power............................................................................ 94 Sensor Supply Short to Power Diagnostic Procedure............................................................... 94 522374.04 — Sensor Supply Short to Ground........................................................................... 95 Sensor Supply Short to Ground Diagnostic Procedure.............................................................. 95 522375.00 — Transmission Oil Filter Restricted...................................................................... 96 Transmission Oil Filter Restricted Diagnostic Procedure......................................................... 97 522376.00 — Transmission Oil Temperature Over Maximum Value......................................................... 98 Transmission Oil Temperature Over Maximum Value Diagnostic Procedure............................................ 98 522379.03 — Park Brake Solenoid Short to Power...................................................................... 99 Park Brake Solenoid Short to Power Diagnostic Procedure......................................................... 99 522379.04 — Park Brake Solenoid Short to Ground..................................................................... 100 Park Brake Solenoid Short to Ground Diagnostic Procedure........................................................ 100 522379.05 — Park Brake Solenoid Open Circuit........................................................................ 101 Park Brake Solenoid Open Circuit Diagnostic Procedure........................................................... 101 522382.03 — Backup Alarm Short to Power............................................................................. 102 Backup Alarm Short to Power Diagnostic Procedure................................................................ 103 522382.04 — Backup Alarm Short to Ground............................................................................ 103 Backup Alarm Short to Ground Diagnostic Procedure............................................................... 104 522383.02 — Transmission Clutch KR Slippage......................................................................... 105 Transmission Clutch KR Slippage Diagnostic Procedure............................................................ 105 522383.03 — Transmission Clutch Reverse Solenoid Short to Power..................................................... 107 Transmission Clutch Reverse Solenoid Short to Power Diagnostic Procedure........................................ 107 522383.04 — Transmission Clutch Reverse Solenoid Short to Ground.................................................... 108 Transmission Clutch Reverse Solenoid Short to Ground Diagnostic Procedure....................................... 108 522383.05 — Transmission Clutch Reverse Solenoid Open Circuit....................................................... 110 Transmission Clutch Reverse Solenoid Open Circuit Diagnostic Procedure.......................................... 110 522386.02 — Transmission Clutch KV Slippage......................................................................... 111 Transmission Clutch KV Slippage Diagnostic Procedure............................................................ 111 522386.03 — Transmission Clutch Forward Solenoid Short to Power..................................................... 113 Transmission Clutch Forward Solenoid Short to Power Diagnostic Procedure........................................ 113 522386.04 — Transmission Clutch Forward Solenoid Short to Ground.................................................... 115 Transmission Clutch Forward Solenoid Short to Ground Diagnostic Procedure....................................... 115 522386.05 — Transmission Clutch Forward Solenoid Open Circuit....................................................... 116 Transmission Clutch Forward Solenoid Open Circuit Diagnostic Procedure.......................................... 116 522389.02 — Transmission Clutch K4 Slippage......................................................................... 118 Transmission Clutch K4 Slippage Diagnostic Procedure............................................................ 118 522389.03 — Transmission Clutch K4 Solenoid Short to Power.......................................................... 119 Transmission Clutch K4 Solenoid Short to Power Diagnostic Procedure............................................. 120 522389.04 — Transmission Clutch K4 Solenoid Short to Ground......................................................... 121 Transmission Clutch K4 Solenoid Short to Ground Diagnostic Procedure............................................ 121 522389.05 — Transmission Clutch K4 Solenoid Open Circuit............................................................ 123 Transmission Clutch K4 Solenoid Open Circuit Diagnostic Procedure............................................... 123 522392.02 — Transmission Clutch K3 Slippage......................................................................... 124 Transmission Clutch K3 Slippage Diagnostic Procedure............................................................ 124 522392.03 — Transmission Clutch K3 Solenoid Short to Power.......................................................... 126 Transmission Clutch K3 Solenoid Short to Power Diagnostic Procedure............................................. 126 522392.04 — Transmission Clutch K3 Solenoid Short to Ground......................................................... 127 Transmission Clutch K3 Solenoid Short to Ground Diagnostic Procedure............................................ 127 522392.05 — Transmission Clutch K3 Solenoid Open Circuit............................................................ 129 Transmission Clutch K3 Solenoid Open Circuit Diagnostic Procedure............................................... 129 522395.02 — Transmission Clutch K2 Slippage......................................................................... 130 Transmission Clutch K2 Slippage Diagnostic Procedure............................................................ 130 522395.03 — Transmission Clutch K2 Solenoid Short to Power.......................................................... 132 Transmission Clutch K2 Solenoid Short to Power Diagnostic Procedure............................................. 132 522395.04 — Transmission Clutch K2 Solenoid Short to Ground......................................................... 133 Transmission Clutch K2 Solenoid Short to Ground Diagnostic Procedure............................................ 133 522395.05 — Transmission Clutch K2 Solenoid Open Circuit............................................................ 135 Transmission Clutch K2 Solenoid Open Circuit Diagnostic Procedure............................................... 135 522399.02 — Transmission Clutch K1 Slippage......................................................................... 136 Transmission Clutch K1 Slippage Diagnostic Procedure............................................................ 136 522399.03 — Transmission Clutch K1 Solenoid Short to Power.......................................................... 138 Transmission Clutch K1 Solenoid Short to Power Diagnostic Procedure............................................. 138 522399.04 — Transmission Clutch K1 Solenoid Short to Ground......................................................... 139 Transmission Clutch K1 Solenoid Short to Ground Diagnostic Procedure............................................ 139 522399.05 — Transmission Clutch K1 Solenoid Open Circuit............................................................ 141 Transmission Clutch K1 Solenoid Open Circuit Diagnostic Procedure............................................... 141 522401.02 — Transmission Output Shaft Speed Sensor Fault............................................................ 142 Transmission Output Shaft Speed Sensor Fault Diagnostic Procedure............................................... 142 522401.03 — Transmission Output Shaft Open or Short to Power........................................................ 143 Transmission Output Shaft Open or Short to Power Diagnostic Procedure........................................... 143 522401.04 — Transmission Output Shaft Short to Ground............................................................... 145 Transmission Output Shaft Short to Ground Diagnostic Procedure.................................................. 146 522401.12 — Transmission Output Shaft Fault......................................................................... 147 Transmission Output Shaft Fault Diagnostic Procedure............................................................ 147 522401.15 — Transmission Output Shaft Overspeed..................................................................... 148 Transmission Output Shaft Overspeed Diagnostic Procedure........................................................ 148 522402.03 — Clutch Speed Sensor Open or Short....................................................................... 149 Transmission Clutch Speed Sensor Open or Short Diagnostic Procedure............................................. 149 522402.04 — Transmission Clutch Speed Sensor Short to Ground........................................................ 150 Transmission Clutch Speed Sensor Short to Ground Diagnostic Procedure........................................... 150 522402.12 — Transmission Clutch Speed Sensor Fault.................................................................. 151 Transmission Clutch Speed Sensor Fault Diagnostic Procedure..................................................... 152 522403.03 — Torque Converter Output Speed Sensor Open or Short to Power............................................. 152 Torque Converter Output Speed Sensor Open or Short to Power Diagnostic Procedure................................ 152 522403.04 — Torque Converter Output Speed Sensor Short to Ground.................................................... 154 Torque Converter Output Speed Sensor Short to Ground Diagnostic Procedure....................................... 154 522403.12 — Torque Converter Output Speed Sensor Fault.............................................................. 155 Torque Converter Output Speed Sensor Fault Diagnostic Procedure................................................. 155 522404.03 — Torque Converter Input Speed Sensor Open or Short to Power.............................................. 156 Torque Converter Input Speed Sensor Open or Short to Power Diagnostic Procedure................................. 156 522404.04 — Torque Converter Input Speed Sensor Short to Ground..................................................... 158 Torque Converter Input Speed Sensor Short to Ground Diagnostic Procedure........................................ 158 522404.12 — Torque Converter Input Speed Fault...................................................................... 159 Torque Converter Input Speed Sensor Fault Diagnostic Procedure.................................................. 159 522406.03 — Transmission Oil Temperature Sensor Open or Short to Power.............................................. 160 Transmission Oil Temperature Sensor Open or Short to Power Diagnostic Procedure................................. 160 522406.04 — Transmission Oil Temperature Sensor Short to Ground..................................................... 162 Transmission Oil Temperature Sensor Short to Ground Diagnostic Procedure........................................ 162 522407.03 — Transmission Clutch Cut-Off Sensor Short to Power....................................................... 164 Transmission Clutch Cut-Off Sensor Short to Power Diagnostic Procedure.......................................... 164 522407.04 — Transmission Clutch Cut-Off Sensor Open or Short to Ground.............................................. 164 Transmission Clutch Cut-Off Sensor Open or Short to Ground Diagnostic Procedure................................. 165 522409.05 — 2nd FNR (Pilot Control Joystick FNR) Open Circuit....................................................... 167 2nd FNR (Pilot Control Joystick FNR) Open Circuit Diagnostic Procedure.......................................... 167 2nd FNR (Pilot Control Joystick FNR) Open Circuit Diagnostic Procedure.......................................... 168 522409.12 — 2nd FNR (Pilot Control Joystick FNR) Multiple Inputs.................................................... 169 2nd FNR (Pilot Control Joystick FNR) Multiple Inputs Diagnostic Procedure....................................... 170 2nd FNR Multiple Inputs Diagnostic Procedure (Joystick Steering FNR)............................................ 171 522411.05 — 1st FNR Open Circuit.................................................................................... 173 1st FNR (Steering Column FNR) Open Circuit Diagnostic Procedure................................................. 173 1st FNR (Steering Column FNR) Open Circuit Diagnostic Procedure................................................. 174 522411.12 — 1st FNR Multiple Inputs................................................................................. 176 1st FNR (Steering Column FNR) Multiple Inputs Diagnostic Procedure.............................................. 176 1st FNR Multiple Inputs (Pilot Control Joystick FNR) Diagnostic Procedure....................................... 178 522412.12 — Gear Selection Error.................................................................................... 179 Gear Selection Error Diagnostic Procedure....................................................................... 180 522419.02 — Transmission Clutch Cut-Off Disabled.................................................................... 182 Clutch Cut-off Disabled Diagnostic Procedure.................................................................... 182 522420.02 — Manual Down Shift Disabled.............................................................................. 182 Manual Downshift Disabled Diagnostic Procedure.................................................................. 183 522421.02 — Automatic to 1st Disabled............................................................................... 183 Automatic to 1st Disabled Diagnostic Procedure.................................................................. 183 524048.00 — Transmission Output Torque Exceeded..................................................................... 184 Transmission Output Torque Exceeded Diagnostic Procedure........................................................ 184 524049.00 — Transmission Input Torque Exceeded...................................................................... 184 Transmission Input Torque Exceeded Diagnostic Procedure......................................................... 184 524287.00 — Configure Machine Model................................................................................. 185 Configure Machine Model Diagnostic Procedure.................................................................... 185 Vehicle Control Unit (VCU) Diagnostic Trouble Codes..................................................................... 187 Vehicle Control Unit (VCU) Diagnostic Trouble Codes................................................................. 187 000075.00 — Front Axle Oil High Temperature......................................................................... 187 Front Axle Oil High Temperature Diagnostic Procedure............................................................ 187 000075.04 — Front Axle Oil Temp Sensor Short to Ground.............................................................. 188 Front Axle Oil Temp Sensor Short to Ground Diagnostic Procedure................................................. 188 000096.04 — Fuel Level Short to Ground.............................................................................. 189 Fuel Level Short to Ground Diagnostic Procedure................................................................. 189 000096.05 — Fuel Level Open or Short................................................................................ 191 Fuel Level Open or Short Diagnostic Procedure................................................................... 191 000167.16 — Alternator High Voltage................................................................................. 192 Alternator High Voltage Diagnostic Procedure.................................................................... 192 000167.18 — Alternator Low Voltage.................................................................................. 193 Alternator Low Voltage Diagnostic Procedure..................................................................... 193 000168.16 — High Battery Voltage.................................................................................... 193 High Battery Voltage Diagnostic Procedure....................................................................... 194 000234.02 — Invalid Transmission Control Unit (TCU) Software Revision............................................... 194 Invalid TCU Software Revision Diagnostic Procedure.............................................................. 194 000444.05 — 12 V Center Tap Open or Short........................................................................... 194 12 V Center Tap Open or Short Diagnostic Procedure.............................................................. 195 000444.18 — Battery Voltage Imbalance............................................................................... 196 Battery Voltage Imbalance Diagnostic Procedure.................................................................. 196 000521.00 — Brake Pedal High Voltage................................................................................ 197 Brake Pedal High Voltage Diagnostic Procedure................................................................... 197 000578.00 — Rear Axle Oil High Temperature.......................................................................... 197 Rear Axle Oil High Temperature Diagnostic Procedure............................................................. 198 000578.04 — Rear Axle Oil Temp Sensor Short to Ground............................................................... 198 Rear Axle Oil Temp Sensor Short to Ground Diagnostic Procedure.................................................. 198 000628.12 — Controller Not Programmed............................................................................... 200 Controller Not Programmed Diagnostic Procedure.................................................................. 200 000629.12 — Vehicle Control Unit (VCU) Watchdog Time Out............................................................ 200 Vehicle Control Unit (VCU) Watchdog Time Out Diagnostic Procedure............................................... 200 000639.12 — Vehicle Control Unit (VCU) Controller Area Network (CAN) Failure........................................ 201 Vehicle Control Unit (VCU) Controller Area Network (CAN) Failure Diagnostic Procedure........................... 