tm10293 - 750J Crawler Dozer (S.N.

141344—219962)
Technical Manual
Table of Contents
Foreword
Technical Information Feedback Form
Section 9000: General Information
Group 01: Safety

Recognize Safety Information

Follow Safety Instructions

Operate Only If Qualified

Wear Protective Equipment

Avoid Unauthorized Machine Modifications

Inspect Machine

Stay Clear of Moving Parts

Avoid High-Pressure Fluids

Avoid High-Pressure Oil

Beware of Exhaust Fumes

Prevent Fires

Prevent Battery Explosions

Handle Chemical Products Safely

Dispose of Waste Properly

Prepare for Emergencies

Add Cab Guarding For Special Uses

Use Steps and Handholds Correctly

Start Only From Operator's Seat

Use and Maintain Seat Belt

Prevent Unintended Machine Movement

Avoid Work Site Hazards

Keep Riders Off Machine

Avoid Backover Accidents

Avoid Machine Tip Over and Machine Damage

 Add and Operate Attachments Safely

Prevent Unintended Detonation of Explosive Devices

Park and Prepare for Service Safely

Service Cooling System Safely

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Drive Metal Pins Safely

Section 9001: Diagnostic Trouble Codes (DTC)

Group 10: CAN Monitor Unit (CMU) Diagnostic Trouble Codes

CAN Monitor Unit (CMU) Diagnostic Trouble Codes

000096.03 - Fuel Level Sensor Open or Short

000096.04 - Fuel Level Sensor Short to Ground

000107.03 - Engine Air Filter Restriction Indicator Switch Short to Power

000107.04 - Engine Air Filter Restricted

000177.03 - Transmission Oil Temperature Sensor Short to Power

000177.04 - Transmission Oil Temperature Sensor Short to Ground

000177.16 - Transmission Oil Temperature High

000609.09 - CAN Communication Error, No TCU Message

001638.00 - Hydraulic Oil Temperature High

001638.03 - Hydraulic Oil Temperature Short to Power

001638.04 - Hydraulic Oil Temperature Short to Ground

1713.31 - Hydraulic Oil Filter Restricted

002000.09 - CAN Communication Error, No ECU Configuration

003156.09 - CAN Blade Mode Missing From EHC

3359.31 - Transmission Oil Filter Restricted

524227.31 - Fan Oil Filter Restricted

Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes

Engine Control Unit (ECU) Diagnostic Trouble Codes

000091.09 - CAN Throttle Missing from TCU

000091.14 - Throttle Voltage Out of Range

000100.01 - Engine Oil Pressure Signal Extremely Low

000100.03 - Eng Oil Press Short to Power

 000100.04 - Engine Oil Pressure Signal Out of Range Low

000171.03 - Ambient Air Temp Open or Short

000171.04 - Ambient Air Temp Short to Gnd

000627.01 - Injector Current Incorrect

000651.00 - Cyl 1 Injector Max Cal

000651.01 - Cyl 1 Injector Min Cal

000652.00 - Cyl 2 Injector Max Cal

000652.01 - Cyl 2 Injector Min Cal

000653.00 - Cyl 3 Injector Max Cal

000653.01 - Cyl 3 Injector Min Cal

000654.00 - Cyl 4 Injector Max Cal

000654.01 - Cyl 4 Injector Min Cal

000655.00 - Cyl 5 Injector Max Cal

000655.01 - Cyl 5 Injector Min Cal

000656.00 - Cyl 6 Injector Max Cal

000656.01 - Cyl 6 Injector Min Cal

Group 30: Transmission Control Unit (TCU) Diagnostic Trouble Codes

Transmission Control Unit (TCU) Diagnostic Trouble Codes

000070.00 - Park Lock Lever Inputs Both ON

000070.01 - Park Lock Lever Inputs Both OFF

000091.00 - Throttle Sensor Input Greater Than Maximum Calibration Value

000091.01 - Throttle Sensor Input Less Than Minimum Calibration Value

000091.03 - Throttle Sensor Short to Power

000091.04 - Throttle Sensor Open or Short

000091.15 - Throttle Sensor Minimum Calibration Value Too High

000091.16 - Throttle Sensor Maximum Calibration Value Too High

000091.17 - Throttle Sensor Minimum Calibration Value Too Low

000091.18 - Throttle Sensor Maximum Calibration Value Too Low

000116.00 - Brake Pressure High

000116.01 - Brake Pressure Low

000116.03 - Brake Pressure Short to Power

000116.04 - Brake Pressure Open or Short

000158.03 - TCU System Voltage Too High

000158.04 - TCU System Voltage Too Low

000177.00 - Transmission Over Temp

000190.09 - CAN Communication Error No Engine Speed

000190.19 - CAN Communication Error Invalid Engine Speed

000521.00 - Decel Sensor Input Greater Than Maximum Calibration Value

000521.01 - Decel Sensor Input Less Than Minimum Calibration Value

000521.03 - Decel Sensor Short to Power

000521.04 - Decel Sensor Open or Short

000521.05 - Decel Sensor Brake Calibration Value Too Low

000521.06 - Decel Sensor Brake Calibration Value Too High

000521.15 - Decel Sensor Minimum Calibration Value Too High

000521.16 - Decel Sensor Maximum Calibration Value Too High

000521.17 - Decel Sensor Minimum Calibration Value Too Low

