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John Deere 544K 4WD Loader Operation & Test Technical Manual TM13363X19 – PDF DOWNLOAD
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John Deere 544K 4WD Loader Operation & Test Technical Manual TM13363X19 – PDF DOWNLOAD
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Description
John Deere 544K 4WD Loader Operation & Test Technical Manual TM13363X19 – PDF DOWNLOAD
FILE DETAILS:
John Deere 544K 4WD Loader Operation & Test Technical Manual TM13363X19 – PDF DOWNLOAD
Language : English
Pages : 1250
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere 544K 4WD Loader Operation & Test Technical Manual TM13363X19 – 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.
TABLE OF CONTENTS:
John Deere 544K 4WD Loader Operation & Test Technical Manual TM13363X19 – 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 Inspect Machine.................................................................................................. 10 Stay Clear of Moving Parts....................................................................................... 10 Avoid High-Pressure Fluids....................................................................................... 11 Avoid High-Pressure Oils......................................................................................... 11 Work In Ventilated Area.......................................................................................... 11 Avoid Static Electricity Risk When Refueling..................................................................... 12 Prevent Fires.................................................................................................... 12 In Case of Machine Fire.......................................................................................... 13 Prevent Battery Explosions....................................................................................... 13 Clean Debris from Machine........................................................................................ 13 Handle Chemical Products Safely.................................................................................. 14 Handle Starting Fluid Safely..................................................................................... 14 Decommissioning โ Proper Recycling and Disposal of Fluids and Components......................................... 15 Exhaust Filter Ash Handling and Disposal......................................................................... 15 Prepare for Emergencies.......................................................................................... 15 Add Cab Guarding for Special Uses................................................................................ 16 Park and Prepare for Service Safely.............................................................................. 16 Clean Exhaust Filter Safely...................................................................................... 17 Service Cooling System Safely.................................................................................... 18 Service Tires Safely............................................................................................. 18 Remove Paint Before Welding or Heating........................................................................... 19 Make Welding Repairs Safely...................................................................................... 19 Drive Metal Pins Safely.......................................................................................... 19 Diagnostics.............................................................................................................. 35 Engine Control Unit (ECU) Diagnostic Trouble Codes................................................................... 37 Engine Control Unit (ECU) Diagnostic Trouble Codes............................................................... 37 000091.03 โ Engine Throttle Short to Power....................................................................... 37 Engine Throttle Short to Power Diagnostic Procedure.......................................................... 37 000091.04 โ Engine Throttle Open or Short........................................................................ 38 Engine Throttle Open or Short Diagnostic Procedure........................................................... 38 000091.14 โ Engine Throttle Sensor Invalid....................................................................... 40 000111.01 โ Engine Coolant Level Extremely Low................................................................... 40 Engine Coolant Level Extremely Low Diagnostic Procedure...................................................... 40 000111.18 โ Engine Coolant Very Low Level........................................................................ 41 Engine Coolant Very Low Level Diagnostic Procedure........................................................... 41 000168.01 โ Engine Control Unit (ECU) Battery Voltage Low........................................................ 42 Engine Control Unit (ECU) Battery Voltage Low Diagnostic Procedure........................................... 42 000237.31 โ Invalid Vehicle Identification Number (VIN).......................................................... 43 Invalid Vehicle Identification Number (VIN) Diagnostic Procedure............................................. 43 001321.05 โ Starter Relay Open Circuit........................................................................... 44 Starter Relay Open Circuit Diagnostic Procedure.............................................................. 44 001321.06 โ Starter Relay High Current........................................................................... 44 Starter Relay High Current Diagnostic Procedure.............................................................. 45 001321.09 โ Starter Signal Invalid............................................................................... 46 Starter Signal Invalid Diagnostic Procedure.................................................................. 46 001321.16 โ Too Long to Start.................................................................................... 47 Too Long to Start Diagnostic Procedure....................................................................... 47 001321.31 โ Starter Solenoid Open Circuit........................................................................ 48 Starter Solenoid Open Circuit Diagnostic Procedure........................................................... 48 001761.01 โ Diesel Exhaust Fluid is Extremely Low................................................................ 49 001761.18 โ Diesel Exhaust Fluid is Very Low..................................................................... 49 002003.09 โ Controller Area Network (CAN) Communication Lost for Transmission Control Unit (TCU)................. 49 Controller Area Network (CAN) Communication Lost for Transmission Control Unit (TCU) Diagnostic Procedure.... 49 002033.09 โ Controller Area Network (CAN) Communication Lost for Vehicle Control Unit (VCU)...................... 51 Controller Area Network (CAN) Communication Lost for Vehicle Control Unit (VCU) Diagnostic Procedure......... 51 003031.12 โ Diesel Exhaust Fluid Temperature Sensor Fault........................................................ 53 003353.31 โ Alternator Excitation Condition Exists............................................................... 54 Alternator Excitation Condition Exists Diagnostic Procedure.................................................. 54 003516.01 โ Diesel Exhaust Fluid Concentration is Low............................................................ 55 003516.09 โ Diesel Exhaust Fluid Tank Header Communication Fault................................................. 55 003516.12 โ Diesel Exhaust Fluid Tank Quality Sensor Fault....................................................... 56 003516.14 โ Improper Fluid in Diesel Exhaust Fluid Tank.......................................................... 56 003516.16 โ Diesel Exhaust Fluid Concentration is High........................................................... 56 003517.12 โ Diesel Exhaust Fluid Tank Level Sensor Fault......................................................... 57 004490.12 โ Humidity Sensor Failure.............................................................................. 57 Humidity Sensor Failure Diagnostic Procedure................................................................. 57 Transmission Control Unit (TCU) Diagnostic Trouble Codes............................................................. 59 Transmission Control Unit (TCU) Diagnostic Trouble Codes......................................................... 59 000091.09 โ Timeout EEC2 Message................................................................................. 59 Timeout EEC2 Message Diagnostic Procedure.................................................................... 59 000161.00 โ Input Speed High..................................................................................... 60 000513.02 โ Percent Torque Invalid............................................................................... 60 Percent Torque Invalid Diagnostic Procedure.................................................................. 60 000513.09 โ Timeout EEC1 Message................................................................................. 61 Timeout EEC1 Message Diagnostic Procedure.................................................................... 61 000514.02 โ Friction Invalid..................................................................................... 62 Friction Invalid Diagnostic Procedure........................................................................ 62 000514.09 โ Timeout EEC3 Message................................................................................. 63 Timeout EEC3 Message Diagnostic Procedure.................................................................... 63 000544.02 โ Reference Torque Invalid............................................................................. 64 Reference Torque Invalid Diagnostic Procedure................................................................ 64 000544.09 โ Timeout Engine Configuration Message................................................................. 65 Timeout Engine Configuration Message Diagnostic Procedure.................................................... 65 000777.02 โ Torque Converter Clutch Slippage..................................................................... 66 Torque Converter Clutch Slippage Diagnostic Procedure........................................................ 66 000777.03 โ Torque Converter Lockup Solenoid Short to Power...................................................... 68 Torque Converter Lockup Solenoid Short to Power Diagnostic Procedure......................................... 68 000777.04 โ Torque Converter Lockup Solenoid Short to Ground..................................................... 69 Torque Converter Lockup Solenoid Short to Ground Diagnostic Procedure........................................ 69 000777.05 โ Torque Converter Lockup Solenoid Open Circuit........................................................ 70 Torque Converter Lockup Solenoid Open Circuit Diagnostic Procedure........................................... 70 000928.03 โ Axle Disconnect Solenoid Short to Power.............................................................. 71 Axle Disconnect Solenoid Short to Power Diagnostic Procedure................................................. 71 000928.04 โ Axle Disconnect Solenoid High Current................................................................ 72 Axle Disconnect Solenoid High Current Diagnostic Procedure................................................... 73 000928.05 โ Axle Disconnect Solenoid Open Circuit................................................................ 74 Axle Disconnect Solenoid Open Circuit Diagnostic Procedure................................................... 74 001785.09 โ Engine Speed Limit Function Does Not Work Properly................................................... 75 002033.09 โ Controller Area Network (CAN) Communication Lost for Vehicle Control Unit (VCU)...................... 75 Controller Area Network (CAN) Communication Lost for Vehicle Control Unit (VCU) Diagnostic Procedure......... 75 002141.09 โ Controller Area Network (CAN) Communication Lost for Sealed Switch Module (SSM)...................... 78 Controller Area Network (CAN) Communication Lost for Sealed Switch Module (SSM) Diagnostic Procedure......... 78 004201.03 โ Converter Input Speed Sensor Open or Short........................................................... 80 004201.04 โ Converter Input Speed Sensor Short to Ground......................................................... 81 004201.12 โ Converter Input Speed Sensor Fault................................................................... 82 522344.00 โ Torque Converter Overtemperature..................................................................... 82 Torque Converter Overtemperature Diagnostic Procedure........................................................ 82 522350.15 โ Transmission Input Torque Overload................................................................... 83 Transmission Input Torque Overload Diagnostic Procedure...................................................... 83 522364.07 โ Transmission Clutch Calibration Failed............................................................... 84 Transmission Clutch Calibration Failed Diagnostic Procedure.................................................. 84 522364.13 โ Transmission Clutch Calibration Fault................................................................ 85 Transmission Clutch Calibration Fault Diagnostic Procedure................................................... 85 522365.13 โ Limp Home Mode....................................................................................... 86 Limp Home Mode Diagnostic Procedure.......................................................................... 86 522366.12 โ Application Invalid.................................................................................. 86 Application Invalid Diagnostic Procedure..................................................................... 87 522367.13 โ Transmission Control Unit (TCU) Configuration Invalid................................................ 87 Transmission Control Unit (TCU) Configuration Invalid Diagnostic Procedure................................... 87 522368.02 โ Transmission Control Unit (TCU) Memory Failure....................................................... 88 TCU Memory Failure Diagnostic Procedure...................................................................... 88 522370.02 โ Transmission Control Unit (TCU) Valve Power Supply 2 Short Circuit................................... 89 Transmission Control Unit (TCU) Valve Power Supply 2 Short Circuit Diagnostic Procedure...................... 89 522371.02 โ Transmission Control Unit (TCU) Valve Power Supply 1 Short Circuit................................... 90 Transmission Control Unit (TCU) Valve Power Supply 1 Short Circuit Diagnostic Procedure...................... 90 522373.03 โ Power Supply High Voltage............................................................................ 91 Power Supply High Voltage Diagnostic Procedure............................................................... 91 522373.04 โ Power Supply Low Voltage............................................................................. 92 Power Supply Low Voltage Diagnostic Procedure................................................................ 92 522375.00 โ Transmission Oil Filter Restricted................................................................... 93 Transmission Oil Filter Restricted Diagnostic Procedure...................................................... 93 522376.00 โ Transmission Oil Temperature Over Maximum Value...................................................... 94 Transmission Oil Temperature Over Maximum Value Diagnostic Procedure......................................... 94 522379.03 โ Park Brake Solenoid Short to Power................................................................... 95 Park Brake Solenoid Short to Power Diagnostic Procedure...................................................... 96 522379.04 โ Park Brake Solenoid Short to Ground.................................................................. 96 Park Brake Solenoid Short to Ground Diagnostic Procedure..................................................... 97 522379.05 โ Park Brake Solenoid Open Circuit..................................................................... 98 Park Brake Solenoid Open Circuit Diagnostic Procedure........................................................ 98 522382.03 โ Backup Alarm Short to Power.......................................................................... 99 Backup Alarm Short to Power Diagnostic Procedure............................................................. 99 522382.04 โ Backup Alarm Short to Ground......................................................................... 100 Backup Alarm Short to Ground Diagnostic Procedure............................................................ 100 522383.02 โ Transmission Clutch KR Slippage...................................................................... 101 Transmission Clutch KR Slippage Diagnostic Procedure......................................................... 101 522383.03 โ Transmission Reverse Clutch Solenoid Short to Power.................................................. 103 Transmission Reverse Clutch Solenoid Short to Power Diagnostic Procedure..................................... 103 522383.04 โ Transmission Reverse Clutch Solenoid Short to Ground................................................. 104 Transmission Reverse Clutch Solenoid Short to Ground Diagnostic Procedure.................................... 104 522383.05 โ Transmission Reverse Clutch Solenoid Open Circuit.................................................... 106 Transmission Reverse Clutch Solenoid Open Circuit Diagnostic Procedure....................................... 106 522386.02 โ Transmission Clutch KV Slippage...................................................................... 107 Transmission Clutch KV Slippage Diagnostic Procedure......................................................... 107 522386.03 โ Transmission Forward Clutch Solenoid Short to Power.................................................. 