201 000639.14 — Vehicle Control Unit (VCU) Controller Area Network (CAN) 1 Bus Off...................................... 201 Vehicle Control Unit (VCU) Controller Area Network (CAN) 1 Bus Off Diagnostic Procedure......................... 201 000746.03 — Differential Lock Solenoid Short to Power............................................................... 202 Differential Lock Solenoid Short to Power Diagnostic Procedure.................................................. 202 000746.05 — Differential Lock Solenoid Open......................................................................... 203 Differential Lock Solenoid Open Diagnostic Procedure............................................................ 203 000746.06 — Differential Lock Solenoid High Current................................................................. 205 Differential Lock Solenoid High Current Diagnostic Procedure.................................................... 205 000785.03 — Pilot Solenoid Short to Power........................................................................... 206 Pilot Solenoid Short to Power Diagnostic Procedure.............................................................. 206 000785.05 — Pilot Solenoid Open or Short............................................................................ 207 Pilot Solenoid Open or Short Diagnostic Procedure............................................................... 207 000785.06 — Pilot Solenoid High Current............................................................................. 209 Pilot Solenoid High Current Diagnostic Procedure................................................................ 209 000880.03 — Brake Lights Short to Power............................................................................. 211 Brake Lights Short to Power Diagnostic Procedure................................................................ 211 000880.05 — Brake Lights Open or Short.............................................................................. 212 Brake Lights Open or Short Diagnostic Procedure................................................................. 212 000880.06 — Brake Lights High Current............................................................................... 213 Brake Lights High Current Diagnostic Procedure.................................................................. 213 000977.03 — Reversing Fan Solenoid Short to Power................................................................... 215 Reversing Fan Solenoid Short to Power Diagnostic Procedure...................................................... 215 000977.05 — Reversing Fan Solenoid Open or Short.................................................................... 216 Reversing Fan Solenoid Open or Short Diagnostic Procedure....................................................... 216 000977.06 — Reversing Fan Solenoid High Current..................................................................... 218 Reversng Fan Solenoid High Current Diagnostic Procedure......................................................... 218 001069.02 — Tire Size Incorrect..................................................................................... 219 Tire Size Incorrect Diagnostic Procedure........................................................................ 219 001071.03 — Proportional Fan Solenoid High Side (HS) Short to Power................................................. 220 Proportional Fan Solenoid High Side (HS) Short to Power Diagnostic Procedure.................................... 220 001071.05 — Proportional Fan Solenoid High Side (HS) Open or Short.................................................. 221 Proportional Fan Solenoid High Side (HS) Open or Short Diagnostic Procedure..................................... 221 001071.06 — Proportional Fan Solenoid High Side (HS) High Current................................................... 223 Proportional Fan Solenoid High Side (HS) High Current Diagnostic Procedure...................................... 223 001071.13 — Proportional Fan Solenoid Out of Calibration............................................................ 224 001071.16 — Proportional Fan Solenoid Low Side (LS) High Current.................................................... 224 Proportional Fan Solenoid Low Side (LS) High Current Diagnostic Procedure....................................... 224 001071.17 — Proportional Fan Solenoid Low Side (LS) Open or Short................................................... 226 Proportional Fan Solenoid Low Side (LS) Open or Short Diagnostic Procedure...................................... 226 001071.18 — Proportional Fan Solenoid Low Side (LS) Short to Power.................................................. 228 Proportional Fan Solenoid Low Side (LS) Short to Power Diagnostic Procedure..................................... 228 001231.12 — Vehicle Control Unit (VCU) Controller Area Network (CAN) 2 Failure...................................... 229 Vehicle Control Unit (VCU) Controller Area Network (CAN) 2 Failure Diagnostic Procedure......................... 229 001231.14 — Vehicle Control Unit (VCU) Controller Area Network (CAN) 2 Bus Off...................................... 230 Vehicle Control Unit (VCU) Controller Area Network (CAN) 2 Bus Off Diagnostic Procedure......................... 230 001503.04 — Arm Rest Down Switch Short to Ground.................................................................... 231 Arm Rest Down Switch Short to Ground Diagnostic Procedure....................................................... 231 001503.11 — Arm Rest Position Undetermined.......................................................................... 232 Arm Rest Position Undetermined Diagnostic Procedure............................................................. 232 001550.03 — Air Conditioner Clutch Short to Power................................................................... 235 Air Conditioner Clutch Short to Power Diagnostic Procedure...................................................... 235 001550.06 — Air Conditioner Clutch High Current..................................................................... 236 Air Conditioner Clutch High Current Diagnostic Procedure........................................................ 236 001565.04 — Arm Rest Up Switch Short to Ground...................................................................... 237 Arm Rest Up Switch Short to Ground Diagnostic Procedure......................................................... 237 001638.00 — Hydraulic Oil High Temperature.......................................................................... 239 Hydraulic Oil High Temperature Diagnostic Procedure............................................................. 239 001638.04 — Hydraulic Oil Temperature Sensor Short to Ground........................................................ 239 Hydraulic Oil Temperature Sensor Short to Ground Diagnostic Procedure........................................... 239 001639.02 — Fan Speed Sensor Out of Synchronization................................................................. 241 Fan Speed Sensor Out of Synchronization Diagnostic Procedure.................................................... 241 001639.04 — Fan Speed Sensor Short to Ground........................................................................ 242 Fan Speed Sensor Short to Ground Diagnostic Procedure........................................................... 242 001639.05 — Fan Speed Sensor Open Circuit........................................................................... 243 Fan Speed Sensor Open Circuit................................................................................... 243 001639.08 — Fan Speed Sensor No Signal.............................................................................. 245 Fan Speed Sensor No Signal Diagnostic Procedure................................................................. 245 001639.10 — Fan Speed Sensor Fault.................................................................................. 246 Fan Speed Sensor Fault Diagnostic Procedure..................................................................... 246 001639.13 — Fan Speed Sensor Out of Calibration..................................................................... 248 001713.01 — Hydraulic Oil Filter Restricted......................................................................... 248 Hydraulic Oil Filter Restricted Diagnostic Procedure............................................................ 248 001762.03 — Hydraulic Pressure Sensor Short to Power................................................................ 249 Hydraulic Pressure Sensor Short to Power Diagnostic Procedure................................................... 249 001762.04 — Hydraulic Pressure Sensor Open or Short................................................................. 250 Hydraulic Pressure Sensor Open or Short Diagnostic Procedure.................................................... 250 001841.03 — Blackout Brake Lights Short to Power.................................................................... 251 Blackout Brake Lights Short to Power Diagnostic Procedure....................................................... 252 001841.05 — Blackout Brake Lights Open or Short..................................................................... 252 Blackout Brake Lights Open or Short Diagnostic Procedure........................................................ 253 001841.06 — Blackout Brake Lights High Current...................................................................... 254 Blackout Brake Lights High Current Diagnostic Procedure......................................................... 254 001842.03 — Blackout Lights Short to Power.......................................................................... 255 Blackout Lights Short to Power Diagnostic Procedure............................................................. 256 001842.05 — Blackout Lights Open or Short........................................................................... 257 Blackout Lights Open or Short Diagnostic Procedure.............................................................. 257 001842.06 — Blackout Lights High Current............................................................................ 259 Blackout Lights High Current Diagnostic Procedure............................................................... 259 002000.09 — Controller Area Network (CAN) Communication Lost for Engine Control Unit (ECU).......................... 261 Controller Area Network (CAN) Communication Lost for Engine Control Unit (ECU) Diagnostic Procedure............. 261 002003.09 — Controller Area Network (CAN) Communication Lost for Transmission Control Unit (TCU).................... 263 Controller Area Network (CAN) Communication Lost for Transmission Control Unit (TCU) Diagnostic Procedure....... 263 002033.14 — Flexpower Handshaking Error............................................................................. 264 002040.09 — Controller Area Network (CAN) Communication Lost for Advanced Displaying Unit (ADU)..................... 265 Controller Area Network (CAN) Communication Lost for Advanced Displaying Unit (ADU) Diagnostic Procedure........ 265 002051.09 — Controller Area Network (CAN) Communication Lost for Tire Pressure Monitoring System (TPMS)............. 266 CAN Communication Lost for TPMS Diagnostic Procedure............................................................ 266 002052.09 — Controller Area Network (CAN) Communication Lost for Joystick Steering Controller (JSC)................. 268 Controller Area Network (CAN) Communication Lost for Joystick Steering Controller (JSC) Diagnostic Procedure.... 268 002129.09 — Controller Area Network (CAN) Communication Lost for Joystick Steering Valve (JSV)...................... 269 Controller Area Network (CAN) Communication Lost for Joystick Steering Valve (JSV) Diagnostic Procedure......... 269 002132.09 — Controller Area Network (CAN) Communication Lost for Radar Object Detection (ROD)....................... 271 Controller Area Network (CAN) Communication Lost for Radar Object Detection (ROD) Diagnostic Procedure.......... 271 002141.09 — Controller Area Network (CAN) Communication Lost for Sealed Switch Module (SSM)......................... 272 Controller Area Network (CAN) Communication Lost for Sealed Switch Module (SSM) Diagnostic Procedure............ 272 002169.09 — Controller Area Network (CAN) Communication Lost for Ground Speed Radar (RDR)........................... 274 Controller Area Network (CAN) Communication Lost for Ground Speed Radar (RDR) Diagnostic Procedure.............. 274 002251.09 — Controller Area Network (CAN) Lost for JDLink™.......................................................... 276 002350.03 — Drive Lamps Short to Power.............................................................................. 277 Drive Lamps Short to Power Diagnostic Procedure................................................................. 277 002350.05 — Drive Lamps Open or Short............................................................................... 278 Drive Lamps Open or Short Diagnostic Procedure.................................................................. 278 002350.06 — Drive Lamps High Current................................................................................ 279 Drive Lamps High Current Diagnostic Procedure................................................................... 279 002350.18 — Drive Lamps Failure..................................................................................... 280 Drive Lamps Failure Diagnostic Procedure........................................................................ 280 002355.03 — Front Work Lights Short to Power........................................................................ 281 Front Work Lights Short to Power................................................................................ 282 002355.05 — Front Work Lights Open or Short......................................................................... 282 Front Work Lights Open or Short Diagnostic Procedure............................................................ 283 002355.06 — Front Work Lights High Current.......................................................................... 284 Front Work Lights High Current Diagnostic Procedure............................................................. 284 002355.18 — Front Work Lights Failure............................................................................... 286 Front Work Lights Failure Diagnostic Procedure.................................................................. 286 002356.03 — Front Work Lights Short to Power........................................................................ 287 Front Work Lights Short to Power Diagnostic Procedure........................................................... 287 002356.05 — Front Work Lights Open or Short......................................................................... 288 Front Work Lights Open or Short Diagnostic Procedure............................................................ 288 002356.06 — Front Work Lights High Current.......................................................................... 290 Front Work Lights High Current Diagnostic Procedure............................................................. 290 002356.18 — Front Work Lights Failure............................................................................... 291 Front Work Lights Failure Diagnostic Procedure.................................................................. 291 002359.03 — Machine Work Lights Short to Power...................................................................... 292 Machine Work Lights Short to Power Diagnostic Procedure......................................................... 292 002359.05 — Machine Work Lights Open or Short....................................................................... 293 Machine Work Lights Open or Short Diagnostic Procedure.......................................................... 294 002359.06 — Machine Work Lights High Current........................................................................ 295 Machine Work Lights High Current Diagnostic Procedure........................................................... 295 002359.18 — Machine Work Lights Failure............................................................................. 296 Machine Work Lights Failure Diagnostic Procedure................................................................ 297 002362.03 — Rear Work Lights Short to Power......................................................................... 298 Rear Work Lights Short to Power Diagnostic Procedure............................................................ 298 002362.05 — Rear Work Lights Open or Short.......................................................................... 299 Rear Work Lights Open or Short Diagnostic Procedure............................................................. 299 002362.06 — Rear Work Lights High Current........................................................................... 301 Rear Work Lights High Current Diagnostic Procedure.............................................................. 301 002362.18 — Rear Work Lights Failure................................................................................ 302 Rear Work Lights Failure Diagnostic Procedure................................................................... 302 002367.04 — Left Turn Switch Short to Ground........................................................................ 303 Left Turn Switch Short to Ground Diagnostic Procedure........................................................... 304 002368.03 — Left Turn Lights Short to Power......................................................................... 305 Left Turn Lights Short to Power Diagnostic Procedure............................................................ 305 002368.05 — Left Turn Lights Open or Short.......................................................................... 306 Left Turn Lights Open or Short Diagnostic Procedure............................................................. 306 002368.06 — Left Turn Lights High Current........................................................................... 308 Left Turn Lights High Current Diagnostic Procedure.............................................................. 308 002369.04 — Right Turn Switch Short to Ground....................................................................... 310 Right Turn Switch Short to Ground Diagnostic Procedure.......................................................... 310 002370.03 — Right Turn Lights Short to Power........................................................................ 311 Right Turn Lights Short to Power Diagnostic Procedure........................................................... 311 002370.05 — Right Turn Lights Open or Short......................................................................... 