000521.18 - Decel Sensor Maximum Calibration Value Too Low

000581.00 - Speed Buttons Input Greater Than Maximum Calibration Value

000581.01 - Speed Buttons Input Less Than Minimum Calibration Value

000581.03 - Speed Buttons Short to Power

000581.04 - Speed Buttons Open or Short

000581.15 - Speed Buttons Minimum Calibration Value Too High

000581.16 - Speed Buttons Maximum Calibration Value Too High

000581.17 - Speed Buttons Minimum Calibration Value Too Low

000581.18 - Speed Buttons Maximum Calibration Value Too Low

000604.03 - FNR Neutral Switch Open Circuit

000604.04 - FNR Neutral Switch Short Circuit

000604.15 - FNR Neutral Switch Minimum Calibration Value Too High

000604.16 - FNR Neutral Switch Maximum Calibration Value Too High

000604.17 - FNR Neutral Switch Minimum Calibration Value Too Low

000604.18 - FNR Neutral Switch Maximum Calibration Value Too Low

000619.05 - Brake Solenoid No Response

000620.03 - TCU 5V Supply Short to Power

000620.04 - TCU 5V Supply Open or Short

000907.03 - Left Speed Sensor Short to Power

000907.04 - Left Speed Sensor Short

000907.07 - Left Speed Sensor No Response

000907.12 - Left Speed Sensor Open

000908.03 - Right Speed Sensor Short to Power

000908.04 - Right Speed Sensor Short

000908.07 - Right Speed Sensor No Response

000908.12 - Right Speed Sensor Open

000977.05 - Fan Reverse Solenoid No Response

001071.05 - Fan Drive Solenoid Open Circuit

001071.06 - Fan Drive Solenoid Short Circuit

002660.00 - Steer Sensor Input Greater Than Maximum Calibration Value

002660.01 - Steer Sensor Input Less Than Minimum Calibration Value

002660.03 - Steer Sensor Short to Power

002660.04 - Steer Sensor Open or Short

002660.15 - Steer Sensor Minimum Calibration Value Too High

002660.16 - Steer Sensor Maximum Calibration Value Too High

002660.17 - Steer Sensor Minimum Calibration Value Too Low

002660.18 - Steer Sensor Maximum Calibration Value Too Low

002661.00 - FNR Sensor Input Greater Than Maximum Calibration Value

002661.01 - FNR Sensor Input Less Than Minimum Calibration Value

002661.03 - FNR Sensor Short to Power

002661.04 - FNR Sensor Open or Short

002661.15 - FNR Sensor Minimum Calibration Value Too High

002661.16 - FNR Sensor Maximum Calibration Value Too High

002661.17 - FNR Sensor Minimum Calibration Value Too Low

002661.18 - FNR Sensor Maximum Calibration Value Too Low

522439.05 - Tank Bypass Solenoid Open Circuit

522440.05 - Blade Left Solenoid Open Circuit

522440.06 - Blade Left Solenoid Short Circuit

522441.05 - Blade Right Solenoid Open Circuit

522441.06 - Blade Right Solenoid Short Circuit

522442.00 - Blade Buttons Input Greater Than Maximum Calibration Value

522442.01 - Blade Buttons Input Less Than Minimum Calibration Value

522442.03 - Blade Buttons Short to Power

522442.04 - Blade Buttons Open or Short

522442.15 - Blade Buttons Minimum Calibration Value Too High

522442.16 - Blade Buttons Maximum Calibration Value Too High

522442.17 - Blade Buttons Minimum Calibration Value Too Low

522442.18 - Blade Buttons Maximum Calibration Value Too Low

522444.00 - Charge Pressure High

522444.01 - Charge Pressure Low

522444.03 - Charge Pressure Short to Power

522444.04 - Charge Pressure Open or Short

522445.00 - Right System Pressure High

522445.01 - Right System Pressure Low

522445.03 - Right System Press. Short to Power

522445.04 - Right System Press. Open or Short

522446.00 - Left System Pressure High

522446.01 - Left System Pressure Low

522446.03 - Left System Press. Short to Power

522446.04 - Left System Press. Open or Short

522447.05 - Right Forward Pump Coil Open

522447.06 - Right Forward Pump Coil Short

522447.15 - Right Forward Pump Threshold Calibration Value Too High

522447.16 - Right Forward Pump Max Speed Calibration Value Too High

522447.17 - Right Forward Pump Threshold Calibration Value Too Low

522447.18 - Right Forward Pump Max Speed Calibration Value Too Low

522448.05 - Right Reverse Pump Coil Open

522448.06 - Right Reverse Pump Coil Short

522448.15 - Right Reverse Pump Threshold Calibration Value Too High

522448.16 - Right Reverse Pump Max Speed Calibration Value Too High

522448.17 - Right Reverse Pump Thresh Calibration Value Too Low

522448.18 - Right Reverse Pump Max Speed Calibration Value Too Low

522449.05 - Left Reverse Pump Coil Open

522449.06 - Left Reverse Pump Coil Short

522449.15 - Left Reverse Pump Threshold Calibration Value Too High

522449.16 - Left Reverse Pump Max Speed Calibration Value Too High
 522449.17 - Left Reverse Pump Threshold Calibration Value Too Low