109 Transmission Forward Clutch Solenoid Short to Power Diagnostic Procedure..................................... 109 522386.04 โ Transmission Forward Clutch Solenoid Short to Ground................................................. 111 Transmission Forward Clutch Solenoid Short to Ground Diagnostic Procedure.................................... 111 522386.05 โ Transmission Forward Clutch Solenoid Open Circuit.................................................... 112 Transmission Forward Clutch Solenoid Open Circuit Diagnostic Procedure....................................... 112 522389.02 โ Transmission Clutch K4 Slippage...................................................................... 114 Transmission Clutch K4 Slippage Diagnostic Procedure......................................................... 114 522389.03 โ Transmission Clutch K4 Solenoid Short to Power....................................................... 115 Transmission Clutch K4 Solenoid Short to Power Diagnostic Procedure.......................................... 116 522389.04 โ Transmission Clutch K4 Solenoid Short to Ground...................................................... 117 Transmission Clutch K4 Solenoid Short to Ground Diagnostic Procedure......................................... 117 522389.05 โ Transmission Clutch K4 Solenoid Open Circuit......................................................... 119 Transmission Clutch K4 Solenoid Open Circuit Diagnostic Procedure............................................ 119 522392.02 โ Transmission Clutch K3 Slippage...................................................................... 120 Transmission Clutch K3 Slippage Diagnostic Procedure......................................................... 120 522392.03 โ Transmission Clutch K3 Solenoid Short to Power....................................................... 122 Transmission Clutch K3 Solenoid Short to Power Diagnostic Procedure.......................................... 122 522392.04 โ Transmission Clutch K3 Solenoid Short to Ground...................................................... 123 Transmission Clutch K3 Solenoid Short to Ground Diagnostic Procedure......................................... 123 522392.05 โ Transmission Clutch K3 Solenoid Open Circuit......................................................... 124 Transmission Clutch K3 Solenoid Open Circuit Diagnostic Procedure............................................ 125 522395.02 โ Transmission Clutch K2 Slippage...................................................................... 126 Transmission Clutch K2 Slippage Diagnostic Procedure......................................................... 126 522395.03 โ Transmission Clutch K2 Solenoid Short to Power....................................................... 128 Transmission Clutch K2 Solenoid Short to Power Diagnostic Procedure.......................................... 128 522395.04 โ Transmission Clutch K2 Solenoid Short to Ground...................................................... 129 Transmission Clutch K2 Solenoid Short to Ground Diagnostic Procedure......................................... 129 522395.05 โ Transmission Clutch K2 Solenoid Open Circuit......................................................... 131 Transmission Clutch K2 Solenoid Open Circuit Diagnostic Procedure............................................ 131 522399.02 โ Transmission Clutch K1 Slippage...................................................................... 132 Transmission Clutch K1 Slippage Diagnostic Procedure......................................................... 132 522399.03 โ Transmission Clutch K1 Solenoid Short to Power....................................................... 134 Transmission Clutch K1 Solenoid Short to Power Diagnostic Procedure.......................................... 134 522399.04 โ Transmission Clutch K1 Solenoid Short to Ground...................................................... 135 Transmission Clutch K1 Solenoid Short to Ground Diagnostic Procedure......................................... 135 522399.05 โ Transmission Clutch K1 Solenoid Open Circuit......................................................... 137 Transmission Clutch K1 Solenoid Open Circuit Diagnostic Procedure............................................ 137 522401.02 โ Transmission Output Shaft Speed Sensor Fault......................................................... 138 Transmission Output Shaft Speed Sensor Fault Diagnostic Procedure............................................ 138 522401.03 โ Transmission Output Shaft Open or Short to Power..................................................... 139 Transmission Output Shaft Open or Short to Power Diagnostic Procedure........................................ 139 522401.04 โ Transmission Output Shaft Short to Ground............................................................ 141 Transmission Output Shaft Short to Ground Diagnostic Procedure............................................... 141 522401.12 โ Transmission Output Shaft Fault...................................................................... 143 Transmission Output Shaft Fault Diagnostic Procedure......................................................... 143 522401.15 โ Transmission Output Shaft Overspeed.................................................................. 144 Transmission Output Shaft Overspeed Diagnostic Procedure..................................................... 144 522402.03 โ Clutch Speed Sensor Open or Short.................................................................... 145 Internal Clutch Speed Sensor Open or Short Diagnostic Procedure.............................................. 145 522402.04 โ Transmission Clutch Speed Sensor Short to Ground..................................................... 146 Transmission Clutch Speed Sensor Short to Ground Diagnostic Procedure........................................ 146 522402.12 โ Transmission Clutch Speed Sensor Fault............................................................... 147 Transmission Internal Clutch Speed Sensor Fault Diagnostic Procedure......................................... 147 522407.03 โ Transmission Clutch Cut-Off Sensor Short to Power.................................................... 148 Transmission Clutch Cut-Off Sensor Short to Power Diagnostic Procedure....................................... 148 522407.04 โ Transmission Clutch Cut-Off Sensor Open or Short to Ground........................................... 149 Transmission Clutch Cut-Off Sensor Open or Short to Ground Diagnostic Procedure.............................. 149 522409.05 โ 2nd FNR (Pilot Control Joystick FNR) Open Circuit.................................................... 151 2nd FNR (Pilot Control Joystick FNR) Open Circuit Diagnostic Procedure....................................... 151 522409.12 โ 2nd FNR (Pilot Control Joystick FNR) Multiple Inputs................................................. 153 2nd FNR (Pilot Control Joystick FNR) Multiple Inputs Diagnostic Procedure.................................... 153 522411.05 โ 1st FNR Open Circuit................................................................................. 154 1st FNR (Steering Column FNR) Open Circuit Diagnostic Procedure.............................................. 155 1st FNR (Pilot Control Joystick FNR) Open Circuit Diagnostic Procedure....................................... 155 522411.12 โ 1st FNR Multiple Inputs.............................................................................. 157 1st FNR (Steering Column FNR) Multiple Inputs Diagnostic Procedure........................................... 157 1st FNR Multiple Inputs (Pilot Control Joystick FNR) Diagnostic Procedure.................................... 158 522412.12 โ Gear Selection Error................................................................................. 160 Gear Selection Error Diagnostic Procedure.................................................................... 160 522419.02 โ Transmission Clutch Cut-Off Disabled................................................................. 162 Transmission Clutch Cut-Off Disabled Diagnostic Procedure.................................................... 162 522420.02 โ Manual Down Shift Disabled........................................................................... 163 Manual Downshift Disabled Diagnostic Procedure............................................................... 163 522421.02 โ Automatic to 1st Disabled............................................................................ 164 Automatic to 1st Disabled Diagnostic Procedure............................................................... 164 524048.00 โ Transmission Output Torque Exceeded.................................................................. 164 Transmission Output Torque Exceeded Diagnostic Procedure..................................................... 164 524049.00 โ Transmission Input Torque Exceeded................................................................... 165 Transmission Input Torque Exceeded Diagnostic Procedure...................................................... 165 524287.00 โ Configure Machine Model.............................................................................. 165 Configure Machine Model Diagnostic Procedure................................................................. 165 524287.02 โ Communication Error.................................................................................. 166 Vehicle Control Unit (VCU) Diagnostic Trouble Codes.................................................................. 167 Vehicle Control Unit (VCU) Diagnostic Trouble Codes.............................................................. 167 000075.00 โ Front Axle Oil High Temperature...................................................................... 167 Front Axle Oil High Temperature Diagnostic Procedure......................................................... 167 000075.04 โ Front Axle Oil Temp Sensor Short to Ground........................................................... 168 Front Axle Oil Temp Sensor Short to Ground Diagnostic Procedure.............................................. 168 000096.04 โ Fuel Level Short to Ground........................................................................... 169 Fuel Level Short to Ground Diagnostic Procedure.............................................................. 169 000096.05 โ Fuel Level Open or Short............................................................................. 170 Fuel Level Open or Short Diagnostic Procedure................................................................ 170 000096.10 โ Fuel Level Abnormal Rate of Change................................................................... 173 000167.16 โ Alternator High Voltage.............................................................................. 173 Alternator High Voltage Diagnostic Procedure................................................................. 173 000167.18 โ Alternator Low Voltage............................................................................... 174 Alternator Low Voltage Diagnostic Procedure.................................................................. 174 000168.16 โ High Battery Voltage................................................................................. 174 High Battery Voltage Diagnostic Procedure.................................................................... 174 000171.04 โ Ambient Air Short to Ground.......................................................................... 176 000234.02 โ Invalid Transmission Control Unit (TCU) Software Revision............................................ 176 Invalid TCU Software Revision Diagnostic Procedure........................................................... 176 000521.00 โ Brake Pedal High Voltage............................................................................. 177 Brake Pedal High Voltage Diagnostic Procedure................................................................ 177 000578.00 โ Rear Axle Oil High Temperature....................................................................... 177 Rear Axle Oil High Temperature Diagnostic Procedure.......................................................... 177 000578.04 โ Rear Axle Oil Temp Sensor Short to Ground............................................................ 178 Rear Axle Oil Temp Sensor Short to Ground Diagnostic Procedure............................................... 178 000628.12 โ Controller Not Programmed............................................................................ 179 Controller Not Programmed Diagnostic Procedure............................................................... 179 000629.12 โ Vehicle Control Unit (VCU) Watchdog Time Out......................................................... 180 Vehicle Control Unit (VCU) Watchdog Time Out Diagnostic Procedure............................................ 180 000639.12 โ Vehicle Control Unit (VCU) Controller Area Network (CAN) Failure..................................... 180 Vehicle Control Unit (VCU) Controller Area Network (CAN) Failure Diagnostic Procedure........................ 180 000639.14 โ Vehicle Control Unit (VCU) Controller Area Network (CAN) 1 Bus Off................................... 181 Vehicle Control Unit (VCU) Controller Area Network (CAN) 1 Bus Off Diagnostic Procedure...................... 181 000746.03 โ Differential Lock Solenoid Short to Power............................................................ 182 Differential Lock Solenoid Short to Power Diagnostic Procedure............................................... 182 000746.05 โ Differential Lock Solenoid Open...................................................................... 183 Differential Lock Solenoid Open Diagnostic Procedure......................................................... 183 000746.06 โ Differential Lock Solenoid High Current.............................................................. 185 Differential Lock Solenoid High Current Diagnostic Procedure................................................. 185 000785.03 โ Pilot Solenoid Short to Power........................................................................ 186 Pilot Solenoid Short to Power Diagnostic Procedure........................................................... 186 000785.05 โ Pilot Solenoid Open or Short......................................................................... 187 Pilot Solenoid Open or Short Diagnostic Procedure............................................................ 187 000785.06 โ Pilot Solenoid High Current.......................................................................... 189 Pilot Solenoid High Current Diagnostic Procedure............................................................. 189 000880.03 โ Brake Lights Short to Power.......................................................................... 191 Brake Lights Short to Power Diagnostic Procedure............................................................. 191 000880.05 โ Brake Lights Open or Short........................................................................... 192 Brake Lights Open or Short Diagnostic Procedure.............................................................. 192 000880.06 โ Brake Lights High Current............................................................................ 193 Brake Lights High Current Diagnostic Procedure............................................................... 193 000920.03 โ Alarm Short to Power................................................................................. 195 000920.05 โ Alarm Open Circuit................................................................................... 196 000920.06 โ Alarm Short to Ground................................................................................ 197 000977.03 โ Reversing Fan Solenoid Short to Power................................................................ 197 Reversing Fan Solenoid Short to Power Diagnostic Procedure................................................... 197 000977.05 โ Reversing Fan Solenoid Open or Short................................................................. 198 Reversing Fan Solenoid Open or Short Diagnostic Procedure.................................................... 198 000977.06 โ Reversing Fan Solenoid High Current.................................................................. 200 Reversing Fan Solenoid High Current Diagnostic Procedure..................................................... 200 001069.02 โ Tire Size Incorrect.................................................................................. 201 Tire Size Incorrect Diagnostic Procedure..................................................................... 201 001071.03 โ Proportional Fan Solenoid High Side (HS) Short to Power.............................................. 202 Proportional Fan Solenoid High Side (HS) Short to Power Diagnostic Procedure................................. 202 001071.05 โ Proportional Fan Solenoid High Side (HS) Open or Short............................................... 203 Proportional Fan Solenoid High Side (HS) Open or Short Diagnostic Procedure.................................. 203 001071.06 โ Proportional Fan Solenoid High Side (HS) High Current................................................ 205 Proportional Fan Solenoid High Side (HS) High Current Diagnostic Procedure................................... 205 001071.13 โ Proportional Fan Solenoid Out of Calibration......................................................... 206 001071.16 โ Proportional Fan Solenoid Low Side (LS) High Current................................................. 206 Proportional Fan Solenoid Low Side (LS) High Current Diagnostic Procedure.................................... 206 001071.17 โ Proportional Fan Solenoid Low Side (LS) Open or Short................................................ 207 Proportional Fan Solenoid Low Side (LS) Open or Short Diagnostic Procedure................................... 207 001071.18 โ Proportional Fan Solenoid Low Side (LS) Short to Power............................................... 209 Proportional Fan Solenoid Low Side (LS) Short to Power Diagnostic Procedure.................................. 209 001231.12 โ Vehicle Control Unit (VCU) Controller Area Network (CAN) 2 Failure................................... 210 Vehicle Control Unit (VCU) Controller Area Network (CAN) 2 Failure Diagnostic Procedure...................... 210 001231.14 โ Vehicle Control Unit (VCU) Controller Area Network (CAN) 2 Bus Off................................... 211 Vehicle Control Unit (VCU) Controller Area Network (CAN) 2 Bus Off Diagnostic Procedure...................... 