312 Right Turn Lights Open or Short Diagnostic Procedure............................................................ 312 002370.06 — Right Turn Lights High Current.......................................................................... 314 Right Turn Lights High Current Diagnostic Procedure............................................................. 314 002378.03 — Marker/Tail Lights Short to Power....................................................................... 316 Marker/Tail Lights Short to Power Diagnostic Procedure.......................................................... 316 002378.06 — Marker/Tail Lights High Current......................................................................... 317 Marker/Tail Lights High Current Diagnostic Procedure............................................................ 317 002386.03 — Beacon Light Short to Power............................................................................. 319 Beacon Light Short to Power Diagnostic Procedure................................................................ 319 002386.06 — Beacon Light High Current............................................................................... 320 Beacon Light High Current Diagnostic Procedure.................................................................. 320 002650.03 — Lockout Fan Solenoid Short to Power..................................................................... 322 Lockout Fan Solenoid Short to Power Diagnostic Procedure........................................................ 322 002650.05 — Lockout Fan Solenoid Open or Short...................................................................... 323 Lockout Fan Solenoid Open or Short Diagnostic Procedure......................................................... 323 002650.06 — Lockout Fan Solenoid High Current....................................................................... 324 Lockout Fan Solenoid High Current Diagnostic Procedure.......................................................... 324 002680.03 — Return-to-Carry (RTC)/Float Detent Short to Power....................................................... 326 Return-to-Carry (RTC)/Float Detent Short to Power Diagnostic Procedure.......................................... 326 002680.05 — Return-to-Carry (RTC)/Float Detent Open or Short........................................................ 327 Return-to-Carry (RTC)/Float Detent Open or Short Diagnostic Procedure........................................... 327 002680.06 — Return-to-Carry (RTC)/Float Detent High Current......................................................... 328 Return-to-Carry (RTC)/Float Detent High Current Diagnostic Procedure............................................ 328 002697.02 — Timeout Joystick Steering Controller (JSC) Message...................................................... 330 Timeout Joystick Steering Controller (JSC) Message Diagnostic Procedure......................................... 330 002717.03 — Return-to-Dig (RTD) Detent Short to Power............................................................... 331 Return-to-Dig (RTD) Detent Short to Power Diagnostic Procedure.................................................. 331 002717.05 — Return-to-Dig (RTD) Detent Open or Short................................................................ 332 Return-to-Dig (RTD) Detent Open or Short Diagnostic Procedure................................................... 332 002717.06 — Return-to-Dig (RTD) Detent High Current................................................................. 333 Return-to-Dig (RTD) Detent High Current Diagnostic Procedure.................................................... 333 002754.03 — Boom Height Kickout (BHKO) Detent Short to Power........................................................ 334 Boom Height Kickout (BHKO) Detent Short to Power Diagnostic Procedure........................................... 334 002754.05 — Boom Height Kickout (BHKO) Detent Open or Short......................................................... 335 Boom Height Kickout (BHKO) Detent Open or Short Diagnostic Procedure............................................ 335 002754.06 — Boom Height Kickout (BHKO) Detent High Current.......................................................... 337 Boom Height Kickout (BHKO) Detent High Current Diagnostic Procedure............................................. 337 002875.04 — Hazard Wakeup Short to Ground........................................................................... 338 Hazard Wakeup Short to Ground Diagnostic Procedure.............................................................. 338 003509.04 — Vehicle Control Unit (VCU) Sensor 1 Voltage Low......................................................... 339 Vehicle Control Unit (VCU) Sensor 1 Voltage Low Diagnostic Procedure............................................ 339 003510.04 — Vehicle Control Unit (VCU) Sensor 2 Voltage Low......................................................... 341 Vehicle Control Unit (VCU) Sensor 2 Voltage Low Diagnostic Procedure............................................ 341 003511.04 — Vehicle Control Unit (VCU) Sensor 3 Voltage Low......................................................... 342 Vehicle Control Unit (VCU) Sensor 3 Voltage Low Diagnostic Procedure............................................ 342 003598.02 — 7 V Supply Voltage Low.................................................................................. 343 7 V Supply Voltage Low Diagnostic Procedure..................................................................... 343 299621.02 — Machine Configuration Invalid........................................................................... 344 Machine Configuration Invalid Diagnostic Procedure.............................................................. 344 521948.02 — Engine Tier Level Invalid............................................................................... 344 Engine Tier Level Invalid Diagnostic Procedure.................................................................. 345 521985.04 — Central Processing Unit (CPU) Switched Power Voltage Low................................................ 345 Central Processing Unit (CPU) Switched Power Voltage Low Diagnostic Procedure................................... 345 521986.04 — Unswitched Power Voltage Low............................................................................ 347 Unswitched Power Voltage Low Diagnostic Procedure............................................................... 347 522280.01 — Brake Pressure Low...................................................................................... 348 Brake Pressure Low Diagnostic Procedure......................................................................... 348 522341.03 — Heated Mirror Short to Power............................................................................ 349 Heated Mirror Short to Power Diagnostic Procedure............................................................... 349 522341.05 — Heated Mirror Open Circuit.............................................................................. 350 Heated Mirror Open Circuit Diagnostic Procedure................................................................. 350 522341.06 — Heated Mirror High Current.............................................................................. 352 Heated Mirror High Current Diagnostic Procedure................................................................. 352 522426.04 — Rear Wiper Park Short to Ground......................................................................... 353 Rear Wiper Park Short to Ground Diagnostic Procedure............................................................ 353 522427.04 — Front Wiper Park Short to Ground........................................................................ 354 Front Wiper Park Short to Ground Diagnostic Procedure........................................................... 354 522431.02 — Memory Test Failure..................................................................................... 355 Memory Test Failure Diagnostic Procedure........................................................................ 355 522432.03 — Rear Wiper High Speed Shorted to Power.................................................................. 356 Rear Wiper High Speed Shorted to Power Diagnostic Procedure..................................................... 356 522432.05 — Rear Wiper High Speed Open Circuit...................................................................... 357 Rear Wiper High Speed Open Circuit.............................................................................. 357 522432.06 — Rear Wiper High Speed High Current...................................................................... 358 Rear Wiper High Speed High Current Diagnostic Procedure......................................................... 359 522433.03 — Rear Wiper Low Speed Short to Power..................................................................... 360 Rear Wiper Low Speed Short to Power Diagnostic Procedure........................................................ 360 522433.05 — Rear Wiper Low Speed Open Circuit....................................................................... 361 Rear Wiper Low Speed Open Circuit Diagnostic Procedure.......................................................... 361 522433.06 — Rear Wiper Low Speed High Current....................................................................... 362 Rear Wiper Low Speed High Current Diagnostic Procedure.......................................................... 363 522434.03 — Front Wiper Low Speed Short to Power.................................................................... 364 Front Wiper Low Speed Short to Power Diagnostic Procedure....................................................... 364 522434.05 — Front Wiper Low Speed Open Circuit...................................................................... 365 Front Wiper Low Speed Open Circuit Diagnostic Procedure......................................................... 365 522434.06 — Front Wiper Low Speed High Current...................................................................... 366 Front Wiper Low Speed High Current Diagnostic Procedure......................................................... 367 522435.03 — Front Wiper High Speed Short to Power................................................................... 368 Front Wiper High Speed Short to Power Diagnostic Procedure...................................................... 368 522435.05 — Front Wiper High Speed Open Circuit..................................................................... 369 Front Wiper High Speed Open Circuit Diagnostic Procedure........................................................ 369 522435.06 — Front Wiper High Speed High Current..................................................................... 370 Front Wiper High Speed High Current Diagnostic Procedure........................................................ 371 522436.03 — Bucket Position Short to Power.......................................................................... 372 Bucket Position Short to Power Diagnostic Procedure............................................................. 372 522436.04 — Bucket Position Open or Short........................................................................... 373 Bucket Position Open or Short Diagnostic Procedure.............................................................. 373 522437.04 — Return-to-Dig (RTD) Switch Short to Ground.............................................................. 375 Return-to-Dig (RTD) Switch Short to Ground Diagnostic Procedure................................................. 375 522438.03 — Pin Disconnect Solenoid Short to Power.................................................................. 376 Pin Disconnect Solenoid Short to Power Diagnostic Procedure..................................................... 376 522438.05 — Pin Disconnect Solenoid Open or Short................................................................... 377 Pin Disconnect Solenoid Open or Short Diagnostic Procedure...................................................... 377 522438.06 — Pin Disconnect Solenoid High Current.................................................................... 379 Pin Disconnect Solenoid High Current Diagnostic Procedure....................................................... 379 522543.03 — Boom Cylinder Rod Pressure Sensor Open or Short......................................................... 380 Boom Cylinder Rod Pressure Sensor Open or Short Diagnostic Procedure............................................ 380 522543.04 — Boom Cylinder Rod Pressure Sensor Short to Ground....................................................... 382 Boom Cylinder Rod Pressure Sensor Short to Ground Diagnostic Procedure.......................................... 382 522544.03 — Boom Cylinder Head Pressure Sensor Open or Short........................................................ 383 Boom Cylinder Head Pressure Sensor Open or Short Diagnostic Procedure........................................... 383 522544.04 — Boom Cylinder Head Pressure Sensor Short to Ground...................................................... 385 Boom Cylinder Head Pressure Sensor Short to Ground Diagnostic Procedure......................................... 385 522620.03 — Vehicle Horn Short to Power............................................................................. 386 Vehicle Horn Short to Power Diagnostic Procedure................................................................ 386 522620.06 — Vehicle Horn High Current............................................................................... 387 Vehicle Horn High Current Diagnostic Procedure.................................................................. 387 522796.03 — Rear Washer Pump Short to Power......................................................................... 388 Rear Washer Pump Short to Power Diagnostic Procedure............................................................ 388 522796.05 — Rear Washer Pump Open or Short.......................................................................... 389 Rear Washer Pump Open or Short Diagnostic Procedure............................................................. 389 522796.06 — Rear Washer Pump High Current........................................................................... 391 Rear Washer Pump High Current Diagnostic Procedure.............................................................. 391 522797.03 — Front Washer Pump Short to Power........................................................................ 392 Front Washer Pump Short to Power Diagnostic Procedure........................................................... 392 522797.05 — Front Washer Pump Open or Short......................................................................... 393 Front Washer Pump Open or Short Diagnostic Procedure............................................................ 393 522797.06 — Front Washer Pump High Current.......................................................................... 395 Front Washer Pump High Current Diagnostic Procedure............................................................. 395 523137.01 — Steering System Pressure Low............................................................................ 396 Steering System Pressure Low Diagnostic Procedure............................................................... 397 523137.03 — Steering Pressure Sensor Short to Power................................................................. 397 Steering Pressure Sensor Short to Power Diagnostic Procedure.................................................... 397 523137.04 — Steering Pressure Sensor Short to Ground................................................................ 398 Steering Pressure Sensor Open or Short Diagnostic Procedure..................................................... 398 523137.05 — Steering Pressure Sensor Open Circuit................................................................... 400 Steering Pressure Sensor Open or Short Diagnostic Procedure..................................................... 400 523137.12 — Steering Pressure Sensor Invalid........................................................................ 402 Steering Pressure Sensor Invalid Diagnostic Procedure........................................................... 402 523219.04 — Switched Power Voltage Low.............................................................................. 403 Switched Power Voltage Low Diagnostic Procedure................................................................. 403 523440.04 — Unswitched Power Voltage Low............................................................................ 404 Unswitched Power Voltage Low Diagnostic Procedure............................................................... 404 523577.03 — Secondary Steering Pump Shorted to Power................................................................ 406 Secondary Steering Pump Shorted to Power Diagnostic Procedure................................................... 406 523577.05 — Secondary Steering Pump Open or Short Circuit........................................................... 407 Secondary Steering Pump Open or Short Circuit Diagnostic Procedure.............................................. 407 523577.06 — Secondary Steering Pump High Current.................................................................... 409 Secondary Steering Pump High Current Diagnostic Procedure....................................................... 409 523689.04 — Differential Lock Switch Short to Ground................................................................ 410 Differential Lock Switch Short to Ground Diagnostic Procedure................................................... 410 523767.04 — Joystick Steering Activation Switch Short to Ground..................................................... 411 Joystick Steering Activation Switch Short to Ground Diagnostic Procedure........................................ 412 523767.10 — Joystick Steering Activation Switch Button Stuck........................................................ 413 Joystick Steering Activation Switch Button Stuck Diagnostic Procedure........................................... 413 523786.02 — Boom Position Sensor Failure............................................................................ 414 Boom Position Sensor Failure Diagnostic Procedure............................................................... 414 523786.03 — Boom Position Sensor Short to Power..................................................................... 415 Boom Position Sensor Short to Power Diagnostic Procedure........................................................ 415 523786.06 — Boom Position Sensor Short to Ground.................................................................... 416 Boom Position Sensor Short to Ground Diagnostic Procedure....................................................... 416 523786.13 — Boom Position Sensor Out of Calibration................................................................. 