522449.18 - Left Reverse Pump Max Speed Calibration Value Too Low

522450.05 - Left Forward Pump Coil Open

522450.06 - Left Forward Pump Coil Short

522450.15 - Left Forward Pump Threshold Calibration Value Too High

522450.16 - Left Forward Pump Max Speed Calibration Value Too High

522450.17 - Left Forward Pump Threshold Calibration Value Too Low

522450.18 - Left Forward Pump Max Speed Calibration Value Too Low

522451.05 - Cooler Bypass Solenoid No Response

523108.13 - TCU Not Calibrated High Speed Not Done

523108.14 - TCU Not Calibrated Sensor/Pump/Motor

523436.07 - TCU Watchdog Timer Exceeded

523577.05 - Left Motor Solenoid Open Circuit

523577.06 - Left Motor Solenoid Short Circuit

523577.16 - Left Motor Maximum Calibration Value Too High

523577.18 - Left Motor Maximum Calibration Value Too Low

523578.05 - Right Motor Solenoid Open Circuit

523578.06 - Right Motor Solenoid Short Circuit

523578.16 - Right Motor Maximum Calibration Value Too High

523578.18 - Right Motor Maximum Calibration Value Too Low

Group 40: Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

000158.03 - EHC System Volts Too High

000158.04 - EHC System Volts Too Low

000620.03 - Sensor Short to Power

000620.04 - Sensor Short to GND

001903.00 - Aux 1 PVE Open Circuit

001903.01 - Aux 1 PVE Low or Open Circuit

001903.03 - Aux 1 PVE Short to Power

001903.04 - Aux 1 PVE Short to GND

001903.31 - Aux 1 PVE Spool Pos Error

001915.00 - Aux 2 PVE Open Circuit

001915.01 - Aux 2 PVE Low or Open Circuit

001915.03 - Aux 2 PVE Short to Power

001915.04 - Aux 2 PVE Short to GND

001915.31 - Aux 2 PVE Spool Pos Error

002697.09 - CAN Joystick Pos Missing From BCJ

002712.00 - Hyd Enable Sw Inputs Both On

002712.01 - Hyd Enable Sw Inputs Both Off

003157.03 - Incr / Decr Buttons Short to Power

003157.04 - Incr / Decr Buttons Open or Short

003751.31 - Incr / Decr Buttons Invalid Output

522442.31 - Blade Buttons Invalid Output

523779.00 - Blade Rotate Current Above Max

523779.01 - Blade Rotate Current Below Min

523780.00 - Tilt PVE Open Circuit

523780.01 - Tilt PVE Low or Open Circuit

523780.03 - Tilt PVE Short to Power

523780.04 - Tilt PVE Short to GND

523780.31 - Tilt PVE Spool Pos Error

523781.00 - Height PVE Open Circuit

523781.01 - Height PVE Low or Open Circuit

523781.03 - Height PVE Short to Power

523781.04 - Height PVE Short to GND

523781.31 - Height PVE Spool Pos Error

524059.00 - Aux 2 Jstk Sensor 2 Volts High

524059.01 - Aux 2 Jstk Sensor 2 Volts Low

524059.03 - Aux 2 Jstk Sensor 2 Short to Power

524059.04 - Aux 2 Jstk Sensor 2 Short to GND

524059.31 - Aux 2 Jstk Sensor 2 Invalid Output

524062.00 - Aux 1 Jstk Sensor 2 Volts High

524062.01 - Aux 1 Jstk Sensor 2 Volts Low

524062.03 - Aux 1 Jstk Sensor 2 Short to Power

524062.04 - Aux 1 Jstk Sensor 2 Short to GND