211 001550.03 โ Air Conditioner Clutch Short to Power................................................................ 212 Air Conditioner Clutch Short to Power Diagnostic Procedure................................................... 212 001550.06 โ Air Conditioner Clutch High Current.................................................................. 212 Air Conditioner Clutch High Current Diagnostic Procedure..................................................... 212 001638.00 โ Hydraulic Oil High Temperature....................................................................... 213 Hydraulic Oil High Temperature Diagnostic Procedure.......................................................... 213 001638.04 โ Hydraulic Oil Temperature Sensor Short to Ground..................................................... 214 Hydraulic Oil Temperature Sensor Short to Ground Diagnostic Procedure........................................ 214 001639.02 โ Fan Speed Sensor Out of Synchronization.............................................................. 216 Fan Speed Sensor Out of Synchronization Diagnostic Procedure................................................. 216 001639.04 โ Fan Speed Sensor Short to Ground..................................................................... 217 Fan Speed Sensor Short to Ground Diagnostic Procedure........................................................ 217 001639.05 โ Fan Speed Sensor Open Circuit........................................................................ 218 Fan Speed Sensor Open Circuit................................................................................ 218 001639.07 โ Fan Speed Did Not Lower During Reversal.............................................................. 220 001639.08 โ Fan Speed Sensor No Signal........................................................................... 220 Fan Speed Sensor No Signal Diagnostic Procedure.............................................................. 220 001639.10 โ Fan Speed Sensor Fault............................................................................... 221 Fan Speed Sensor Fault Diagnostic Procedure.................................................................. 221 001639.13 โ Fan Speed Sensor Out of Calibration.................................................................. 223 001713.01 โ Hydraulic Oil Filter Restricted...................................................................... 223 Hydraulic Oil Filter Restricted Diagnostic Procedure......................................................... 223 001762.03 โ Hydraulic Pressure Sensor Short to Power............................................................. 224 Hydraulic System Pressure Sensor Short to Power Diagnostic Procedure......................................... 224 001762.04 โ Hydraulic Pressure Sensor Open or Short.............................................................. 225 Hydraulic System Pressure Sensor Open or Short Diagnostic Procedure.......................................... 225 001841.03 โ Blackout Brake Lights Short to Power................................................................. 226 Blackout Brake Lights Short to Power Diagnostic Procedure.................................................... 227 001841.05 โ Blackout Brake Lights Open or Short.................................................................. 228 Blackout Brake Lights Open or Short Diagnostic Procedure..................................................... 228 001841.06 โ Blackout Brake Lights High Current................................................................... 229 Blackout Brake Lights High Current Diagnostic Procedure...................................................... 229 001842.03 โ Blackout Lights Short to Power....................................................................... 230 Blackout Lights Short to Power Diagnostic Procedure.......................................................... 231 001842.05 โ Blackout Lights Open or Short........................................................................ 232 Blackout Lights Open or Short Diagnostic Procedure........................................................... 232 001842.06 โ Blackout Lights High Current......................................................................... 234 Blackout Lights High Current Diagnostic Procedure............................................................ 234 002000.09 โ Controller Area Network (CAN) Communication Lost for Engine Control Unit (ECU)....................... 236 Controller Area Network (CAN) Communication Lost for Engine Control Unit (ECU) Diagnostic Procedure.......... 236 002003.09 โ Controller Area Network (CAN) Communication Lost for Transmission Control Unit (TCU)................. 238 Controller Area Network (CAN) Communication Lost for Transmission Control Unit (TCU) Diagnostic Procedure.... 238 002033.14 โ Flexpower Handshaking Error.......................................................................... 239 002040.09 โ Controller Area Network (CAN) Communication Lost for Advanced Displaying Unit (ADU).................. 240 Controller Area Network (CAN) Communication Lost for Advanced Displaying Unit (ADU) Diagnostic Procedure..... 240 002051.09 โ Controller Area Network (CAN) Communication Lost for Tire Pressure Monitoring System (TPMS).......... 241 CAN Communication Lost for TPMS Diagnostic Procedure......................................................... 241 002132.09 โ Controller Area Network (CAN) Communication Lost for Radar Object Detection (ROD).................... 243 Controller Area Network (CAN) Communication Lost for Radar Object Detection (ROD) Diagnostic Procedure....... 243 002141.09 โ Controller Area Network (CAN) Communication Lost for Sealed Switch Module (SSM)...................... 244 Controller Area Network (CAN) Communication Lost for Sealed Switch Module (SSM) Diagnostic Procedure......... 244 002169.09 โ Controller Area Network (CAN) Communication Lost for Ground Speed Radar (RDR)........................ 246 Controller Area Network (CAN) Communication Lost for Ground Speed Radar (RDR) Diagnostic Procedure........... 246 002251.09 โ Controller Area Network (CAN) Lost for JDlink........................................................ 248 002350.03 โ Drive Lamps Short to Power........................................................................... 248 Drive Lamps Short to Power Diagnostic Procedure.............................................................. 248 002350.05 โ Drive Lamps Open or Short............................................................................ 249 Drive Lamps Open or Short Diagnostic Procedure............................................................... 249 002350.06 โ Drive Lamps High Current............................................................................. 251 Drive Lamps High Current Diagnostic Procedure................................................................ 251 002355.03 โ Front Work Lights Short to Power..................................................................... 252 Front Work Lights Short to Power............................................................................. 252 002355.05 โ Front Work Lights Open or Short...................................................................... 253 Front Work Lights Open or Short Diagnostic Procedure......................................................... 253 002355.06 โ Front Work Lights High Current....................................................................... 255 Front Work Lights High Current Diagnostic Procedure.......................................................... 255 002356.03 โ Front Work Lights Short to Power..................................................................... 256 Front Work Lights Short to Power Diagnostic Procedure........................................................ 257 002356.05 โ Front Work Lights Open or Short...................................................................... 257 Front Work Lights Open or Short Diagnostic Procedure......................................................... 258 002356.06 โ Front Work Lights High Current....................................................................... 259 Front Work Lights High Current Diagnostic Procedure.......................................................... 259 002359.03 โ Machine Work Lights Short to Power................................................................... 260 Machine Work Lights Short to Power Diagnostic Procedure...................................................... 261 002359.05 โ Machine Work Lights Open or Short.................................................................... 261 Machine Work Lights Open or Short Diagnostic Procedure....................................................... 261 002359.06 โ Machine Work Lights High Current..................................................................... 263 Machine Work Lights High Current Diagnostic Procedure........................................................ 263 002362.03 โ Rear Work Lights Short to Power...................................................................... 264 Rear Work Lights Short to Power Diagnostic Procedure......................................................... 264 002362.05 โ Rear Work Lights Open or Short....................................................................... 265 Rear Work Lights Open or Short Diagnostic Procedure.......................................................... 265 002362.06 โ Rear Work Lights High Current........................................................................ 267 Rear Work Lights High Current Diagnostic Procedure........................................................... 267 002367.04 โ Left Turn Switch Short to Ground..................................................................... 268 Left Turn Switch Short to Ground Diagnostic Procedure........................................................ 268 002368.03 โ Left Turn Lights Short to Power...................................................................... 269 Left Turn Lights Short to Power Diagnostic Procedure......................................................... 269 002368.05 โ Left Turn Lights Open or Short....................................................................... 270 Left Turn Lights Open or Short Diagnostic Procedure.......................................................... 271 002368.06 โ Left Turn Lights High Current........................................................................ 272 Left Turn Lights High Current Diagnostic Procedure........................................................... 272 002369.04 โ Right Turn Switch Short to Ground.................................................................... 274 Right Turn Switch Short to Ground Diagnostic Procedure....................................................... 274 002370.03 โ Right Turn Lights Short to Power..................................................................... 275 Right Turn Lights Short to Power Diagnostic Procedure........................................................ 275 002370.05 โ Right Turn Lights Open or Short...................................................................... 276 Right Turn Lights Open or Short Diagnostic Procedure......................................................... 276 002370.06 โ Right Turn Lights High Current....................................................................... 278 Right Turn Lights High Current Diagnostic Procedure.......................................................... 278 002378.03 โ Marker/Tail Lights Short to Power.................................................................... 280 Marker/Tail Lights Short to Power Diagnostic Procedure....................................................... 280 002378.05 โ Marker/Tail Lights Open Circuit...................................................................... 282 002378.06 โ Marker/Tail Lights High Current...................................................................... 283 Marker/Tail Lights High Current Diagnostic Procedure......................................................... 283 002386.03 โ Beacon Light Short to Power.......................................................................... 284 Beacon Light Short to Power Diagnostic Procedure............................................................. 284 002386.06 โ Beacon Light High Current............................................................................ 285 Beacon Light High Current Diagnostic Procedure............................................................... 285 002650.03 โ Lockout Fan Solenoid Short to Power.................................................................. 286 Lockout Fan Solenoid Short to Power Diagnostic Procedure..................................................... 286 002650.05 โ Lockout Fan Solenoid Open or Short................................................................... 287 Lockout Fan Solenoid Open or Short Diagnostic Procedure...................................................... 287 002650.06 โ Lockout Fan Solenoid High Current.................................................................... 289 Lockout Fan Solenoid High Current Diagnostic Procedure....................................................... 289 002680.03 โ Return-to-Carry (RTC)/Float Detent Short to Power.................................................... 291 Return-to-Carry (RTC)/Float Detent Short to Power Diagnostic Procedure....................................... 291 002680.05 โ Return-to-Carry (RTC)/Float Detent Open or Short..................................................... 292 Return-to-Carry (RTC)/Float Detent Open or Short Diagnostic Procedure........................................ 292 002680.06 โ Return-to-Carry (RTC)/Float Detent High Current...................................................... 293 Return-to-Carry (RTC)/Float Detent High Current Diagnostic Procedure......................................... 293 002717.03 โ Return-to-Dig (RTD) Detent Short to Power............................................................ 295 Return-to-Dig (RTD) Detent Short to Power Diagnostic Procedure............................................... 295 002717.05 โ Return-to-Dig (RTD) Detent Open or Short............................................................. 295 Return-to-Dig (RTD) Detent Open or Short Diagnostic Procedure................................................ 296 002717.06 โ Return-to-Dig (RTD) Detent High Current.............................................................. 297 Return-to-Dig (RTD) Detent High Current Diagnostic Procedure................................................. 297 002754.03 โ Boom Height Kickout (BHKO) Detent Short to Power..................................................... 298 Boom Height Kickout (BHKO) Detent Short to Power Diagnostic Procedure........................................ 298 002754.05 โ Boom Height Kickout (BHKO) Detent Open or Short...................................................... 299 Boom Height Kickout (BHKO) Detent Open or Short Diagnostic Procedure......................................... 299 002754.06 โ Boom Height Kickout (BHKO) Detent High Current....................................................... 301 Boom Height Kickout (BHKO) Detent High Current Diagnostic Procedure.......................................... 301 002875.04 โ Hazard Wakeup Short to Ground........................................................................ 302 Hazard Wakeup Short to Ground Diagnostic Procedure........................................................... 302 003509.04 โ Vehicle Control Unit (VCU) Sensor 1 Voltage Low...................................................... 303 Vehicle Control Unit (VCU) Sensor 1 Voltage Low Diagnostic Procedure......................................... 303 003510.04 โ Vehicle Control Unit (VCU) Sensor 2 Voltage Low...................................................... 305 Vehicle Control Unit (VCU) Sensor 2 Voltage Low Diagnostic Procedure......................................... 305 003511.04 โ Vehicle Control Unit (VCU) Sensor 3 Voltage Low...................................................... 306 Vehicle Control Unit (VCU) Sensor 3 Voltage Low Diagnostic Procedure......................................... 306 003598.02 โ 7 V Supply Voltage Low............................................................................... 307 7 V Supply Voltage Low Diagnostic Procedure.................................................................. 308 004086.03 โ HPM Pressure Sensor Short to Power................................................................... 308 Hydraulic Power Management (HPM) Pressure Sensor Short to Power Diagnostic Procedure......................... 308 004086.04 โ HPM Pressure Sensor Open or Short.................................................................... 309 Hydraulic Power Management (HPM) Pressure Sensor (B65) Open or Short Diagnostic Procedure.................... 309 520194.02 โ Invalid Vehicle Identification Number (VIN).......................................................... 311 521948.02 โ Engine Tier Level Invalid............................................................................ 311 Engine Tier Level Invalid Diagnostic Procedure............................................................... 311 521985.04 โ Central Processing Unit (CPU) Switched Power Voltage Low............................................. 311 Central Processing Unit (CPU) Switched Power Voltage Low Diagnostic Procedure................................ 312 522280.01 โ Brake Pressure Low................................................................................... 313 Brake Pressure Low Diagnostic Procedure...................................................................... 313 522341.03 โ Heated Mirror Short to Power......................................................................... 314 Heated Mirror Short to Power Diagnostic Procedure............................................................ 314 522341.05 โ Heated Mirror Open Circuit........................................................................... 315 Heated Mirror Open Circuit Diagnostic Procedure.............................................................. 315 522341.06 โ Heated Mirror High Current........................................................................... 317 Heated Mirror High Current Diagnostic Procedure.............................................................. 