417 Boom Position Sensor Out of Calibration Diagnostic Procedure.................................................... 417 523795.03 — Joystick Steering Valve (JSV) Power Short to Power...................................................... 418 JSV Power Short to Power Diagnostic Procedure................................................................... 418 523795.05 — Joystick Steering Valve (JSV) Power Open or Short....................................................... 419 JSV Power Open or Short Diagnostic Procedure.................................................................... 419 523795.06 — Joystick Steering Valve (JSV) High Current.............................................................. 420 JSV High Current Diagnostic Procedure........................................................................... 420 523837.01 — Brake Pressure Low—Rear................................................................................. 421 Brake Pressure Low—Rear Diagnostic Procedure.................................................................... 421 523837.03 — Rear Brake Pressure Sensor Short to Power............................................................... 422 Rear Brake Pressure Sensor Short to Power Diagnostic Procedure.................................................. 422 523837.04 — Rear Brake Pressure Open or Short....................................................................... 423 Rear Brake Pressure Open or Short Diagnostic Procedure.......................................................... 423 523840.01 — Brake Pressure Low—Front................................................................................ 424 Brake Pressure Low—Front Diagnostic Procedure................................................................... 424 523840.03 — Front Brake Pressure Sensor Short to Power.............................................................. 425 Front Brake Pressure Sensor Short to Power Diagnostic Procedure................................................. 425 523840.04 — Front Brake Pressure Sensor Open or Short............................................................... 426 Front Brake Pressure Sensor Open or Short Diagnostic Procedure.................................................. 426 523865.04 — Add Truck Switch Short to Ground........................................................................ 428 Add Truck Switch Short to Ground Diagnostic Procedure........................................................... 428 523867.04 — Counter Switch Short to Ground.......................................................................... 429 Counter Switch Short to Ground Diagnostic Procedure............................................................. 429 523868.04 — Add Bucket Switch Short to Ground....................................................................... 430 Add Bucket Switch Short to Ground Diagnostic Procedure.......................................................... 430 523948.03 — Ride Control Solenoid Short to Power.................................................................... 431 Ride Control Solenoid Short to Power Diagnostic Procedure....................................................... 431 523948.05 — Ride Control Solenoid Open Circuit...................................................................... 432 Ride Control Solenoid Open Circuit Diagnostic Procedure......................................................... 432 523948.06 — Ride Control Solenoid High Current...................................................................... 433 Ride Control Solenoid High Current Diagnostic Procedure......................................................... 434 524044.01 — Axle Oil Filter Restricted.............................................................................. 435 524044.03 — Axle Oil Filter Short to Power.......................................................................... 435 524250.31 — Inspect Park Brake...................................................................................... 435 Inspect Park Brake Diagnostic Procedure......................................................................... 435 524265.19 — Checksum Error.......................................................................................... 436 Check Sum Error Diagnostic Procedure............................................................................ 436 Sealed Switch Module (SSM) Diagnostic Trouble Codes..................................................................... 437 Sealed Switch Module (SSM) Diagnostic Trouble Codes................................................................. 437 000629.12 — Sealed Switch Module (SSM) Watchdog Time Out............................................................ 437 SSM Watchdog Time Out Diagnostic Procedure...................................................................... 437 002033.09 — Controller Area Network (CAN) Communication Lost For Vehicle Control Unit (VCU)......................... 437 SSM Lost Communications Diagnostic Procedure.................................................................... 438 002634.04 — Sealed Switch Module (SSM) Ignition Relay Signal Short to Ground........................................ 439 Sealed Switch Module (SSM) Ignition Relay Signal Short to Ground Diagnostic Procedure........................... 439 002634.05 — Sealed Switch Module (SSM) Ignition Relay Signal Open Circuit........................................... 440 Sealed Switch Module (SSM) Ignition Relay Signal Open Circuit Diagnostic Procedure.............................. 440 520752.04 — Button 17 Keypad Stuck.................................................................................. 441 Button 17 Keypad Stuck Diagnostic Procedure..................................................................... 441 520752.09 — Button 17 Light-Emitting Diode (LED) Message............................................................ 442 Button 17 Light-Emitting Diode (LED) Message Diagnostic Procedure............................................... 442 520753.04 — Front Washer Keypad Stuck............................................................................... 444 Front Washer Keypad Stuck Diagnostic Procedure.................................................................. 444 520754.04 — Front Wiper Keypad Stuck................................................................................ 444 Front Wiper Keypad Stuck Diagnostic Procedure................................................................... 445 520754.09 — Lost Front Wiper Light-Emitting Diode (LED) Message..................................................... 445 Lost Front Wiper Light-Emitting Diode (LED) Message Diagnostic Procedure........................................ 445 520755.04 — Drive Lights Keypad Stuck............................................................................... 447 Drive Lights Keypad Stuck Diagnostic Procedure.................................................................. 447 520755.09 — Lost Drive Lights Light-Emitting Diode (LED) Message.................................................... 448 Lost Drive Lights Light-Emitting Diode (LED) Message Diagnostic Procedure....................................... 448 523335.04 — Work Lights Keypad Stuck................................................................................ 449 Work Lights Keypad Stuck Diagnostic Procedure................................................................... 449 523335.09 — Lost Work Lights Light-Emitting Diode (LED) Message..................................................... 450 Lost Work Lights Light-Emitting Diode (LED) Message Diagnostic Procedure........................................ 450 523336.04 — Rear Wiper Keypad Stuck................................................................................. 451 Rear Wiper Keypad Stuck Diagnostic Procedure.................................................................... 451 523336.09 — Lost Rear Wiper Light-Emitting Diode (LED) Message...................................................... 452 Lost Rear Wiper Light-Emitting Diode (LED) Message Diagnostic Procedure......................................... 452 523338.04 — Rear Washer Keypad Stuck................................................................................ 454 Rear Washer Keypad Stuck Diagnostic Procedure................................................................... 454 523339.04 — Axle Disconnect Keypad Stuck............................................................................ 454 Axle Disconnect Keypad Stuck Diagnostic Procedure............................................................... 455 523339.09 — Lost Axle Disconnect Light-Emitting Diode (LED) Message................................................. 455 Lost Axle Disconnect Light-Emitting Diode (LED) Message Diagnostic Procedure.................................... 455 523340.04 — Button 21 Keypad Stuck.................................................................................. 457 Button 21 Keypad Stuck Diagnostic Procedure..................................................................... 457 523340.09 — Button 21 Light-Emitting Diode (LED) Message............................................................ 458 Button 21 Light-Emitting Diode (LED) Message Diagnostic Procedure............................................... 458 523849.04 — Air Conditioner Keypad Stuck............................................................................ 459 Air Conditioner Keypad Stuck Diagnostic Procedure............................................................... 459 523349.09 — Lost Air Conditioner Light-Emitting Diode (LED) Message................................................. 460 Lost Air Conditioner Light-Emitting Diode (LED) Message Diagnostic Procedure.................................... 460 523850.04 — Pin Disconnect Keypad Stuck............................................................................. 461 Pin Disconnect Keypad Stuck Diagnostic Procedure................................................................ 461 523850.09 — Lost Pin Disconnect Light-Emitting Diode (LED) Message.................................................. 462 Lost Pin Disconnect Light-Emitting Diode (LED) Message Diagnostic Procedure..................................... 462 523852.04 — Spin Control Keypad Stuck............................................................................... 464 Spin Control Keypad Stuck Diagnostic Procedure.................................................................. 464 523852.09 — Lost Spin Control Light-Emitting Diode (LED) Message.................................................... 464 Lost Spin Control Light-Emitting Diode (LED) Message Diagnostic Procedure....................................... 465 523854.04 — Differential Lock Keypad Stuck.......................................................................... 466 Differential Lock Keypad Stuck Diagnostic Procedure............................................................. 466 523854.09 — Lost Differential Lock Light-Emitting Diode (LED) Message............................................... 467 Lost Differential Lock Light-Emitting Diode (LED) Message Diagnostic Procedure.................................. 467 523855.04 — Return To Carry Keypad Stuck............................................................................ 468 Return-to-Carry Keypad Stuck Diagnostic Procedure............................................................... 468 523855.09 — Lost Return To Carry Light-Emitting Diode (LED) Message................................................. 469 Lost Return To Carry Light-Emitting Diode (LED) Message Diagnostic Procedure.................................... 469 523856.04 — Boom Height Kick Out Keypad Stuck....................................................................... 471 Boom Height Kickout Keypad Stuck Diagnostic Procedure........................................................... 471 523856.09 — Lost Boom Height Kick Out Light-Emitting Diode (LED) Message............................................ 471 Lost Boom Height Kickout Light-Emitting Diode (LED) Message Diagnostic Procedure................................ 472 523857.04 — Clutch Cut-Off Keypad Stuck............................................................................. 473 Clutch Cut-Off Keypad Stuck Diagnostic Procedure................................................................ 473 523857.09 — Lost Clutch Cut-Off Light-Emitting Diode (LED) Message.................................................. 474 Lost Clutch Cut-Off Light-Emitting Diode (LED) Message Diagnostic Procedure..................................... 474 523858.04 — Ride Control Keypad Stuck............................................................................... 475 Ride Control Keypad Stuck Diagnostic Procedure.................................................................. 475 523858.09 — Lost Ride Control Light-Emitting Diode (LED) Message.................................................... 476 Lost Ride Control Light-Emitting Diode (LED) Message Diagnostic Procedure....................................... 476 523860.04 — Auto Transmission Keypad Stuck.......................................................................... 478 Auto Transmission Keypad Stuck Diagnostic Procedure............................................................. 478 523860.09 — Lost Auto Transmission Light-Emitting Diode (LED) Message............................................... 478 Lost Auto Transmission Light-Emitting Diode (LED) Message Diagnostic Procedure.................................. 479 523861.04 — Return To Dig Keypad Stuck.............................................................................. 480 Return-to-Dig Keypad Stuck Diagnostic Procedure................................................................. 480 523861.09 — Lost Return To Dig Light-Emitting Diode (LED) Message................................................... 481 Lost Return To Dig Light-Emitting Diode (LED) Message Diagnostic Procedure...................................... 481 523862.04 — Park Brake Keypad Stuck................................................................................. 482 Park Brake Keypad Stuck Diagnostic Procedure.................................................................... 482 523862.09 — Lost Park Brake Light-Emitting Diode (LED) Message...................................................... 483 Lost Park Brake Light-Emitting Diode (LED) Message Diagnostic Procedure......................................... 483 523863.04 — Pilot Enable Keypad Stuck............................................................................... 485 Pilot Enable Keypad Stuck Diagnostic Procedure.................................................................. 485 523863.09 — Lost Pilot Enable Light-Emitting Diode (LED) Message.................................................... 485 Lost Pilot Enable Light-Emitting Diode (LED) Message Diagnostic Procedure....................................... 486 523864.04 — Hazards Keypad Stuck.................................................................................... 487 Hazards Keypad Stuck Diagnostic Procedure....................................................................... 487 523864.09 — Lost Hazard Light-Emitting Diode (LED) Message.......................................................... 488 Lost Hazard Light-Emitting Diode (LED) Message Diagnostic Procedure............................................. 488 523865.04 — Beacon Light Keypad Stuck............................................................................... 489 Beacon Light Keypad Stuck Diagnostic Procedure.................................................................. 489 523865.09 — Lost Beacon Light-Emitting Diode (LED) Message.......................................................... 490 Lost Beacon Light-Emitting Diode (LED) Message Diagnostic Procedure............................................. 490 523867.04 — Ignition Off Keypad Stuck............................................................................... 492 Ignition Off Keypad Stuck Diagnostic Procedure.................................................................. 492 523868.04 — Ignition On Keypad Stuck................................................................................ 492 Ignition On Keypad Stuck Stuck Diagnostic Procedure............................................................. 493 523868.09 — Lost Ignition On Light-Emitting Diode (LED) Message..................................................... 493 Lost Ignition On Light-Emitting Diode (LED) Message Diagnostic Procedure........................................ 493 Advanced Display Unit (ADU) Diagnostic Trouble Codes.................................................................... 497 Advanced Display Unit (ADU) Diagnostic Trouble Codes................................................................ 497 000158.03 — Switched Power Voltage High............................................................................. 497 Switched Power Voltage High Diagnostic Procedure................................................................ 497 000158.04 — Switched Power Voltage Low.............................................................................. 498 Switched Power Voltage Low Diagnostic Procedure................................................................. 498 000168.03 — High Battery Voltage.................................................................................... 499 High Battery Voltage Diagnostic Procedure....................................................................... 499 000168.04 — Low Battery Voltage..................................................................................... 500 Low Battery Voltage Diagnostic Procedure........................................................................ 500 000442.00 — Display Temp High....................................................................................... 501 Display Temp High Diagnostic Procedure.......................................................................... 502 000442.01 — Display Temp Low........................................................................................ 502 Display Temp Low Diagnostic Procedure........................................................................... 502 001491.11 — LCD Backlight Failure................................................................................... 503 LCD Backlight Failure Diagnostic Procedure...................................................................... 503 003597.02 — 5 Volt Power Supply Invalid............................................................................. 503 5 Volt Power Supply Invalid Diagnostic Procedure................................................................ 503 003598.02 — 1.5 Volt Power Supply Invalid........................................................................... 504 1.5 Volt Power Supply Invalid Diagnostic Procedure.............................................................. 