524062.31 - Aux 1 Jstk Sensor 2 Invalid Output

524085.00 - Aux 2 Jstk Sensor 2 Volts High

 524085.01 - Aux 2 Jstk Sensor 2 Volts Low

524085.03 - Aux 2 Jstk Sensor 1 Short to Power

524085.04 - Aux 2 Jstk Sensor 1 Short to GND

524085.14 - Aux 2 Jstk Sensor Mismatch

524085.31 - Aux 2 Jstk Sensor 1 Invalid Output

524086.00 - Aux 1 Jstk Sensor 1 Volts High

524086.01 - Aux 1 Jstk Sensor 1 Volts Low

524086.03 - Aux 1 Jstk Sensor 1 Short to Power

524086.04 - Aux 1 Jstk Sensor 1 Short to GND

524086.14 - Aux 1 Jstk Sensor Mismatch

524086.31 - Aux 1 Jstk Sensor 1 Invalid Output

Group 50: Blade Control Joystick (BCJ) Diagnostic Trouble Codes

Blade Control Joystick (BCJ) Diagnostic Trouble Codes

002697.03 - X-Axis Sensor Out of Range High

002697.04 - X-Axis Sensor Out of Range Low

002697.12 - X-Axis Joystick Internal Failure

002697.13 - X-Axis Joystick Setup Failure

002697.14 - X-Axis Joystick Sensor Failure

002698.03 - Y-Axis Sensor Out of Range High

002698.04 - Y-Axis Sensor Out of Range Low

002698.12 - Y-Axis Joystick Internal Failure

002698.13 - Y-Axis Joystick Setup Failure

002698.14 - Y-Axis Joystick Sensor Failure

Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout

Section 9010: Engine

Group 05: Theory of Operation

PowerTech™ E 6.8 L (6068) John Deere Engine

Group 15: Diagnostic Information

PowerTech™ E 6.8 L (6068) John Deere Engine

Engine Cooling System Component Location

 Engine Fuel System Component Location

Engine Intake and Exhaust Component Location

Group 25: Tests

Slow and Fast Idle Test

Intake Manifold Pressure Test—Turbocharger Boost

Fuel Supply Pump Pressure Test

Section 9015: Electrical System

Group 05: System Information

Electrical Diagram Information

Group 10: System Diagrams

Fuse and Relay Specifications

System Functional Schematic, Wiring Diagram, and Component Location Legend

System Functional Schematic and Section Legend

JDLink™ System Functional Schematic—MIG/GTT

JDLink™ System Functional Schematic—MTG/SAT

Operator's Station Harness (W7) Component Location

Operator's Station Harness (W7) Wiring Diagram

Canopy Roof Harness (W8) Component Location

Canopy Roof Harness (W8) Wiring Diagram

Cab Roof Harness (W9) Component Location

Cab Roof Harness (W9) Wiring Diagram

Engine Harness (W10) Component Location

Engine Harness (W10) Wiring Diagram

Transmission Harness (W11) Component Location

Transmission Harness (W11) Wiring Diagram

Air Conditioning Harness (W14) Component Location

Air Conditioning Harness (W14) Wiring Diagram

Radio Harness (W15) Component Location

Radio Harness (W15) Wiring Diagram

IGC Machine Harness (W21) and IGC Cab Harness (W22) Component Location—If Equipped

Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped

Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped
 Pressure Sensor Harness (W27) Wiring Diagram