317 522426.04 โ Rear Wiper Park Short to Ground...................................................................... 318 Rear Wiper Park Short to Ground Diagnostic Procedure......................................................... 318 522427.04 โ Front Wiper Park Short to Ground..................................................................... 319 Front Wiper Park Short to Ground Diagnostic Procedure........................................................ 319 522431.02 โ Memory Test Failure.................................................................................. 320 Memory Test Failure Diagnostic Procedure..................................................................... 320 522432.03 โ Rear Wiper High Speed Short to Power................................................................. 321 Rear Wiper High Speed Short to Power Diagnostic Procedure.................................................... 321 522432.05 โ Rear Wiper High Speed Open Circuit................................................................... 322 Rear Wiper High Speed Open Circuit........................................................................... 322 522432.06 โ Rear Wiper High Speed High Current................................................................... 324 Rear Wiper High Speed High Current Diagnostic Procedure...................................................... 324 522433.03 โ Rear Wiper Low Speed Short to Power.................................................................. 325 Rear Wiper Low Speed Short to Power Diagnostic Procedure..................................................... 325 522433.05 โ Rear Wiper Low Speed Open Circuit.................................................................... 326 Rear Wiper Low Speed Open Circuit Diagnostic Procedure....................................................... 326 522433.06 โ Rear Wiper Low Speed High Current.................................................................... 328 Rear Wiper Low Speed High Current Diagnostic Procedure....................................................... 328 522434.03 โ Front Wiper Low Speed Short to Power................................................................. 329 Front Wiper Low Speed Short to Power Diagnostic Procedure.................................................... 329 522434.05 โ Front Wiper Low Speed Open Circuit................................................................... 330 Front Wiper Low Speed Open Circuit Diagnostic Procedure...................................................... 330 522434.06 โ Front Wiper Low Speed High Current................................................................... 331 Front Wiper Low Speed High Current Diagnostic Procedure...................................................... 332 522435.03 โ Front Wiper High Speed Short to Power................................................................ 333 Front Wiper High Speed Short to Power Diagnostic Procedure................................................... 333 522435.05 โ Front Wiper High Speed Open Circuit.................................................................. 333 Front Wiper High Speed Open Circuit Diagnostic Procedure..................................................... 333 522435.06 โ Front Wiper High Speed High Current.................................................................. 335 Front Wiper High Speed High Current Diagnostic Procedure..................................................... 335 522436.03 โ Bucket Position Short to Power....................................................................... 336 Bucket Position Short to Power Diagnostic Procedure.......................................................... 336 522436.04 โ Bucket Position Open or Short........................................................................ 337 Bucket Position Open or Short Diagnostic Procedure........................................................... 337 522437.04 โ Return-to-Dig (RTD) Switch Short to Ground........................................................... 339 Return-to-Dig (RTD) Switch Short to Ground Diagnostic Procedure.............................................. 339 522438.03 โ Pin Disconnect Solenoid Short to Power............................................................... 340 Pin Disconnect Solenoid Short to Power Diagnostic Procedure.................................................. 340 522438.05 โ Pin Disconnect Solenoid Open or Short................................................................ 341 Pin Disconnect Solenoid Open or Short Diagnostic Procedure................................................... 341 522438.06 โ Pin Disconnect Solenoid High Current................................................................. 343 Pin Disconnect Solenoid High Current Diagnostic Procedure.................................................... 343 522543.03 โ Boom Cylinder Rod Pressure Sensor Open or Short...................................................... 344 Boom Cylinder Rod Pressure Sensor Open or Short Diagnostic Procedure......................................... 344 522543.04 โ Boom Cylinder Rod Pressure Sensor Short to Ground.................................................... 346 Boom Cylinder Rod Pressure Sensor Short to Ground Diagnostic Procedure....................................... 346 522544.03 โ Boom Cylinder Head Pressure Sensor Open or Short..................................................... 347 Boom Cylinder Head Pressure Sensor Open or Short Diagnostic Procedure........................................ 347 522544.04 โ Boom Cylinder Head Pressure Sensor Short to Ground................................................... 349 Boom Cylinder Head Pressure Sensor Short to Ground Diagnostic Procedure...................................... 349 522620.03 โ Vehicle Horn Short to Power.......................................................................... 350 Vehicle Horn Short to Power Diagnostic Procedure............................................................. 350 522620.05 โ Vehicle Horn Open Circuit............................................................................ 351 Vehicle Horn Open Circuit Diagnostic Procedure............................................................... 351 522620.06 โ Vehicle Horn High Current............................................................................ 352 Vehicle Horn High Current Diagnostic Procedure............................................................... 352 522796.03 โ Rear Washer Pump Short to Power...................................................................... 353 Rear Washer Pump Short to Power Diagnostic Procedure......................................................... 353 522796.05 โ Rear Washer Pump Open or Short....................................................................... 354 Rear Washer Pump Open or Short Diagnostic Procedure.......................................................... 354 522796.06 โ Rear Washer Pump High Current........................................................................ 356 Rear Washer Pump High Current Diagnostic Procedure........................................................... 356 522797.03 โ Front Washer Pump Short to Power..................................................................... 357 Front Washer Pump Short to Power Diagnostic Procedure........................................................ 357 522797.05 โ Front Washer Pump Open or Short...................................................................... 358 Front Washer Pump Open or Short Diagnostic Procedure......................................................... 358 522797.06 โ Front Washer Pump High Current....................................................................... 360 Front Washer Pump High Current Diagnostic Procedure.......................................................... 360 523137.01 โ Steering System Pressure Low......................................................................... 361 Steering System Pressure Low Diagnostic Procedure............................................................ 361 523137.03 โ Steering Pressure Sensor Short to Power.............................................................. 362 Steering Pressure Sensor Short to Power Diagnostic Procedure................................................. 362 523137.04 โ Steering Pressure Sensor Short to Ground............................................................. 363 Steering Pressure Sensor Open or Short Diagnostic Procedure.................................................. 363 523137.05 โ Steering Pressure Sensor Open Circuit................................................................ 365 Steering Pressure Sensor Open or Short Diagnostic Procedure.................................................. 365 523137.12 โ Steering Pressure Sensor Invalid..................................................................... 367 Steering Pressure Sensor Invalid Diagnostic Procedure........................................................ 367 523219.04 โ Switched Power Voltage Low........................................................................... 367 Switched Power Voltage Low Diagnostic Procedure.............................................................. 367 523440.04 โ Unswitched Power Voltage Low......................................................................... 369 Unswitched Power Voltage Low Diagnostic Procedure............................................................ 369 523577.03 โ Secondary Steering Pump Shorted to Power............................................................. 370 Secondary Steering Pump Shorted to Power Diagnostic Procedure................................................ 370 523577.05 โ Secondary Steering Pump Open or Short Circuit........................................................ 371 Secondary Steering Pump Open or Short Circuit Diagnostic Procedure........................................... 371 523577.06 โ Secondary Steering Pump High Current................................................................. 373 Secondary Steering Pump High Current Diagnostic Procedure.................................................... 373 523689.04 โ Differential Lock Switch Short to Ground............................................................. 374 Differential Lock Switch Short to Ground Diagnostic Procedure................................................ 374 523786.03 โ Boom Position Sensor Short to Power.................................................................. 376 Boom Position Sensor Short to Power Diagnostic Procedure..................................................... 376 523786.06 โ Boom Position Sensor Short to Ground................................................................. 377 Boom Position Sensor Short to Ground Diagnostic Procedure.................................................... 377 523837.01 โ Brake Pressure LowโRear.............................................................................. 378 Brake Pressure LowโRear Diagnostic Procedure................................................................. 378 523837.03 โ Rear Brake Pressure Sensor Short to Power............................................................ 379 Rear Brake Pressure Sensor Short to Power Diagnostic Procedure............................................... 379 523837.04 โ Rear Brake Pressure Open or Short.................................................................... 380 Rear Brake Pressure Open or Short Diagnostic Procedure....................................................... 380 523840.01 โ Brake Pressure LowโFront............................................................................. 382 Brake Pressure LowโFront Diagnostic Procedure................................................................ 382 523840.03 โ Front Brake Pressure Sensor Short to Power........................................................... 383 Front Brake Pressure Sensor Short to Power Diagnostic Procedure.............................................. 383 523840.04 โ Front Brake Pressure Sensor Open or Short............................................................ 384 Front Brake Pressure Sensor Open or Short Diagnostic Procedure............................................... 384 523865.04 โ Add Truck Switch Short to Ground..................................................................... 386 Add Truck Switch Short to Ground Diagnostic Procedure........................................................ 386 523867.04 โ Counter Switch Short to Ground....................................................................... 387 Counter Switch Short to Ground Diagnostic Procedure.......................................................... 387 523868.04 โ Add Bucket Switch Short to Ground.................................................................... 388 Add Bucket Switch Short to Ground Diagnostic Procedure....................................................... 388 523911.03 โ Hydraulic Power Management Solenoid High Side Short to Power......................................... 389 Hydraulic Power Management (HPM) Solenoid High Side Short to Power Diagnostic Procedure...................... 389 523911.05 โ Hydraulic Power Management Solenoid High Side Open Circuit........................................... 390 HPM Solenoid High Side Open Circuit Diagnostic Procedure..................................................... 391 523911.06 โ Hydraulic Power Management Solenoid High Side High Current........................................... 392 Hydraulic Power Management Solenoid High Side High Current Diagnostic Procedure.............................. 392 523911.13 โ Hydraulic Power Management System Out of Calibration................................................. 393 523911.16 โ Hydraulic Power Management Solenoid Low Side High Current............................................ 393 Hydraulic Power Management Solenoid Low Side High Current Diagnostic Procedure............................... 393 523911.17 โ Hydraulic Power Management Solenoid Low Side Open Circuit............................................ 394 Hydraulic Power Management Solenoid Low Side Open Circuit Diagnostic Procedure............................... 394 523911.18 โ Hydraulic Power Management Solenoid Low Side Short to Power.......................................... 396 Hydraulic Power Management Solenoid Low Side Short to Power Diagnostic Procedure............................. 396 523948.03 โ Ride Control Solenoid Short to Power................................................................. 397 Ride Control Solenoid Short to Power Diagnostic Procedure.................................................... 398 523948.05 โ Ride Control Solenoid Open Circuit................................................................... 398 Ride Control Solenoid Open Circuit Diagnostic Procedure...................................................... 398 523948.06 โ Ride Control Solenoid High Current................................................................... 400 Ride Control Solenoid High Current Diagnostic Procedure...................................................... 400 524044.01 โ Axle Oil Filter Restricted........................................................................... 401 524044.03 โ Axle Oil Filter Short to Power....................................................................... 401 524250.31 โ Inspect Park Brake................................................................................... 402 Inspect Park Brake Diagnostic Procedure...................................................................... 402 524265.19 โ Checksum Error....................................................................................... 402 Check Sum Error Diagnostic Procedure......................................................................... 402 Sealed Switch Module (SSM) Diagnostic Trouble Codes.................................................................. 403 Sealed Switch Module (SSM) Diagnostic Trouble Codes.............................................................. 403 000629.12 โ Sealed Switch Module (SSM) Watchdog Time Out......................................................... 403 SSM Watchdog Time Out Diagnostic Procedure................................................................... 403 002033.09 โ Controller Area Network (CAN) Communication Lost for Vehicle Control Unit (VCU)...................... 404 CAN Communication Lost for VCU Diagnostic Procedure.......................................................... 404 002634.04 โ Sealed Switch Module (SSM) Ignition Relay Signal Short to Ground..................................... 405 Sealed Switch Module (SSM) Ignition Relay Signal Short to Ground Diagnostic Procedure........................ 405 002634.05 โ Sealed Switch Module (SSM) Ignition Relay Signal Open Circuit........................................ 406 Sealed Switch Module (SSM) Ignition Relay Signal Open Circuit Diagnostic Procedure........................... 406 520752.04 โ Button 17 Keypad Stuck............................................................................... 407 Button 17 Keypad Stuck Diagnostic Procedure.................................................................. 407 520752.09 โ Button 17 Light-Emitting Diode (LED) Message......................................................... 408 Button 17 Light-Emitting Diode (LED) Message Diagnostic Procedure............................................ 408 520753.04 โ Front Washer Keypad Stuck............................................................................ 410 Front Washer Keypad Stuck Diagnostic Procedure............................................................... 410 520754.04 โ Front Wiper Keypad Stuck............................................................................. 410 Front Wiper Keypad Stuck Diagnostic Procedure................................................................ 410 520754.09 โ Lost Front Wiper Light-Emitting Diode (LED) Message.................................................. 411 Lost Front Wiper Light-Emitting Diode (LED) Message Diagnostic Procedure..................................... 411 520755.04 โ Drive Lights Keypad Stuck............................................................................ 413 Drive Lights Keypad Stuck Diagnostic Procedure............................................................... 413 520755.09 โ Lost Drive Lights Light-Emitting Diode (LED) Message................................................. 413 Lost Drive Lights Light-Emitting Diode (LED) Message Diagnostic Procedure.................................... 413 523335.04 โ Work Lights Keypad Stuck............................................................................. 