504 003599.02 — 3.3 Volt Power Supply Invalid........................................................................... 504 3.3 Volt Power Supply Invalid Diagnostic Procedure.............................................................. 504 523436.14 — ADU Watchdog Time Out................................................................................... 505 ADU Watchdog Time Out Diagnostic Procedure...................................................................... 505 523438.31 — Memory Error............................................................................................ 505 Memory Error Diagnostic Procedure............................................................................... 505 523651.02 — Memory Stack Overflow................................................................................... 506 Memory Stack Overflow Diagnostic Procedure...................................................................... 506 523773.03 — CAN HIGH Voltage High................................................................................... 506 CAN HIGH Voltage High Diagnostic Procedure...................................................................... 506 523773.04 — CAN HIGH Voltage Low.................................................................................... 507 CAN HIGH Voltage Low Diagnostic Procedure....................................................................... 507 523774.03 — CAN LOW Voltage High.................................................................................... 508 CAN LOW Voltage High Diagnostic Procedure....................................................................... 508 523774.04 — CAN LOW Voltage Low..................................................................................... 508 CAN LOW Voltage Low Diagnostic Procedure........................................................................ 508 524076.10 — Information Button Stuck................................................................................ 509 Information Button Stuck Diagnostic Procedure................................................................... 509 524077.10 — Back Key Button Stuck................................................................................... 510 Back Key Button Stuck Diagnostic Procedure...................................................................... 510 524078.10 — Menu Select Button Stuck................................................................................ 510 Menu Select Button Stuck Diagnostic Procedure................................................................... 510 524080.10 — Down Arrow Button Stuck................................................................................. 511 Down Arrow Button Stuck Diagnostic Procedure.................................................................... 511 524082.10 — Up Arrow Button Stuck................................................................................... 512 Up Arrow Button Stuck Diagnostic Procedure...................................................................... 512 Radar Object Detection (ROD) Diagnostic Trouble Codes................................................................... 513 Radar Object Detection (ROD) Diagnostic Trouble Codes............................................................... 513 000896.12 — ROD Unit Failure........................................................................................ 513 ROD Unit Failure Diagnostic Procedure........................................................................... 513 Ground Speed Radar (RDR) Diagnostic Trouble Codes....................................................................... 515 Ground Speed Radar (RDR) Diagnostic Trouble Codes................................................................... 515 000628.12 — Controller Not Programmed............................................................................... 515 Controller Not Programmed Diagnostic Procedure.................................................................. 515 523456.18 — Degraded Mode........................................................................................... 515 Degraded Mode Diagnostic Procedure.............................................................................. 515 Joystick Steering Valve (JSV) Diagnostic Trouble Codes.................................................................. 517 Joystick Steering Valve (JSV) Diagnostic Trouble Codes.............................................................. 517 000627.03 — Supply High Voltage.................................................................................... 517 Power Supply Voltage High Diagnostic Procedure.................................................................. 517 000627.04 — Supply Voltage Low...................................................................................... 517 Supply Voltage Low Diagnostic Procedure......................................................................... 517 000628.12 — Memory Error............................................................................................ 518 Memory Error Diagnostic Procedure............................................................................... 518 000630.12 — Memory Error............................................................................................ 519 Memory Error Diagnostic Procedure............................................................................... 519 000638.12 — Memory Error............................................................................................ 519 Memory Error Diagnostic Procedure............................................................................... 519 298965.12 — Control ASIC............................................................................................ 520 Control ASIC Diagnostic Procedure............................................................................... 520 298970.02 — Invalid Option.......................................................................................... 520 Invalid Option Diagnostic Procedure............................................................................. 520 298971.02 — Invalid Valve State..................................................................................... 520 Invalid Valve State Diagnostic Procedure........................................................................ 520 298972.02 — Invalid Valve State..................................................................................... 521 Invalid Valve State Diagnostic Procedure........................................................................ 521 298973.02 — Port Flow Greater Than 100%............................................................................. 521 Port Flow Greater Than 100% Diagnostic Procedure................................................................ 521 298974.02 — Port Flow Error Float................................................................................... 522 Port Flow Error Float Diagnostic Procedure...................................................................... 522 298975.02 — Port Flow Error Block................................................................................... 522 Port Flow Error Block Diagnostic Procedure...................................................................... 522 298976.02 — Invert Port Error....................................................................................... 522 Invert Port Error Diagnostic Procedure.......................................................................... 522 298977.02 — Shape Error............................................................................................. 523 298978.02 — Invalid Slope Command................................................................................... 523 Invalid Slope Command Diagnostic Procedure...................................................................... 523 298979.02 — Dead Band Error......................................................................................... 523 298980.02 — Invalid Float Command................................................................................... 523 Program Controller.............................................................................................. 523 298981.02 — Invalid Ramps Command................................................................................... 524 Invalid Ramps Command Diagnostic Procedure...................................................................... 524 298982.02 — Invalid Scale Command................................................................................... 524 Invalid Scale Command Diagnostic Procedure...................................................................... 524 298983.02 — Flow Command Error...................................................................................... 525 Flow Command Error Diagnostic Procedure......................................................................... 525 298984.02 — CAN ID Invalid.......................................................................................... 525 CAN ID Invalid Diagnostic Procedure............................................................................. 525 298985.19 — CAN Communication Lost For VCU.......................................................................... 525 CAN Communication Lost for VCU Diagnostic Procedure............................................................. 526 298986.07 — Spool Fail Float Position............................................................................... 527 Spool Fail Float Position Diagnostic Procedure.................................................................. 527 298987.07 — Spool Position Wrong Direction.......................................................................... 527 Spool Position Wrong Direction Diagnostic Procedure............................................................. 528 298988.07 — Spool Position Greater Than Reference................................................................... 528 Spool Position Greater Than Reference Diagnostic Procedure...................................................... 528 298989.07 — Spool Not at Neutral.................................................................................... 528 Spool Not at Neutral Diagnostic Procedure....................................................................... 528 298990.07 — Spool Float Position Error.............................................................................. 529 Spool Float Position Error Diagnostic Procedure................................................................. 529 298991.07 — Main Spool Stuck........................................................................................ 529 Main Spool Stuck Diagnostic Procedure........................................................................... 529 298992.11 — Self Test Failure....................................................................................... 529 Self Test Failure Diagnostic Procedure.......................................................................... 529 298993.11 — Component Failure....................................................................................... 530 Component Failure Diagnostic Procedure.......................................................................... 530 298994.11 — Memory Error............................................................................................ 530 Memory Error Diagnostic Procedure............................................................................... 530 298994.12 — LVDT Wiring Error....................................................................................... 531 LVDT Wiring Error Diagnostic Procedure.......................................................................... 531 298995.11 — Memory Test Failure..................................................................................... 531 Memory Test Failure Diagnostic Procedure........................................................................ 531 298998.13 — Invalid Mechanical Spool Values......................................................................... 531 Invalid Mechanical Spool Values Diagnostic Procedure............................................................ 531 298999.13 — Memory Error............................................................................................ 532 299001.12 — Memory Error............................................................................................ 532 Memory Error Diagnostic Procedure............................................................................... 532 299002.11 — Software Error.......................................................................................... 532 Software Error Diagnostic Procedure............................................................................. 532 299003.11 — Software Error.......................................................................................... 533 Software Error Diagnostic Procedure............................................................................. 533 299004.11 — Software Error.......................................................................................... 533 Software Error Diagnostic Procedure............................................................................. 534 299006.12 — Software Error.......................................................................................... 534 299007.12 — Memory Test Failure..................................................................................... 534 Memory Test Failure Diagnostic Procedure........................................................................ 534 Joystick Steering Controller (JSC) Diagnostic Trouble Codes............................................................. 535 Joystick Steering Controller (JSC) Diagnostic Trouble Codes......................................................... 535 002697.03 — Joystick Position Sensor Voltage Above Normal........................................................... 535 Joystick Position Sensor Voltage Above Normal Diagnostic Procedure.............................................. 535 002697.04 — Joystick Position Sensor Voltage Below Normal........................................................... 535 Joystick Position Sensor Voltage Below Normal Diagnostic Procedure.............................................. 535 002697.13 — Joystick Out of Calibration............................................................................. 535 Joystick Out of Calibration Diagnostic Procedure................................................................ 536 002697.14 — Joystick Redundant Sensor Failure....................................................................... 536 Joystick Redundant Sensor Failure Diagnostic Procedure.......................................................... 536 Operational Checkout Procedure.............................................................................................. 537 Operational Checkout Procedure.......................................................................................... 539 Operational Checkout................................................................................................ 539 Diagnostic Trouble Code Check................................................................................... 539 Operational Checks—Ignition OFF, Engine OFF Checks.............................................................. 539 Operational Checks—Ignition ON, Engine OFF Checks............................................................... 540 Operational Checks—Ignition ON, Engine ON Checks................................................................ 547 Engine...................................................................................................................... 573 Theory of Operation..................................................................................................... 575 John Deere Engine................................................................................................... 575 Cold Start Aid System Theory of Operation........................................................................... 575 Diagnostic Information.................................................................................................. 577 John Deere Engine................................................................................................... 577 Engine Cranks/Will Not Start........................................................................................ 577 Engine Cranks/Will Not Start Diagnostic Procedure............................................................... 577 Engine Misfires/Runs Irregularly.................................................................................... 578 Engine Misfires/Runs Irregularly Diagnostic Procedure........................................................... 578 Engine does not Develop Full Power.................................................................................. 578 Engine Does Not Develop Full Power Diagnostic Procedure......................................................... 579 Engine Emits Excessive White Exhaust Smoke.......................................................................... 579 Engine Emits Excessive White Exhaust Smoke Diagnostic Procedure................................................. 579 Engine Emits Excessive Black or Gray Exhaust Smoke.................................................................. 580 Engine Emits Excessive Black or Gray Exhaust Smoke Diagnostic Procedure......................................... 580 Engine will not Crank............................................................................................... 580 Engine Will Not Crank Diagnostic Procedure...................................................................... 581 Engine Idles Poorly................................................................................................. 582 Engine Idles Poorly Diagnostic Procedure........................................................................ 582 Engine Noise........................................................................................................ 582 Abnormal Engine Noise Diagnostic Procedure...................................................................... 582 Low Pressure Fuel System Check...................................................................................... 583 Low Pressure Fuel System Diagnostic Procedure................................................................... 583 Extreme Fuel Consumption............................................................................................ 583 Excessive Fuel Consumption Diagnostic Procedure................................................................. 583 Fuel In Oil......................................................................................................... 584 Fuel in Oil Diagnostic Procedure................................................................................ 