JDLink™ System Harnesses Component Location—MIG/GTT

JDLink™ System Harnesses Component Location—MTG/SAT

JDLink™ System Wiring Diagrams—MIG/GTT

JDLink™ System Wiring Diagrams—MTG/SAT

Group 15: Sub-System Diagnostics

Starting and Charging Circuit Theory of Operation

Controller Area Network (CAN) Circuit Theory of Operation

Engine Control Unit (ECU) Circuit Theory of Operation

Transmission Control Unit (TCU) Circuit Theory of Operation

CAN Monitor Unit (CMU) Circuit Theory of Operation

Integrated Grade Control (IGC) Theory of Operation—If Equipped

JDLink™ Circuit Theory of Operation—If Equipped

Group 20: References

Electrical Component Specifications

Diagnostic Trouble Codes (DTC) Quick Reference List

Service ADVISOR™ Diagnostic Application

Service ADVISOR™ Connection Procedure

Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application

JDLink™ System Identification

JDLink™ Connection Procedure—If Equipped

CAN Monitor Unit (CMU) Menu Structure—Service Mode

Integrated Grade Control (IGC) Checks—If Equipped

Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped

Alternator Test

CAN Circuit Test

Transmission Control Unit (TCU) Calibration

Wire Harness Test

Decelerator/Brake Pedal Adjustment

Engine Speed Control Remove and Install

Rotary Sensor Remove and Install

Transmission Control Lever (TCL) Adjustment

Bussed Sensor Connectors (X6 and X7) Diagnostics

 Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector

Install Weather Pack™ Contact

Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Connectors

Replace DEUTSCH DEUTSCH is a trademark of Deutsch Co. Rectangular or Triangular

Connectors

Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Contact

Repair 32 and 48 Way CINCH™ Connectors

Replace (Pull Type) Metri-Pack™ Connectors

Replace (Push Type) Metri-Pack™ Connectors

Section 9025: Hydraulics

Group 05: Theory

Hydraulic System Operation

Hydraulic Pump Operation

Hydraulic Control Valve Operation

Hydraulic Control Valve Operation—IGC

Load Sense Circuit Operation

Load Sense Isolator Operation

Circuit Relief Valve with Anticavitation Operation

Hydraulic System Relief Valve Operation

Hydraulic Oil Filter Manifold Operation

Blade Angle Operation

Ripper Operation

Ripper Operation—IGC

Hydraulic Cylinder Operation

Quick-Drop Valve Operation

Group 15: Diagnostic Information

Hydraulic System Schematic

Hydraulic System Schematic—IGC

Main Hydraulic Component Location

Ripper Ready Hydraulic Component Location

Winch Ready Hydraulic Component Location

Main Hydraulic Component Location—IGC

Ripper Hydraulic Component Location—IGC

 Hydraulic System Diagnose Malfunctions

Hydraulic System Diagnose Malfunctions—IGC

Group 25: Tests

JT02156A Digital Pressure/Temperature Analyzer Installation

Ultra Clean® Hand Launcher

Hydraulic Oil Cleanup Procedure

Hydraulic System Relief Valve Test

Hydraulic System Relief Valve Test—IGC

Circuit Relief Valve Test

Circuit Relief Valve Test—IGC

Pump Load Sense Differential and System Pressure (Pump Cut-Off) Test and Adjustment

Pump Load Sense Differential and System Pressure Test and Adjustment—IGC

Lift and Tilt Cylinder Function Drift Test

Cylinder Leakage Test

Pressure Reducing Valve Pressure Test and Adjustment

Blade Down Accumulator Hydraulic Discharge

Blade Down Accumulator Precharge Test

Hydraulic Pump Flow Test

Hydraulic Pump Case Drain Test

Section 9026: Hydrostatic System

Group 05: Theory of Operation

Hydrostatic System

Transmission Control Circuit Operation (Flow Chart)

Charge Pump Operation

Hydrostatic Charge Oil Filter Operation

Neutral Charge Relief Valve Operation

Multi-Function Valve Operation

Hydraulic Integrated Circuit (HIC) Valve Operation

Park Brake Valve Operation

Oil Cooler and Reservoir Bypass Operation

Pump Pressure Control Pilot (PCP) Operation

Pump Displacement Control Valve (PDCV) Operation

 Hydrostatic Pump Operation

Flushing Valve and Operating Charge Relief Valve Operation

Hydrostatic Motor Operation

Hydraulic Reversing Fan Drive Operation

Hydraulic Non-Reversing Fan Drive Operation

Hydraulic Fan Return Filter Operation

Group 15: Diagnostic Information

Overheating Malfunctions

Low Charge Pressure Malfunctions

Mistrack/Index Malfunctions

Machine Full Speed Malfunctions

Low Power Malfunctions

Track Malfunctions

TCU Calibration Malfunctions

Hydrostatic System Component Location

Park Brake System Component Location

Hydrostatic System Schematic—Neutral (Park Brake On)