415 Work Lights Keypad Stuck Diagnostic Procedure................................................................ 415 523335.09 โ Lost Work Lights Light-Emitting Diode (LED) Message.................................................. 416 Lost Work Lights Light-Emitting Diode (LED) Message Diagnostic Procedure..................................... 416 523336.04 โ Rear Wiper Keypad Stuck.............................................................................. 417 Rear Wiper Keypad Stuck Diagnostic Procedure................................................................. 417 523336.09 โ Lost Rear Wiper Light-Emitting Diode (LED) Message................................................... 418 Lost Rear Wiper Light-Emitting Diode (LED) Message Diagnostic Procedure...................................... 418 523338.04 โ Rear Washer Keypad Stuck............................................................................. 419 Rear Washer Keypad Stuck Diagnostic Procedure................................................................ 419 523339.04 โ Axle Disconnect Keypad Stuck......................................................................... 420 Axle Disconnect Keypad Stuck Diagnostic Procedure............................................................ 420 523339.09 โ Lost Axle Disconnect Light-Emitting Diode (LED) Message.............................................. 421 Lost Axle Disconnect Light-Emitting Diode (LED) Message Diagnostic Procedure................................. 421 523340.04 โ Button 21 Keypad Stuck............................................................................... 422 Button 21 Keypad Stuck Diagnostic Procedure.................................................................. 422 523340.09 โ Button 21 Light-Emitting Diode (LED) Message......................................................... 423 Button 21 Light-Emitting Diode (LED) Message Diagnostic Procedure............................................ 423 523849.04 โ Air Conditioner Keypad Stuck......................................................................... 425 Air Conditioner Keypad Stuck Diagnostic Procedure............................................................ 425 523349.09 โ Lost Air Conditioner Light-Emitting Diode (LED) Message.............................................. 425 Lost Air Conditioner Light-Emitting Diode (LED) Message Diagnostic Procedure................................. 425 523850.04 โ Pin Disconnect Keypad Stuck.......................................................................... 427 Pin Disconnect Keypad Stuck Diagnostic Procedure............................................................. 427 523850.09 โ Lost Pin Disconnect Light-Emitting Diode (LED) Message............................................... 428 Lost Pin Disconnect Light-Emitting Diode (LED) Message Diagnostic Procedure.................................. 428 523852.04 โ Spin Control Keypad Stuck............................................................................ 429 Spin Control Keypad Stuck Diagnostic Procedure............................................................... 429 523852.09 โ Lost Spin Control Light-Emitting Diode (LED) Message................................................. 430 Lost Spin Control Light-Emitting Diode (LED) Message Diagnostic Procedure.................................... 430 523854.04 โ Differential Lock Keypad Stuck....................................................................... 431 Differential Lock Keypad Stuck Diagnostic Procedure.......................................................... 431 523854.09 โ Lost Differential Lock Light-Emitting Diode (LED) Message............................................ 432 Lost Differential Lock Light-Emitting Diode (LED) Message Diagnostic Procedure............................... 432 523855.04 โ Return To Carry Keypad Stuck......................................................................... 434 Return-to-Carry Keypad Stuck Diagnostic Procedure............................................................ 434 523855.09 โ Lost Return To Carry Light-Emitting Diode (LED) Message.............................................. 434 Lost Return-to-Carry Light-Emitting Diode (LED) Message Diagnostic Procedure................................. 434 523856.04 โ Boom Height Kick Out Keypad Stuck.................................................................... 436 Boom Height Kick Out Keypad Stuck Diagnostic Procedure....................................................... 436 523856.09 โ Lost Boom Height Kick Out Light-Emitting Diode (LED) Message......................................... 437 Lost Boom Height Kick Out Light-Emitting Diode (LED) Message Diagnostic Procedure............................ 437 523857.04 โ Clutch Cut-Off Keypad Stuck.......................................................................... 438 Clutch Cut-Off Keypad Stuck Diagnostic Procedure............................................................. 438 523857.09 โ Lost Clutch Cut-Off Light-Emitting Diode (LED) Message............................................... 439 Lost Clutch Cut-Off Light-Emitting Diode (LED) Message Diagnostic Procedure.................................. 439 523858.04 โ Ride Control Keypad Stuck............................................................................ 440 Ride Control Keypad Stuck Diagnostic Procedure............................................................... 440 523858.09 โ Lost Ride Control Light-Emitting Diode (LED) Message................................................. 441 Lost Ride Control Light-Emitting Diode (LED) Message Diagnostic Procedure.................................... 441 523860.04 โ Auto Transmission Keypad Stuck....................................................................... 443 Auto Transmission Keypad Stuck Diagnostic Procedure.......................................................... 443 523860.09 โ Lost Auto Transmission Light-Emitting Diode (LED) Message............................................ 443 Lost Auto Transmission Light-Emitting Diode (LED) Message Diagnostic Procedure............................... 444 523861.04 โ Return To Dig Keypad Stuck........................................................................... 445 Return-to-Dig Keypad Stuck Diagnostic Procedure.............................................................. 445 523861.09 โ Lost Return To Dig Light-Emitting Diode (LED) Message................................................ 446 Lost Return-to-Dig Light-Emitting Diode (LED) Message Diagnostic Procedure................................... 446 523862.04 โ Park Brake Keypad Stuck.............................................................................. 447 Park Brake Keypad Stuck Diagnostic Procedure................................................................. 447 523862.09 โ Lost Park Brake Light-Emitting Diode (LED) Message................................................... 448 Lost Park Brake Light-Emitting Diode (LED) Message Diagnostic Procedure...................................... 448 523863.04 โ Pilot Enable Keypad Stuck............................................................................ 449 Pilot Enable Keypad Stuck Diagnostic Procedure............................................................... 449 523863.09 โ Lost Pilot Enable Light-Emitting Diode (LED) Message................................................. 450 Lost Pilot Enable Light-Emitting Diode (LED) Message Diagnostic Procedure.................................... 450 523864.04 โ Hazards Keypad Stuck................................................................................. 452 Hazards Keypad Stuck Diagnostic Procedure.................................................................... 452 523864.09 โ Lost Hazard Light-Emitting Diode (LED) Message....................................................... 452 Lost Hazard Light-Emitting Diode (LED) Message Diagnostic Procedure.......................................... 452 523865.04 โ Beacon Light Keypad Stuck............................................................................ 454 Beacon Light Keypad Stuck Diagnostic Procedure............................................................... 454 523865.09 โ Lost Beacon Light-Emitting Diode (LED) Message....................................................... 455 Lost Beacon Light-Emitting Diode (LED) Message Diagnostic Procedure.......................................... 455 523867.04 โ Ignition Off Keypad Stuck............................................................................ 456 Ignition Off Keypad Stuck Diagnostic Procedure............................................................... 456 523867.09 โ Lost Ignition Off Light-Emitting Diode (LED) Message................................................. 457 523868.04 โ Ignition On Keypad Stuck............................................................................. 457 Ignition On Keypad Stuck Diagnostic Procedure................................................................ 457 523868.09 โ Lost Ignition On Light-Emitting Diode (LED) Message.................................................. 458 Lost Ignition On Light-Emitting Diode (LED) Message Diagnostic Procedure..................................... 458 Advanced Display Unit (ADU) Diagnostic Trouble Codes................................................................. 461 Advanced Display Unit (ADU) Diagnostic Trouble Codes............................................................. 461 000158.03 โ Switched Power Voltage High.......................................................................... 461 Switched Power Voltage High Diagnostic Procedure............................................................. 461 000158.04 โ Switched Power Voltage Low........................................................................... 462 Switched Power Voltage Low Diagnostic Procedure.............................................................. 462 000168.03 โ High Battery Voltage................................................................................. 463 High Battery Voltage Diagnostic Procedure.................................................................... 463 000168.04 โ Low Battery Voltage.................................................................................. 464 Low Battery Voltage Diagnostic Procedure..................................................................... 464 000442.00 โ Display Temp High.................................................................................... 465 Display Temp High Diagnostic Procedure....................................................................... 465 000442.01 โ Display Temp Low..................................................................................... 466 Display Temp Low Diagnostic Procedure........................................................................ 466 001491.11 โ LCD Backlight Failure................................................................................ 466 LCD Backlight Failure Diagnostic Procedure................................................................... 466 003597.02 โ 5 Volt Power Supply Invalid.......................................................................... 467 5 Volt Power Supply Invalid Diagnostic Procedure............................................................. 467 003598.02 โ 1.5 Volt Power Supply Invalid........................................................................ 467 1.5 Volt Power Supply Invalid Diagnostic Procedure........................................................... 467 003599.02 โ 3.3 Volt Power Supply Invalid........................................................................ 468 3.3 Volt Power Supply Invalid Diagnostic Procedure........................................................... 468 523436.14 โ ADU Watchdog Time Out................................................................................ 468 ADU Watchdog Time Out Diagnostic Procedure................................................................... 468 523438.31 โ Memory Error......................................................................................... 469 Memory Error Diagnostic Procedure............................................................................ 469 523651.02 โ Memory Stack Overflow................................................................................ 469 Memory Stack Overflow Diagnostic Procedure................................................................... 469 523773.03 โ CAN HIGH Voltage High................................................................................ 470 CAN HIGH Voltage High Diagnostic Procedure................................................................... 470 523773.04 โ CAN HIGH Voltage Low................................................................................. 470 CAN HIGH Voltage Low Diagnostic Procedure.................................................................... 471 523774.03 โ CAN LOW Voltage High................................................................................. 471 CAN LOW Voltage High Diagnostic Procedure.................................................................... 471 523774.04 โ CAN LOW Voltage Low.................................................................................. 472 CAN LOW Voltage Low Diagnostic Procedure..................................................................... 472 524076.10 โ Information Button Stuck............................................................................. 472 Information Button Stuck Diagnostic Procedure................................................................ 472 524077.10 โ Back Key Button Stuck................................................................................ 473 Back Key Button Stuck Diagnostic Procedure................................................................... 473 524078.10 โ Menu Select Button Stuck............................................................................. 473 Menu Select Button Stuck Diagnostic Procedure................................................................ 473 524080.10 โ Down Arrow Button Stuck.............................................................................. 474 Down Arrow Button Stuck Diagnostic Procedure................................................................. 474 524082.10 โ Up Arrow Button Stuck................................................................................ 475 Up Arrow Button Stuck Diagnostic Procedure................................................................... 475 Radar Object Detection (ROD) Diagnostic Trouble Codes................................................................ 477 Radar Object Detection (ROD) Diagnostic Trouble Codes............................................................ 477 000896.12 โ ROD Unit Failure..................................................................................... 477 ROD Unit Failure Diagnostic Procedure........................................................................ 477 Ground Speed Radar (RDR) Diagnostic Trouble Codes.................................................................... 479 Ground Speed Radar (RDR) Diagnostic Trouble Codes................................................................ 479 000628.12 โ Controller Not Programmed............................................................................ 479 Controller Not Programmed Diagnostic Procedure............................................................... 479 523456.18 โ Degraded Mode........................................................................................ 479 Degraded Mode Diagnostic Procedure........................................................................... 479 Operational Checkout Procedure........................................................................................... 481 Operational Checkout Procedure....................................................................................... 483 Operational Checkout............................................................................................. 483 Diagnostic Trouble Code Check................................................................................ 483 Operational ChecksโIgnition OFF, Engine OFF Checks........................................................... 483 Operational ChecksโIgnition ON, Engine OFF Checks............................................................ 484 Operational ChecksโIgnition ON, Engine ON Checks............................................................. 491 Engine................................................................................................................... 521 Theory of Operation.................................................................................................. 523 John Deere Engine................................................................................................ 523 Exhaust Aftertreatment........................................................................................... 523 System Diagrams...................................................................................................... 524 Engine Cooling System Component Location......................................................................... 524 Engine Fuel System Component Location............................................................................ 526 Engine Intake and Exhaust Component Location..................................................................... 529 Diagnostic Information............................................................................................... 537 John Deere Engine................................................................................................ 537 Engine Cranks/Will Not Start..................................................................................... 537 Engine Cranks/Will Not Start Diagnostic Procedure............................................................ 537 Engine Misfires/Runs Irregularly................................................................................. 538 Engine Misfires/Runs Irregularly Diagnostic Procedure........................................................ 538 Engine Does Not Develop Full Power............................................................................... 539 Engine Does Not Develop Full Power Diagnostic Procedure...................................................... 539 Engine Emits Excessive White Exhaust Smoke....................................................................... 