584 Engine Cooling System Component Location............................................................................ 586 Engine Fuel System Component Location............................................................................... 589 Engine Intake and Exhaust Component Location........................................................................ 591 Adjustments............................................................................................................. 593 John Deere Engine................................................................................................... 593 Service Filter Cleaning............................................................................................. 593 Tests................................................................................................................... 595 John Deere Engine................................................................................................... 595 Fluid Sampling Procedure—If Equipped................................................................................ 596 Engine Idle Speeds and Auto Shutdown Check.......................................................................... 600 Engine Low Idle Speed Adjustment.................................................................................... 601 Exhaust Emissions Test Point........................................................................................ 601 Electrical System........................................................................................................... 605 System Information...................................................................................................... 607 Electrical Diagram Information...................................................................................... 607 Electrical Schematic Symbols........................................................................................ 613 System Diagrams......................................................................................................... 616 Fuse and Relay Specifications....................................................................................... 616 System Functional Schematic, Wiring Diagram, and Component Location Master Legend................................... 618 System Functional Schematic......................................................................................... 623 Power and Ground Cables (W1) Component Location..................................................................... 690 Loader Frame Harness (W2) Component Location........................................................................ 691 Loader Frame Harness (W2) Wiring Diagram............................................................................ 693 Load Center Harness (W3) Component Location......................................................................... 697 Load Center Harness (W3) Wiring Diagram............................................................................. 701 Front Console Harness (W4) Component Location....................................................................... 756 Front Console Harness (W4) Wiring Diagram........................................................................... 758 Engine Frame Harness (W5) Component Location........................................................................ 759 Engine Frame Harness (W5) Wiring Diagram............................................................................ 761 Engine Harness (W6) Component Location.............................................................................. 764 Engine Harness (W6) Wiring Diagram.................................................................................. 767 Cold Start Harness (W7) Component Location.......................................................................... 773 Cold Start Harness (W7) Wiring Diagram.............................................................................. 773 Beacon Light Harness (W8) Component Location—If Equipped............................................................ 774 Beacon Light Harness (W8) Wiring Diagram—If Equipped................................................................ 775 Engine Interface Harness (W9) Component Location.................................................................... 777 Engine Interface Harness (W9) Wiring Diagram........................................................................ 785 Transmission Harness (W10) Component Location....................................................................... 800 Transmission Harness (W10) Wiring Diagram........................................................................... 801 Front Engine Harness (W11) Component Location....................................................................... 803 Front Engine Harness (W11) Wiring Diagram........................................................................... 805 Glow Plug Harness (W12) Component Location.......................................................................... 807 Glow Plug Harness (W12) Wiring Diagram.............................................................................. 807 Rear Frame Harness (W13) Component Location......................................................................... 808 Rear Frame Harness (W13) Wiring Diagram............................................................................. 811 License Plate Light and Backup Light Harness (W14) Component Location—If Equipped................................... 813 License Plate Light and Backup Light Harness (W14) Wiring Diagram—If Equipped....................................... 815 Secondary Steering Harness (W17) Component Location—If Equipped..................................................... 818 Secondary Steering Harness (W17) Wiring Diagram—If Equipped......................................................... 819 Cab Roof Harness (W19) Component Location........................................................................... 820 Cab Roof Harness (W19) Wiring Diagram............................................................................... 821 Heater and Air Conditioner Harness (W20) Component Location......................................................... 824 Heater and Air Conditioner Harness (W20) Wiring Diagram............................................................. 825 Radar Object Detection Harness (W21) Component Location—If Equipped................................................. 828 Radar Object Detection Harness (W21) Wiring Diagram................................................................. 829 Joystick Steering Harness (W22) Component Location.................................................................. 833 Joystick Steering Harness (W22) Wiring Diagram—If Equipped.......................................................... 835 Radio Harness (W23) Component Location.............................................................................. 838 Radio Harness (W23) Wiring Diagram.................................................................................. 839 Ground Speed Radar Harness (W31) Component Location—If Equipped..................................................... 840 Ground Speed Radar Harness (W31) Wiring Diagram—If Equipped......................................................... 840 Surge Tank Harness (W38) Component Location......................................................................... 841 Surge Tank Harness (W38) Wiring Diagram............................................................................. 842 Vehicle Control Unit (VCU) Power Cable (W42) Component Location..................................................... 842 Vehicle Control Unit (VCU) Power Cable (W42) Wiring Diagram......................................................... 843 Modular Telematics Gateway (MTG) and Satellite (SAT) Harness (W6002 and W6003) Component Location—If Equipped....... 844 Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram—If Equipped......................................... 846 Satellite (SAT) Harness (W6003) Wiring Diagram—If Equipped.......................................................... 848 Sub-System Diagnostics.................................................................................................. 851 Start and Charge Circuits Theory of Operation....................................................................... 851 Controller Area Network (CAN) Circuit Theory of Operation........................................................... 861 Engine Control Unit (ECU) Circuit Theory of Operation............................................................... 865 Exhaust Aftertreatment Circuit Theory of Operation.................................................................. 883 Vehicle Control Unit (VCU) Circuit Theory of Operation.............................................................. 885 Transmission Control Unit (TCU) Circuit Theory of Operation......................................................... 917 Park Brake Circuit Theory of Operation.............................................................................. 929 Advanced Display Unit (ADU) Circuit Theory of Operation............................................................. 935 Joystick Steering Circuit Theory of Operation....................................................................... 939 Radar Object Detection (ROD) Circuit Theory of Operation............................................................ 943 Auto-Differential Lock Circuit Theory of Operation.................................................................. 947 Embedded Payload Scale (EPS) Circuit Theory of Operation............................................................ 951 JDLink™ Circuit Theory of Operation................................................................................. 957 Monitor Operation....................................................................................................... 961 Advanced Display Unit (ADU)—Service Mode............................................................................ 961 Advanced Display Unit (ADU)—Clear Codes............................................................................. 961 Advanced Display Unit (ADU)—Auto Idle............................................................................... 962 Advanced Display Unit (ADU)—Auto Shutdown........................................................................... 962 Advanced Display Unit (ADU)—Enable Options.......................................................................... 963 Advanced Display Unit (ADU)—Tire Size............................................................................... 963 Advanced Display Unit (ADU)—Fan Speed............................................................................... 963 Advanced Display Unit (ADU)—Maximum High Gear....................................................................... 964 Advanced Display Unit (ADU)—Transmission Clutch Calibration......................................................... 964 Advanced Display Unit (ADU)—Slow Idle Adjust........................................................................ 965 Advanced Display Unit (ADU)—Hide-Unhide Main Menu................................................................... 965 Advanced Display Unit (ADU)—Service Cleaning........................................................................ 966 Advanced Display Unit (ADU)—Auto Cleaning Settings.................................................................. 966 References.............................................................................................................. 967 Electrical Component Specifications................................................................................. 967 Service ADVISOR™ Diagnostic Application............................................................................. 972 Service ADVISOR™ Connection Procedure............................................................................... 973 Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application....................................... 975 Diagnostic Trouble Codes—After Machine Repair....................................................................... 978 JDLink™ Connection Procedure........................................................................................ 978 CAN Circuit Test.................................................................................................... 979 Controller Area Network (CAN) Diagnostics ...................................................................... 979 Alternator Test..................................................................................................... 983 Hydraulic Pressure Sensor Test...................................................................................... 984 Hydraulic Pressure Sensor Diagnostic Procedure.................................................................. 984 Transmission Control Valve Solenoid Check........................................................................... 986 Clutch Cut-Off Sensor Check......................................................................................... 987 Boom Height Kickout (BHKO) Adjustment............................................................................... 987 Return-to-Carry (RTC) Adjustment.................................................................................... 988 Return-to-Dig (RTD) Adjustment—Z-Bar Linkage........................................................................ 989 Return-to-Dig (RTD) Adjustment—Powerllel Linkage.................................................................... 991 Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Remove and Install................................... 992 Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Disassemble and Assemble............................. 993 Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Calibration.......................................... 994 Embedded Payload Scale (EPS) Diagnostics............................................................................ 994 EPS Diagnostics................................................................................................. 995 Change Backup Alarm Volume.......................................................................................... 997 Air Conditioner Freeze Control Switch Remove and Install............................................................ 998 Air Conditioner High/Low-Pressure Switch Remove and Install......................................................... 998 Pressure Switches and Sensors Remove and Install.................................................................... 999 Intermittent Diagnostic Trouble Code (DTC) Diagnostics.............................................................. 999 Connector Terminal Test.............................................................................................1000 Connector Terminal Test Diagnostic Procedure....................................................................1000 Replace Metri-Pack® (Push Type) Connectors..........................................................................1001 Replace Metri-Pack® Connectors......................................................................................1002 Replace DEUTSCH® Circular Connectors................................................................................1003 Replace DEUTSCH® Rectangular or Triangular Connectors...............................................................1004 Install DEUTSCH® Contact............................................................................................1005 Replace WEATHER PACK® Connector.....................................................................................1006 Install WEATHER PACK® Contact.......................................................................................1007 Replace CINCH™ Connectors...........................................................................................1008 Install CINCH™ Contact..............................................................................................1009 Repair 32 and 48 Way CINCH™ Connectors..............................................................................1010 Remove Connector Body from Blade Terminals..........................................................................1012 Power Train.................................................................................................................1014 Theory of Operation.....................................................................................................1015 TeamMate™ Axles.....................................................................................................1015 Power Train Operation...............................................................................................1015 Torque Converter Operation..........................................................................................1016 Transmission Operation..............................................................................................1017 Transmission Operation—First Gear Forward...........................................................................1018 Transmission Clutch Pack Engagement and Solenoids Activated.........................................................1020 Transmission Filter Bypass Valve Operation..........................................................................1021 Transmission Control Valve Component Operation......................................................................1022 Transmission Clutch Modulation Operation............................................................................1025 Thermal Bypass Valve Operation......................................................................................1026 Standard Differential Operation.....................................................................................1028 Differential Lock Operation.........................................................................................1029 Rear Axle Disconnect Operation......................................................................................1030 Axle Circulation Dual Pump Operation................................................................................1031 Park Brake Operation................................................................................................1032 Diagnostic Information..................................................................................................1035 Transmission System Schematic—First Forward.........................................................................1035 Power Train Component Location......................................................................................1039 Transmission Clutch Slippage........................................................................................1041 Transmission Clutch Slippage Diagnostic