540 Engine Emits Excessive White Exhaust Smoke Diagnostic Procedure.............................................. 540 Engine Emits Excessive Black or Gray Exhaust Smoke............................................................... 540 Engine Emits Excessive Black or Gray Exhaust Smoke Diagnostic Procedure...................................... 540 Engine Will Not Crank............................................................................................ 541 Engine Will Not Crank Diagnostic Procedure................................................................... 541 Engine Idles Poorly.............................................................................................. 542 Engine Idles Poorly Diagnostic Procedure..................................................................... 542 Engine Noise..................................................................................................... 543 Abnormal Engine Noise Diagnostic Procedure................................................................... 543 Low-Pressure Fuel System Check................................................................................... 543 Low-Pressure Fuel System Diagnostic Procedure................................................................ 543 Excessive Fuel Consumption....................................................................................... 543 Fuel in Oil...................................................................................................... 544 Fuel in Oil Diagnostic Procedure............................................................................. 544 Adjustments.......................................................................................................... 545 John Deere Engine................................................................................................ 545 Service Filter Cleaning.......................................................................................... 545 Tests................................................................................................................ 547 John Deere Engine................................................................................................ 547 Fluid Sampling ProcedureโIf Equipped............................................................................. 548 Engine Idle Speeds and Auto Shutdown Check....................................................................... 552 Engine Low Idle Speed Adjustment................................................................................. 553 Exhaust Emissions Test Point..................................................................................... 553 Electrical System........................................................................................................ 556 Theory of Operation.................................................................................................. 557 Start and Charge Circuits Theory of Operation.................................................................... 557 Controller Area Network (CAN) Circuit Theory of Operation........................................................ 563 Engine Control Unit (ECU) Circuit Theory of Operation............................................................ 571 Exhaust Aftertreatment Circuit Theory of Operation............................................................... 589 Vehicle Control Unit (VCU) Circuit Theory of Operation........................................................... 603 Transmission Control Unit (TCU) Circuit Theory of Operation...................................................... 639 Park Brake Circuit Theory of Operation........................................................................... 653 Advanced Display Unit (ADU) Circuit Theory of Operation.......................................................... 659 Radar Object Detection (ROD) Circuit Theory of Operation......................................................... 663 Auto-Differential Lock Circuit Theory of Operation............................................................... 667 Embedded Payload Scale (EPS) Circuit Theory of Operation......................................................... 671 JDLinkโข Circuit Theory of Operation.............................................................................. 677 System Diagrams...................................................................................................... 681 Electrical Diagram Information................................................................................... 681 Electrical Schematic Symbols..................................................................................... 687 Fuse and Relay Specifications.................................................................................... 690 System Functional Schematic, Wiring Diagram, and Component Location Master Legend................................ 692 System Functional Schematic...................................................................................... 698 Power and Ground Cables (W1) Component Location.................................................................. 701 Loader Frame Harness (W2) Component Location..................................................................... 702 Loader Frame Harness (W2) Wiring Diagram......................................................................... 705 Load Center Harness (W3) Component Location...................................................................... 713 Load Center Harness (W3) Wiring Diagram.......................................................................... 717 Front Console Harness (W4) Component Location.................................................................... 742 Front Console Harness (W4) Wiring Diagram........................................................................ 743 Engine Frame Harness (W5) Component Location..................................................................... 745 Engine Frame Harness (W5) Wiring Diagram......................................................................... 753 Engine Harness (W6) Component Location........................................................................... 773 Engine Harness (W6) Wiring Diagram............................................................................... 781 Transmission Harness (W10) Component Location.................................................................... 798 Transmission Harness (W10) Wiring Diagram........................................................................ 799 Rear Frame Harness (W13) Component Location...................................................................... 802 Rear Frame Harness (W13) Wiring Diagram.......................................................................... 805 Secondary Steering Harness (W17) Component Location.............................................................. 808 Secondary Steering Harness (W17) Wiring Diagram.................................................................. 809 Cab Roof Harness (W19) Component Location........................................................................ 810 Cab Roof Harness (W19) Wiring Diagram............................................................................ 811 Heater and Air Conditioner Harness (W20) Component Location...................................................... 814 Heater and Air Conditioner Harness (W20) Wiring Diagram.......................................................... 816 Radar Object Detection (ROD) Harness (W21) Component Location.................................................... 817 Radar Object Detection (ROD) Harness (W21) Wiring Diagram........................................................ 819 Radio Harness (W23) Component Location........................................................................... 823 Radio Harness (W23) Wiring Diagram............................................................................... 826 Ground Speed Radar (RDR) Harness (W31) Component Location........................................................ 826 Ground Speed Radar (RDR) Harness (W31) Wiring Diagram............................................................ 827 Auxiliary Radio Input Harness (W41) Component Locationโ.......................................................... 827 Auxiliary Radio Input Harness (W41) Wiring Diagram............................................................... 828 Satellite Radio Harness (W44) Component Location................................................................. 829 Satellite Radio Harness (W44) Wiring Diagram..................................................................... 829 Aftertreatment Harness (W45) Component Location.................................................................. 830 Aftertreatment Harness (W45) Wiring Diagram...................................................................... 831 Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location.......................................... 834 Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Wiring Diagram.............................................. 835 Diesel Exhaust Fluid (DEF) Dosing Unit Jumper Harness (W47) Component Location................................... 837 Diesel Exhaust Fluid (DEF) Dosing Unit Jumper Harness (W47) Wiring Diagram....................................... 839 Starter Excitation Jumper Harness (W52) Component Location....................................................... 841 Starter Excitation Jumper Harness (W52) Wiring Diagram........................................................... 841 Modular Telematics Gateway (MTG) and Satellite (SAT) Harness (W6002 and W6003) Component Location................ 842 Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram.................................................. 844 Satellite (SAT) Harness (W6003) Wiring Diagram................................................................... 846 Diagnostic Information............................................................................................... 849 Service ADVISORโข Diagnostic Application.......................................................................... 849 Service ADVISORโข Connection Procedure............................................................................ 849 Reading Diagnostic Trouble Codes with Service ADVISORโข Diagnostic Application.................................... 851 Intermittent Diagnostic Trouble Code (DTC) Diagnostics........................................................... 854 Diagnostic Trouble CodesโAfter Machine Repair.................................................................... 854 JDLinkโข Connection Procedure..................................................................................... 854 Embedded Payload Scale (EPS) Diagnostics......................................................................... 855 EPS Diagnostics.............................................................................................. 855 Monitor Operation.................................................................................................... 859 Advanced Display Unit (ADU)โService Mode......................................................................... 859 Advanced Display Unit (ADU)โClear Codes.......................................................................... 859 Advanced Display Unit (ADU)โAuto Idle............................................................................ 860 Advanced Display Unit (ADU)โAuto Shutdown........................................................................ 860 Advanced Display Unit (ADU)โEnable Options....................................................................... 861 Advanced Display Unit (ADU)โTire Size............................................................................ 861 Advanced Display Unit (ADU)โFan Speed............................................................................ 861 Advanced Display Unit (ADU)โMaximum High Gear.................................................................... 862 Advanced Display Unit (ADU)โTransmission Clutch Calibration...................................................... 862 Advanced Display Unit (ADU)โSlow Idle Adjust..................................................................... 863 Advanced Display Unit (ADU)โHide-Unhide Main Menu................................................................ 863 Advanced Display Unit (ADU)โService Cleaning..................................................................... 864 Advanced Display Unit (ADU)โAuto Cleaning Settings............................................................... 864 Diagnostic Test Box.................................................................................................. 865 Setup and Functional Test........................................................................................ 865 Two Wire Sensor Circuit CheckโOut of Range High.................................................................. 870 Two Wire Sensor Circuit CheckโOut of Range Low................................................................... 872 Three Wire Sensor Circuit CheckโOut of Range High................................................................ 873 Three Wire Sensor Circuit CheckโOut of Range Low................................................................. 875 Adjustments.......................................................................................................... 877 Boom Height Kickout (BHKO) Adjustment............................................................................ 877 Return-to-Carry (RTC) Adjustment................................................................................. 878 Return-to-Dig (RTD) AdjustmentโZ-Bar Linkage..................................................................... 879 Return-to-Dig (RTD) AdjustmentโPowerllel Linkage................................................................. 881 Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Calibration....................................... 882 Change Backup Alarm Volume....................................................................................... 882 Tests................................................................................................................ 883 Electrical Component Specifications.............................................................................. 883 CAN Circuit Test................................................................................................. 887 Controller Area Network (CAN) Diagnostics ................................................................... 887 Alternator Test.................................................................................................. 891 Hydraulic Pressure Sensor Test................................................................................... 892 Hydraulic Pressure Sensor Diagnostic Procedure............................................................... 892 Transmission Control Valve Solenoid Check........................................................................ 894 Clutch Cut-Off Sensor Check...................................................................................... 895 Connector Terminal Test.......................................................................................... 896 Connector Terminal Test Diagnostic Procedure................................................................. 896 Power Train.............................................................................................................. 901 Theory of Operation.................................................................................................. 903 TeamMateโข Axles.................................................................................................. 903 Power Train Operation............................................................................................ 903 Torque Converter Operation....................................................................................... 904 Torque Converter With Lockup Clutch Operation.................................................................... 906 Transmission Operation........................................................................................... 907 Transmission OperationโFirst Gear Forward........................................................................ 908 Transmission Clutch Pack Engagement and Solenoids Activated...................................................... 910 Transmission Filter Bypass Valve Operation....................................................................... 911 Transmission Control Valve Component Operation................................................................... 912 Transmission Clutch Modulation Operation......................................................................... 915 Thermal Bypass Valve Operation................................................................................... 916 Standard Differential Operation.................................................................................. 918 Differential Lock Operation...................................................................................... 919 Rear Axle Disconnect Operation................................................................................... 920 Axle Circulation Dual Pump Operation............................................................................. 921 Park Brake Operation............................................................................................. 922 System Diagrams...................................................................................................... 925 Transmission System SchematicโFirst Forward...................................................................... 925 Transmission System SchematicโFirst Forward Lockup Torque Converter.............................................. 929 Power Train Component Location................................................................................... 933 Power Train Cooling System Component Location.................................................................... 937 Transmission Component Location.................................................................................. 940 Diagnostic Information............................................................................................... 943 Transmission Clutch Slippage..................................................................................... 943 Transmission Clutch Slippage Diagnostic Procedure............................................................ 943 Machine Will Not Move in Either Direction........................................................................ 944 Machine Will Not Move in Either Direction Diagnostic Procedure............................................... 944 Machine Will Not Shift Correctly................................................................................. 948 Machine Will Not Shift Correctly Diagnostic Procedure........................................................ 948 Transmission System Pressure Is Low in Neutral................................................................... 951 Transmission System Pressure Is Low in Neutral Diagnostic Procedure.......................................... 951 Transmission Pressure Is Low (One or Two Gear Ranges)............................................................ 952 Transmission Pressure Is Low (One or Two Gear Ranges) Diagnostic Procedure................................... 952 Transmission Shifts Too Slow..................................................................................... 953 Transmission Shifts Too Slow Diagnostic Procedure............................................................ 953 Transmission Shifts Too Fast..................................................................................... 955 Transmission Shifts Too Fast Diagnostic Procedure............................................................ 955 Machine Creeps in Neutral........................................................................................ 956 Machine Creeps in Neutral Diagnostic Procedure............................................................... 957 Transmission Hydraulic System Overheats.......................................................................... 958 Transmission Hydraulic System Overheats Diagnostic Procedure................................................. 958 Transmission Excessive Noise..................................................................................... 960 Transmission Excessive Noise Diagnostic Procedure............................................................ 960 Rear Axle Disconnect Does Not Disengage (2WD State).............................................................. 961 Rear Axle Disconnect Does Not Disengage (2WD State) Diagnostic Procedure..................................... 962 Rear Axle Disconnect Does Not Engage (4WD State)................................................................. 963 Rear Axle Disconnect Does Not Engage (4WD State) Diagnostic Procedure........................................ 964 Oil Aerated...................................................................................................... 965 Oil Aerated Diagnostic Procedure............................................................................. 965 Oil Ejected from Filler Tube..................................................................................... 966 Oil Ejected from Filler Tube Diagnostic Procedure............................................................ 966 Machine Vibrates................................................................................................. 966 Machine Vibrates Diagnostic Procedure........................................................................ 966 Machine Power and Acceleration Low............................................................................... 967 Machine Power and Acceleration Low Diagnostic Procedure...................................................... 967 Torque Converter Stall RPM....................................................................................... 968 Torque Converter Stall RPM Diagnostic Procedure.............................................................. 968 Differential Lock Will Not Engage................................................................................ 970 Differential Lock Will Not Engage Diagnostic Procedure....................................................... 970 Differential Lock Slips and Chatters............................................................................. 970 Differential Lock Slips and Chatters Diagnostic Procedure.................................................... 971 Differential Lock Will Not Disengage............................................................................. 971 Differential Lock Will Not Disengage Diagnostic Procedure.................................................... 971 Differential Oil Level Rises..................................................................................... 972 Differential Oil Level Rises Diagnostic Procedure............................................................ 972 Differential Oil Level Low....................................................................................... 973 Differential Oil Level Low Diagnostic Procedure.............................................................. 973 Differential and Axle Noise Excessive............................................................................ 973 Differential and Axle Noise Excessive Diagnostic Procedure................................................... 973 Axle Wheel Hub Face Seal Leaking................................................................................. 975 Axle Wheel Hub Face Seal Leaking Diagnostic Procedure........................................................ 975 Axle Overheats................................................................................................... 975 Axle Overheats Diagnostic Procedure.......................................................................... 975 Service Brakes Poor or Do Not Apply.............................................................................. 976 Service Brakes Poor or Do Not Apply Diagnostic Procedure..................................................... 976 Service Brakes Aggressive........................................................................................ 977 Service Brakes Aggressive Diagnostic Procedure............................................................... 977 Service Brakes Dragging.......................................................................................... 978 Service Brakes Dragging Diagnostic Procedure................................................................. 978 Service Brakes Lock Up........................................................................................... 979 Service Brakes Lock up Diagnostic Procedure.................................................................. 979 Service Brakes Chatter........................................................................................... 980 Service Brakes Chatter Diagnostic Procedure.................................................................. 980 Service Brake Warning Light On................................................................................... 981 Service Brake Warning Light On Diagnostic Procedure.......................................................... 981 Driveline Excessive Vibration or Noise........................................................................... 983 Driveline Excessive Vibration or Noise Diagnostic Procedure.................................................. 983 Park Brake Will Not Hold......................................................................................... 984 Park Brake Will Not Hold Diagnostic Procedure................................................................ 984 Park Brake Will Not Release...................................................................................... 986 Park Brake Will Not Release Diagnostic Procedure............................................................. 986 Park Brake Overheats............................................................................................. 987 Park Brake Overheats Diagnostic Procedure.................................................................... 987 Park Brake Light Flashes When Shifting From Forward to Reverse................................................... 988 Park Brake Light Flashes When Shifting From Forward to Reverse Diagnostic Procedure.......................... 988 Park Brake Light Flashes During Each Shift....................................................................... 989 Park Brake Light Flashes During Each Shift Diagnostic Procedure.............................................. 989 Park Brake Light Does Not Come On................................................................................ 990 Park Brake Light Does Not Come On Diagnostic Procedure....................................................... 990 Park Brake Will Not Apply........................................................................................ 991 Park Brake Will Not Apply Diagnostic Procedure............................................................... 991 Adjustments.......................................................................................................... 993 Service Brake Bleeding Procedure................................................................................. 993 Transmission Control Unit (TCU)โElectronic Clutch Calibration.................................................... 994 Tests................................................................................................................ 995 Transmission Oil Sampling Procedure.............................................................................. 995 Transmission Oil Warm-Up Procedure............................................................................... 995 Park Brake Pressure Test......................................................................................... 996 Park Brake Drag Test............................................................................................. 997 Transmission Pump Flow Test...................................................................................... 999 Transmission System Pressure Test................................................................................1000 Transmission Clutch Pressure Test................................................................................1002 Transmission Element Leakage Test................................................................................1004 Transmission Lube Pressure Test..................................................................................1006 Torque ConverterโIn Pressure Test................................................................................1008 Torque ConverterโOut Pressure Testฬถ..............................................................................1009 Torque Converter Relief Pressure Test............................................................................1011 Torque ConverterโOut Flow Test...................................................................................1013 Torque Converter Stall Speed Test................................................................................1015 Lockup Torque Converter (LUTC) Pressure Test.....................................................................1016 Transmission Oil Cooler Thermal Bypass Valve Temperature Test....................................................1018 Transmission Oil Cooler Thermal Bypass Valve Pressure Test.......................................................1020 Transmission Oil Cooler Restriction Test.........................................................................1021 Axle Circulation Pump Flow Test..................................................................................1023 Axle Breather Test...............................................................................................1024 Differential Lock Pressure Test..................................................................................1025 Hydraulic System.........................................................................................................1029 Theory of Operation..................................................................................................1031 Loader Hydraulic System Operation................................................................................1031 Main Hydraulic Pump Operation....................................................................................1032 Hydraulic Pump Manifold Operation................................................................................1034 Hydraulic Fan Operation..........................................................................................1037 Hydraulic Reversing Fan Operation................................................................................1040 Orbital Steering System Component Operation......................................................................1043 Orbital Steering Valve Operation.................................................................................1044 Secondary Steering System Operation..............................................................................1045 Secondary Steering Valve Operation...............................................................................1045 Pilot Pressure Reducing Valve Operation..........................................................................1046 Service Brake Hydraulic System Operation.........................................................................1047 Service Brake Accumulator Operation..............................................................................1048 Service Brake Valve Operation....................................................................................1050 Pin Disconnect Operation.........................................................................................1052 Pilot Control Lever Operation....................................................................................1054 Control Valve Pilot Orifice Check Valve Operation................................................................1055 Loader Control Valve Operation...................................................................................1056 Boom Section OperationโBoom Down and Steering....................................................................1057 Bucket Section OperationโBoom Raise and Bucket Dump..............................................................1059 Bucket Section OperationโBoom Raise and Bucket Dump (High-Lift Option)...........................................1061 Auxiliary SectionโOperating and Boom Raise.......................................................................1063 Auxiliary SectionโSpool Stroke Adjuster Operation................................................................1065 Loader Control ValveโOutlet Section Operation....................................................................1066 Load Sense Circuit OperationโNeutral.............................................................................1068 Load Sense Circuit OperationโSteering............................................................................1069 Load Sense Circuit OperationโSteering and Boom Down..............................................................1070 Load Sense Circuit OperationโBoom Raise and Bucket Dump..........................................................1072 Main Relief Valve Operation......................................................................................1073 Load Sense Relief Valve Operation................................................................................1075 Circuit Relief With Anticavitation Valve Operation...............................................................1076 Anticavitation Valve Operation...................................................................................1081 Hydraulic Return Filter Operation................................................................................1082 Ride Control Operation...........................................................................................1084 System Diagrams......................................................................................................1088 Hydraulic System Schematic.......................................................................................1088 Steering and Hydraulic Cooling Fan Circuit Component Location....................................................1091 Loader and Hydraulic Cooling Circuit Component Location..........................................................1099 Ride Control, Pin Disconnect, and Hydraulic Filter Circuit Component Location....................................1103 Service Brake, Park Brake, Differential Lock, and Axle Cooling Circuit Component Location........................1107 Hydraulic Pump Manifold..........................................................................................1110 Diagnostic Information...............................................................................................1113 No Hydraulic Functions...........................................................................................1113 No Hydraulic Functions Diagnostic Procedure..................................................................1113 Hydraulic Functions Slow.........................................................................................1113 Hydraulic Functions Slow Diagnostic Procedure................................................................1114 Main Hydraulic Pump Noisy........................................................................................1116 Main Hydraulic Pump Noisy Diagnostic Procedure...............................................................1116 No Orbital Steering Function.....................................................................................1117 No Orbital Steering Function Diagnostic Procedure............................................................1117 Boom Float Function Not Working..................................................................................1118 Boom Float Function Not Working Diagnostic Procedure.........................................................1118 One Hydraulic Function Not Working...............................................................................1119 One Hydraulic Function Not Working Diagnostic Procedure......................................................1119 Hydraulic Function Drifts Down...................................................................................1121 Hydraulic Function Drifts Down Diagnostic Procedure..........................................................1121 Boom Down Does Not Work (Engine Off).............................................................................1122 Boom Down Does Not Work (Engine Off) Diagnostic