Procedure...............................................................1041 Machine Will Not Move in Either Direction...........................................................................1043 Machine Will Not Move in Either Direction Diagnostic Procedure..................................................1043 Machine Will Not Shift Correctly....................................................................................1047 Machine Will Not Shift Correctly Diagnostic Procedure...........................................................1047 Transmission System Pressure Is Low in Neutral......................................................................1049 Transmission System Pressure Is Low in Neutral Diagnostic Procedure.............................................1049 Transmission Pressure Is Low (One or Two Gear Ranges)...............................................................1050 Transmission Pressure Is Low (One or Two Gear Ranges) Diagnostic Procedure......................................1050 Transmission Shifts Too Slow........................................................................................1052 Transmission Shifts Too Slow Diagnostic Procedure...............................................................1052 Transmission Shifts Too Fast........................................................................................1054 Transmission Shifts Too Fast Diagnostic Procedure...............................................................1054 Machine Creeps in Neutral...........................................................................................1055 Machine Creeps in Neutral Diagnostic Procedure..................................................................1055 Transmission Hydraulic System Overheats.............................................................................1056 Transmission Hydraulic System Overheats Diagnostic Procedure....................................................1056 Transmission Excessive Noise........................................................................................1058 Transmission Excessive Noise Diagnostic Procedure...............................................................1058 Rear Axle Disconnect Does Not Disengage (2WD state).................................................................1060 Rear Axle Disconnect Does Not Disengage (2WD state) Diagnostic Procedure........................................1060 Rear Axle Disconnect Does Not Engage (4WD state)....................................................................1062 Rear Axle Disconnect Does Not Engage (4WD state) Diagnostic Procedure...........................................1062 Oil Aerated.........................................................................................................1064 Oil Aerated Diagnostic Procedure................................................................................1064 Oil Ejected from Filler Tube........................................................................................1064 Oil Ejected from Filler Tube Diagnostic Procedure...............................................................1064 Machine Vibrates....................................................................................................1065 Machine Vibrates Diagnostic Procedure...........................................................................1065 Machine Power and Acceleration Low..................................................................................1066 Machine Power and Acceleration Low Diagnostic Procedure.........................................................1066 Torque Converter Stall RPM..........................................................................................1067 Torque Converter Stall RPM Diagnostic Procedure.................................................................1067 Differential Lock Will Not Engage...................................................................................1068 Differential Lock Will Not Engage Diagnostic Procedure..........................................................1068 Differential Lock Slips and Chatters................................................................................1069 Differential Lock Slips and Chatters Diagnostic Procedure.......................................................1069 Differential Lock Will Not Disengage................................................................................1070 Differential Lock Will Not Disengage Diagnostic Procedure.......................................................1070 Differential Oil Level Rises........................................................................................1071 Differential Oil Level Rises Diagnostic Procedure...............................................................1071 Differential Oil Level Low..........................................................................................1071 Differential Oil Level Low Diagnostic Procedure.................................................................1072 Differential and Axle Noise Excessive...............................................................................1072 Differential and Axle Noise Excessive Diagnostic Procedure......................................................1072 Axle Wheel Hub Face Seal Leaking....................................................................................1073 Axle Wheel Hub Face Seal Leaking Diagnostic Procedure...........................................................1073 Axle Overheats......................................................................................................1074 Axle Overheats Diagnostic Procedure.............................................................................1074 Service Brakes Poor or Do Not Apply.................................................................................1075 Service Brakes Poor or Do Not Apply Diagnostic Procedure........................................................1075 Service Brakes Aggressive...........................................................................................1076 Service Brakes Aggressive Diagnostic Procedure..................................................................1076 Service Brakes Dragging.............................................................................................1077 Service Brakes Dragging Diagnostic Procedure....................................................................1077 Service Brakes Lock up..............................................................................................1078 Service Brakes Lock up Diagnostic Procedure.....................................................................1078 Service Brakes Chatter..............................................................................................1079 Service Brakes Chatter Diagnostic Procedure.....................................................................1079 Service Brake Warning Light On......................................................................................1080 Service Brake Warning Light On Diagnostic Procedure.............................................................1080 Driveline Excessive Vibration or Noise..............................................................................1081 Driveline Excessive Vibration or Noise Diagnostic Procedure.....................................................1081 Park Brake Will Not Hold............................................................................................1083 Park Brake Will Not Hold Diagnostic Procedure...................................................................1083 Park Brake Will Not Release.........................................................................................1084 Park Brake Will Not Release Diagnostic Procedure................................................................1084 Park Brake Overheats................................................................................................1086 Park Brake Overheats Diagnostic Procedure.......................................................................1086 Park Brake Light Flashes When Shifting From Forward to Reverse......................................................1087 Park Brake Light Flashes When Shifting From Forward to Reverse Diagnostic Procedure.............................1087 Park Brake Light Flashes During Each Shift..........................................................................1087 Park Brake Light Flashes During Each Shift Diagnostic Procedure.................................................1087 Park Brake Light Does Not Come On...................................................................................1088 Park Brake Light Does Not Come On Diagnostic Procedure..........................................................1088 Park Brake Will Not Apply...........................................................................................1089 Park Brake Will Not Apply Diagnostic Procedure..................................................................1090 Adjustments.............................................................................................................1091 Service Brake Bleeding Procedure....................................................................................1091 External Service Brake Inspection...................................................................................1092 Transmission Control Unit (TCU)—Electronic Clutch Calibration.......................................................1094 Tests...................................................................................................................1095 Transmission Oil Sampling Procedure.................................................................................1095 Transmission Oil Warm-Up Procedure..................................................................................1095 Park Brake Pressure Test............................................................................................1096 Park Brake Drag Test................................................................................................1097 Transmission Pump Flow Test.........................................................................................1099 Transmission System Pressure Test...................................................................................1100 Transmission Clutch Pressure Test...................................................................................1102 Transmission Element Leakage Test...................................................................................1104 Transmission Lube Pressure Test.....................................................................................1106 Differential Lock Pressure Test.....................................................................................1108 Torque Converter—In Pressure Test...................................................................................1110 Torque Converter—Out Pressure Test..................................................................................1111 Torque Converter Relief Pressure Test...............................................................................1112 Torque Converter—Out Flow Test......................................................................................1114 Torque Converter Stall Speed Test...................................................................................1116 Transmission Oil Cooler Thermal Bypass Valve Temperature Test.......................................................1118 Transmission Oil Cooler Thermal Bypass Valve Pressure Test..........................................................1120 Transmission Oil Cooler Restriction Test............................................................................1121 Axle Circulation Pump Flow Test.....................................................................................1123 Axle Breather Test..................................................................................................1124 Hydraulic System............................................................................................................1127 Theory of Operation.....................................................................................................1129 Loader Hydraulic System Operation...................................................................................1129 Main Hydraulic Pump Operation.......................................................................................1130 Hydraulic Pump Manifold Operation...................................................................................1132 Hydraulic Fan Operation.............................................................................................1135 Hydraulic Reversing Fan Operation—If Equipped.......................................................................1137 Orbital Steering System Component Operation.........................................................................1139 Orbital Steering Valve Operation....................................................................................1140 Joystick Steering Valve Operation—If Equipped.......................................................................1141 Secondary Steering System Operation—If Equipped.....................................................................1143 Secondary Steering Valve Operation..................................................................................1144 Pilot Pressure Reducing Valve Operation.............................................................................1148 Service Brake Hydraulic System Operation............................................................................1148 Service Brake Accumulator Operation.................................................................................1149 Service Brake Valve Operation.......................................................................................1150 Pin Disconnect Operation............................................................................................1152 Pilot Control Lever Operation.......................................................................................1154 Control Valve Pilot Orifice Check Valve Operation...................................................................1155 Loader Control Valve Operation......................................................................................1156 Boom Section Operation—Boom Down and Steering.......................................................................1157 Bucket Section Operation—Boom Raise and Bucket Dump.................................................................1159 Bucket Section Operation—Boom Raise and Bucket Dump (High-Lift Option)..............................................1161 Auxiliary Section—Operating and Boom Raise..........................................................................1163 Auxiliary Section—Spool Stroke Adjuster Operation...................................................................1165 Loader Control Valve—Outlet Section Operation.......................................................................1166 Load Sense Circuit Operation—Neutral................................................................................1168 Load Sense Circuit Operation—Steering...............................................................................1169 Load Sense Circuit Operation—Steering and Boom Down.................................................................1170 Load Sense Circuit Operation—Boom Raise and Bucket Dump.............................................................1172 Main Relief Valve Operation.........................................................................................1173 Load Sense Relief Valve Operation...................................................................................1175 Circuit Relief With Anticavitation Valve Operation..................................................................1176 Anticavitation Valve Operation......................................................................................1181 Hydraulic Return Filter Operation...................................................................................1182 Ride Control Operation—If Equipped..................................................................................1184 Diagnostic Information..................................................................................................1187 Hydraulic System Schematic..........................................................................................1187 Steering and Hydraulic Cooling Fan Circuit Component Location.......................................................1194 Steering and Hydraulic Cooling Fan Circuit Line Identification......................................................1205 Loader and Hydraulic Cooling Circuit Component Location.............................................................1220 Loader and Hydraulic Cooling Circuit Line Identification............................................................1223 Ride Control, Pin Disconnect, and Hydraulic Filter Circuit Component Location.......................................1226 Ride Control, Pin Disconnect, and Hydraulic Filter Circuit Line Identification......................................1229 Service Brake, Park Brake, Differential Lock, and Axle Cooling Circuit Component Location...........................1232 Service Brake, Park Brake, Differential Lock, and Axle Cooling Circuit Line Identification..........................1235 Hydraulic Pump Manifold (Hydraulic System Component Location).......................................................1237 No Hydraulic Functions..............................................................................................1238 No Hydraulic Functions Diagnostic Procedure.....................................................................1238 Hydraulic Functions Slow............................................................................................1239 Hydraulic Functions Slow Diagnostic Procedure...................................................................1239 Main Hydraulic Pump Noisy...........................................................................................1242 Main Hydraulic Pump Noisy Diagnostic Procedure..................................................................1242 No Orbital Steering Function........................................................................................1243 No Orbital Steering Function Diagnostic Procedure...............................................................1243 Boom Float Function Not Working.....................................................................................1244 Boom Float Function Not Working Diagnostic Procedure............................................................1244 One Hydraulic Function Not Working..................................................................................1245 One Hydraulic Function Not Working Diagnostic