Procedure....................................................1122 Ride Control Not Working.........................................................................................1123 Ride Control Not Working Diagnostic Procedure................................................................1123 Oil Overheats....................................................................................................1124 Oil Overheats Diagnostic Procedure...........................................................................1124 Hydraulic Oil Foams..............................................................................................1125 Hydraulic Oil Foams Diagnostic Procedure.....................................................................1125 Pin Disconnect Cylinders Will Not Retract........................................................................1126 Pin Disconnect Cylinders Will Not Retract Diagnostic Procedure...............................................1126 Constant Steering Required to Maintain Straight Travel...........................................................1127 Constant Steering Required to Maintain Straight Travel Diagnostic Procedure..................................1127 Slow Steering Wheel Movement Will Not Cause Frame Movement.......................................................1128 Slow Steering Wheel Movement Will Not Cause Frame Movement Diagnostic Procedure..............................1128 Steering Wheel Turns Without Resistance and Causes No Frame Movement.............................................1128 Steering Wheel Turns Without Resistance and Causes No Frame Movement Diagnostic Procedure....................1128 Steering Erratic.................................................................................................1129 Steering Erratic Diagnostic Procedure........................................................................1129 Steering Wheel Free Play.........................................................................................1129 Steering Wheel Free Play Diagnostic Procedure................................................................1129 Orbital Steering Valve Binds or Locks Up.........................................................................1130 Orbital Steering Valve Binds or Locks Up Diagnostic Procedure................................................1130 Steering Wheel Turns by Itself...................................................................................1130 Steering Wheel Turns by Itself Diagnostic Procedure..........................................................1130 Machine Turns in Opposite Direction as Steering Wheel............................................................1130 Machine Turns in Opposite Direction as Steering Wheel Diagnostic Procedure...................................1131 Steering Wheel Kickback..........................................................................................1131 Steering Wheel Kickback Diagnostic Procedure.................................................................1131 Orbital Steering Jerky...........................................................................................1131 Orbital Steering Jerky Diagnostic Procedure..................................................................1131 Secondary Steering Motor Will Not Operate........................................................................1132 Secondary Steering Motor Will Not Operate Diagnostic Procedure...............................................1132 Secondary Steering Pump Runs But Will Not Steer Machine..........................................................1132 Secondary Steering Pump Runs But Will Not Steer Machine Diagnostic Procedure.................................1132 Hydraulic Fan Does Not Reach Full Speed..........................................................................1133 Hydraulic Fan Does Not Reach Full Speed Diagnostic Procedure.................................................1133 Hydraulic Fan Runs at Full Speed Only............................................................................1134 Hydraulic Fan Runs at Full Speed Only Diagnostic Procedure...................................................1134 Hydraulic Fan Does Not Spin......................................................................................1135 Hydraulic Fan Does Not Spin Diagnostic Procedure.............................................................1135 Hydraulic Fan Will Not Reverse Direction.........................................................................1136 Hydraulic Fan Will Not Reverse Direction Diagnostic Procedure................................................1137 Adjustments..........................................................................................................1139 Pilot Control Lever Adjustment...................................................................................1139 Auxiliary Pilot Control Lever Adjustment.........................................................................1139 Ride Control Accumulator Gas Charge Procedure....................................................................1140 Ride Control Accumulator Draining Procedure......................................................................1141 Auxiliary Valve SectionโStroke Adjustment........................................................................1142 Tests................................................................................................................1143 Hydraulic Oil Sampling Procedure.................................................................................1143 Hydraulic Oil Warm-Up Procedure..................................................................................1143 Vacuum Pump Installation.........................................................................................1144 Hydraulic System Pressure and Accumulators Discharge.............................................................1145 JT02156A Digital Pressure and Temperature Analyzer Kit Installation..............................................1146 Hydraulic System Operating and Standby Pressure Test.............................................................1147 Main Hydraulic Pump Control Valve Test and Adjustment............................................................1148 Load Sense Relief Valve Pressure Test and Adjustment.............................................................1152 Main Hydraulic Pump Flow Test....................................................................................1155 Main Hydraulic Pump Case Drain Test..............................................................................1157 Main Relief Valve Pressure Test..................................................................................1159 Circuit Relief With Anticavitation Valve Pressure Test...........................................................1163 Loader Cylinder Drift Test.......................................................................................1165 Boom, Bucket, and Steering Cylinder Leakage Test.................................................................1166 Hydraulic Oil Cooler Restriction Test............................................................................1167 Steering Cylinder Drift Test.....................................................................................1169 Secondary Steering Pump Pressure Relief Valve Test...............................................................1172 Secondary Steering ValveโHydraulic System Isolation Check Valve Leakage Test.....................................1174 Secondary Steering ValveโSecondary Steering Pump Isolation Check Valve Leakage Test..............................1177 Pilot Control Valve Pressure Test................................................................................1179 Auxiliary Pilot Control Valve Pressure Test......................................................................1183 Pilot Pressure Reducing Valve Pressure Test......................................................................1185 Pilot Accumulator Gas Precharge Test.............................................................................1187 Cycle Time Test..................................................................................................1189 Service Brake Accumulator Gas Precharge and Low Brake Pressure Warning Test......................................1190 Service Brake Valve Pressure Test................................................................................1192 Service Brake Valve Leakage Test.................................................................................1194 Service Brake Accumulator Inlet Check Valve Leakage Test.........................................................1196 Pin Disconnect Pressure Test.....................................................................................1197 Hydraulic Fan Pump Pressure Test.................................................................................1200 Hydraulic Fan Motor Speed Test...................................................................................1203 Hydraulic Fan Pump Flow Test.....................................................................................1204 Hydraulic Fan Motor Case Drain Test..............................................................................1206 Hydraulic Reversing Fan Test.....................................................................................1208 Hydraulic Oil Filter Inspection Procedure........................................................................1209 Heating and Air Conditioning.............................................................................................1211 Theory of Operation..................................................................................................1213 Air Conditioning System Cycle of Operation.......................................................................1213 System Diagrams......................................................................................................1215 Air Conditioner and Heater Component Location....................................................................1215 Diagnostic Information...............................................................................................1219 Air Conditioning System Does Not Operate.........................................................................1219 Air Conditioning System Does Not Operate Diagnostic Procedure................................................1219 Air Conditioning System Does Not Cool Interior of Cab............................................................1221 Air Conditioning System Does Not Cool Interior of Cab Diagnostic Procedure...................................1221 Air Conditioning System Runs Constantly, Too Cold................................................................1223 Air Conditioning System Runs Constantly, Too Cold Diagnostic Procedure.......................................1223 Heating System Does Not Operate..................................................................................1224 Heating System Does Not Operate Diagnostic Procedure.........................................................1224 Heating Does Not Warm Interior of Cab............................................................................1226 Heating Does Not Warm Interior of Cab Diagnostic Procedure...................................................1226 Interior Windows Continue to Fog.................................................................................1227 Interior Windows Continue to Fog Diagnostic Procedure........................................................1227 Tests................................................................................................................1229 R134a Refrigerant Cautions and Proper Handling...................................................................1229 R134a Oil Charge Capacity........................................................................................1229 R134a Refrigerant Charge Capacity................................................................................1229 Heater and Air Conditioner Operational Checks....................................................................1230 Visual Inspection of Components..............................................................................1230 Air Conditioner Compressor Clutch Test...........................................................................1231 R134a Refrigerant Leak Test......................................................................................1232 R134a Refrigerant Hoses and Tubing Inspection....................................................................1232 Air Conditioner High/Low-Pressure Switch Test....................................................................1233 Air Conditioner Freeze Control Switch Test.......................................................................1234 Air Conditioning System Test.....................................................................................1235 Operating Pressure Diagnostic Chart..............................................................................1236 Page Number.................................................................................................................. 5 Section 9000............................................................................................................. 7 Group 01............................................................................................................. 9 Section 9001............................................................................................................. 35 Group 10............................................................................................................. 37 Group 20............................................................................................................. 59 Group 30............................................................................................................. 167 Group 40............................................................................................................. 403 Group 50............................................................................................................. 461 Group 60............................................................................................................. 477 Group 70............................................................................................................. 479 Section 9005............................................................................................................. 481 Group 10............................................................................................................. 483 Section 9010............................................................................................................. 521 Group 05............................................................................................................. 523 Group 10............................................................................................................. 524 Group 15............................................................................................................. 537 Group 20............................................................................................................. 545 Group 25............................................................................................................. 547 Section 9015............................................................................................................. 556 Group 05............................................................................................................. 557 Group 10............................................................................................................. 681 Group 15............................................................................................................. 849 Group 16............................................................................................................. 859 Group 17............................................................................................................. 865 Group 20............................................................................................................. 877 Group 25............................................................................................................. 883 Section 9020............................................................................................................. 901 Group 05............................................................................................................. 903 Group 10............................................................................................................. 925 Group 15............................................................................................................. 943 Group 20............................................................................................................. 993 Group 25............................................................................................................. 995 Section 9025.............................................................................................................1029 Group 05.............................................................................................................1031 Group 10.............................................................................................................1088 Group 15.............................................................................................................1113 Group 20.............................................................................................................1139 Group 25.............................................................................................................1143 Section 9031.............................................................................................................1211 Group 05.............................................................................................................1213 Group 10.............................................................................................................1215 Group 15.............................................................................................................1219 Group 25.............................................................................................................1229
S.S 25/02/2025