Procedure.........................................................1245 Hydraulic Function Drifts Down......................................................................................1247 Hydraulic Function Drifts Down Diagnostic Procedure.............................................................1247 Boom Down Does Not Work (Engine Off)................................................................................1248 Boom Down Does Not Work (Engine Off) Diagnostic Procedure.......................................................1248 Ride Control Not Working............................................................................................1249 Ride Control Not Working Diagnostic Procedure...................................................................1249 Oil Overheats.......................................................................................................1250 Oil Overheats Diagnostic Procedure..............................................................................1250 Hydraulic Oil Foams.................................................................................................1251 Hydraulic Oil Foams Diagnostic Procedure........................................................................1251 Pin Disconnect Cylinders Will Not Retract—If Equipped...............................................................1252 Pin Disconnect Cylinders Will Not Retract Diagnostic Procedure..................................................1252 Constant Steering Required to Maintain Straight Travel..............................................................1253 Constant Steering Required to Maintain Straight Travel Diagnostic Procedure.....................................1253 Slow Steering Wheel Movement Will Not Cause Frame Movement..........................................................1254 Slow Steering Wheel Movement Will Not Cause Frame Movement Diagnostic Procedure.................................1254 Steering Wheel Turns Without Resistance and Causes No Frame Movement................................................1254 Steering Wheel Turns Without Resistance and Causes No Frame Movement Diagnostic Procedure.......................1254 Steering Erratic....................................................................................................1255 Steering Erratic Diagnostic Procedure...........................................................................1255 Steering Wheel Free Play............................................................................................1255 Steering Wheel Free Play Diagnostic Procedure...................................................................1255 Orbital Steering Valve Binds or Locks Up............................................................................1256 Orbital Steering Valve Binds or Locks Up Diagnostic Procedure...................................................1256 Steering Wheel Turns by Itself......................................................................................1256 Steering Wheel Turns by Itself Diagnostic Procedure.............................................................1256 Machine Turns in Opposite Direction as Steering Wheel...............................................................1256 Machine Turns in Opposite Direction as Steering Wheel Diagnostic Procedure......................................1257 Steering Wheel Kickback.............................................................................................1257 Steering Wheel Kickback Diagnostic Procedure....................................................................1257 Orbital Steering Jerky..............................................................................................1257 Orbital Steering Jerky Diagnostic Procedure.....................................................................1257 No Joystick Steering Function—If Equipped...........................................................................1258 No Joystick Steering Function Diagnostic Procedure..............................................................1258 Secondary Steering Motor Will Not Operate—If Equipped...............................................................1258 Secondary Steering Motor Will Not Operate Diagnostic Procedure..................................................1259 Secondary Steering Pump Runs But Will Not Steer Machine—If Equipped.................................................1259 Secondary Steering Pump Runs But Will Not Steer Machine Diagnostic Procedure....................................1259 Hydraulic Fan Does Not Reach Full Speed.............................................................................1259 Hydraulic Fan Does Not Reach Full Speed Diagnostic Procedure....................................................1259 Hydraulic Fan Runs at Full Speed Only...............................................................................1261 Hydraulic Fan Runs at Full Speed Only Diagnostic Procedure......................................................1261 Hydraulic Fan Does Not Spin.........................................................................................1262 Hydraulic Fan Does Not Spin Diagnostic Procedure................................................................1262 Hydraulic Fan Will Not Reverse Direction—If Equipped................................................................1263 Hydraulic Fan Will Not Reverse Direction Diagnostic Procedure...................................................1263 Adjustments.............................................................................................................1265 Pilot Control Lever Adjustment......................................................................................1265 Auxiliary Pilot Control Lever Adjustment............................................................................1265 Ride Control Accumulator Gas Charge Procedure.......................................................................1266 Ride Control Accumulator Draining Procedure.........................................................................1267 Auxiliary Valve Section—Stroke Adjustment...........................................................................1268 Tests...................................................................................................................1269 Hydraulic Oil Sampling Procedure....................................................................................1269 Hydraulic Oil Warm-Up Procedure.....................................................................................1269 Vacuum Pump Installation............................................................................................1270 Hydraulic System Pressure and Accumulators Discharge................................................................1271 JT02156A Digital Pressure and Temperature Analyzer Kit Installation.................................................1272 Hydraulic System Operating and Standby Pressure Test................................................................1273 Main Hydraulic Pump Control Valve Test and Adjustment...............................................................1274 Load Sense Relief Valve Pressure Test and Adjustment................................................................1278 Main Hydraulic Pump Flow Test.......................................................................................1281 Main Hydraulic Pump Case Drain Test.................................................................................1283 Main Relief Valve Pressure Test.....................................................................................1285 Circuit Relief With Anticavitation Valve Pressure Test..............................................................1288 Loader Cylinder Drift Test..........................................................................................1290 Boom, Bucket, and Steering Cylinder Leakage Test....................................................................1291 Hydraulic Oil Cooler Restriction Test...............................................................................1292 Steering Cylinder Drift Test........................................................................................1294 Joystick Steering Valve Pressure Test—If Equipped...................................................................1297 Joystick Steering Circuit Relief Valve Pressure Test—If Equipped....................................................1299 Secondary Steering Pump Pressure Relief Valve Test—If Equipped......................................................1300 Secondary Steering Valve—Hydraulic System Isolation Check Valve Leakage Test—If Equipped............................1302 Secondary Steering Valve—Secondary Steering Pump Isolation Check Valve Leakage Test.................................1305 Pilot Control Valve Pressure Test...................................................................................1307 Auxiliary Pilot Control Valve Pressure Test.........................................................................1311 Pilot Pressure Reducing Valve Pressure Test.........................................................................1313 Pilot Accumulator Gas Precharge Test................................................................................1315 Cycle Time Test.....................................................................................................1316 Service Brake Accumulator Gas Precharge and Low Brake Pressure Warning Test.........................................1317 Service Brake Valve Pressure Test...................................................................................1319 Service Brake Valve Leakage Test....................................................................................1321 Service Brake Accumulator Inlet Check Valve Leakage Test............................................................1323 Pin Disconnect Pressure Test—If Equipped............................................................................1324 Hydraulic Fan Pump Pressure Test....................................................................................1327 Hydraulic Fan Motor Speed Test......................................................................................1329 Hydraulic Fan Pump Flow Test........................................................................................1330 Hydraulic Fan Motor Case Drain Test.................................................................................1332 Hydraulic Reversing Fan Test—If Equipped............................................................................1334 Hydraulic Oil Filter Inspection Procedure...........................................................................1335 Heating and Air Conditioning................................................................................................1337 Theory of Operation.....................................................................................................1339 Air Conditioning System Cycle of Operation..........................................................................1339 Diagnostic Information..................................................................................................1341 Air Conditioner and Heater Component Location.......................................................................1341 Air Conditioning System Does Not Operate............................................................................1343 Air Conditioning System Does Not Operate Diagnostic Procedure...................................................1343 Air Conditioner Does Not Cool Interior of Cab.......................................................................1345 Air Conditioner Does Not Cool Interior of Cab Diagnostic Procedure..............................................1346 Air Conditioner Runs Constantly, Too Cold...........................................................................1347 Air Conditioner Runs Constantly, Too Cold Diagnostic Procedure..................................................1347 Heating System Does Not Operate.....................................................................................1348 Heating System Does Not Operate Diagnostic Procedure............................................................1348 Heater Does Not Warm Interior of Cab................................................................................1349 Heater Does Not Warm Interior of Cab Diagnostic Procedure.......................................................1349 Interior Windows Continue to Fog....................................................................................1350 Interior Windows Continue to Fog Diagnostic Procedure...........................................................1350 Tests...................................................................................................................1351 Refrigerant Cautions and Proper Handling............................................................................1351 R134a Oil Charge Capacity...........................................................................................1351 R134a Refrigerant Charge Capacity...................................................................................1351 Refrigerant Hoses and Tubing Inspection.............................................................................1352 R134a Air Conditioning System Test..................................................................................1353 Operating Pressure Diagnostic Chart.................................................................................1354 Air Conditioner High/Low Pressure Switch Test.......................................................................1355 Freeze Control Switch Test..........................................................................................1356 Refrigerant Leak Testing............................................................................................1356 Page Number..................................................................................................................... 5 Section 9000................................................................................................................ 7 Group 01................................................................................................................ 9 Section 9001................................................................................................................ 43 Group 10................................................................................................................ 45 Group 20................................................................................................................ 63 Group 30................................................................................................................ 187 Group 40................................................................................................................ 437 Group 50................................................................................................................ 497 Group 60................................................................................................................ 513 Group 70................................................................................................................ 515 Group 80................................................................................................................ 517 Group 90................................................................................................................ 535 Section 9005................................................................................................................ 537 Group 10................................................................................................................ 539 Section 9010................................................................................................................ 573 Group 05................................................................................................................ 575 Group 15................................................................................................................ 577 Group 20................................................................................................................ 593 Group 25................................................................................................................ 595 Section 9015................................................................................................................ 605 Group 05................................................................................................................ 607 Group 10................................................................................................................ 616 Group 15................................................................................................................ 851 Group 16................................................................................................................ 961 Group 20................................................................................................................ 967 Section 9020................................................................................................................1014 Group 05................................................................................................................1015 Group 15................................................................................................................1035 Group 20................................................................................................................1091 Group 25................................................................................................................1095 Section 9025................................................................................................................1127 Group 05................................................................................................................1129 Group 15................................................................................................................1187 Group 20................................................................................................................1265 Group 25................................................................................................................1269 Section 9031................................................................................................................1337 Group 05................................................................................................................1339 Group 15................................................................................................................1341 Group 25................................................................................................................1351
S.S 20/02/2025
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