Hydrostatic System Diagram—Neutral (Park Brake On)

Hydrostatic System Diagram—Reverse (Slow Speed)

Hydrostatic System Diagram—Forward (Fast Speed)

Group 25: Tests

JT02156A Digital Pressure/Temperature Analyzer Installation

Ultra Clean® Hand Launcher

Machine Supporting Procedure

Transmission Oil Warm-Up Procedure

Releasing Park Brake to Tow the Machine

Hydrostatic Pump and Motor Initial Start-Up Procedure

Hydrostatic Pump Flushing Procedure

Hydraulic Oil Cleanup Procedure

Pressure Control Pilot (PCP) Manual Override Test

Pressure Control Pilot (PCP) Test

Pressure Control Pilot (PCP) Internal Adjustment

Multi-Function Relief Valve Test

 Transmission Efficiency Test

Neutral Charge Relief and Operating Charge Relief Pressure Test

Pump Displacement Control Valve (PDCV) Neutral (Null) Adjustment

Pump Servo Pressure Test

Motor Displacement Control Valve (MDCV) Adjustment

Hydrostatic Motor Min./Max. Angle Servo Piston Pressure Test

Charge Pump Flow Test

Charge Pressure Sensor Test

Hydrostatic Oil Cooler Bypass Test

Hydrostatic Oil Reservoir Bypass Test

Park Brake Test

Park Brake Relief Valve Test

Cab Tilt Relief Valve Test

Fan Pump Pressure Test

Fan Pump Flow Test

Fan Motor Speed Test

Fan Motor Case Drain Test

Section 9031: Heating and Air Conditioning

Group 05: Theory of Operation

Air Conditioning System Cycle Of Operation

Group 15: Diagnostic Information

Air Conditioning System Diagnose Malfunctions

Heater System Diagnose Malfunctions

Group 25: Tests

Proper Refrigerant Handling

R134a Refrigerant Cautions

R134a Oil Charge Capacity

R134a Refrigerant Charge Capacity

Refrigerant Hoses And Tubing Inspection

R134a Air Conditioning System Test

Operating Pressure Diagnostic Chart

Air Conditioner High/Low Pressure (Binary) Switch Test

Freeze Control Switch Test

Leak Testing
 Foreword

Foreword

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.

This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the
potential for personal injury.

Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the
components. Operation and tests sections help you identify the majority of routine problems quickly.

Information is organized in groups for the various components requiring service instruction. At the beginning of
each group are summary listings of all applicable essential tools, service equipment and tools, other materials
needed to do the job, service parts kits, specifications, wear tolerances, and torque values.

Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital
information needed for diagnosis, analysis, testing, and repair.

Fundamental service information is available from other sources covering basic theory of operation, fundamentals
of troubleshooting, general maintenance, and basic type of failures and their causes.

TX,750C,YY977-19-19950406

17
 Technical Information Feedback Form

Technical Information Feedback Form

We need your help to continually improve our technical publications. Please copy this page and FAX or mail your
comments, ideas and improvements.

-: Technical Manual Fax

SEND TO: John Deere Dubuque Works

18600 South John Deere Road

Attn: Publications, Dept. 324

Dubuque, IA 52004-0538

USA

FAX NUMBER: 1-563-589-5800 (USA)

Publication Number:

Page Number:

Ideas, Comments:

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TX,TM,FAX-19-20010703

18
 Table of Contents

Section 9000: General Information

Group 01: Safety

Recognize Safety Information

Follow Safety Instructions

Operate Only If Qualified

Wear Protective Equipment

Avoid Unauthorized Machine Modifications

Inspect Machine

Stay Clear of Moving Parts

Avoid High-Pressure Fluids

Avoid High-Pressure Oil

Beware of Exhaust Fumes

Prevent Fires

Prevent Battery Explosions

Handle Chemical Products Safely

Dispose of Waste Properly

Prepare for Emergencies

Add Cab Guarding For Special Uses

Use Steps and Handholds Correctly

Start Only From Operator's Seat

Use and Maintain Seat Belt

Prevent Unintended Machine Movement

Avoid Work Site Hazards

Keep Riders Off Machine

Avoid Backover Accidents

Avoid Machine Tip Over and Machine Damage

Add and Operate Attachments Safely

Prevent Unintended Detonation of Explosive Devices

Park and Prepare for Service Safely

Service Cooling System Safely

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Drive Metal Pins Safely

19
 Recognize Safety Information

Recognize Safety Information

T133555-UN: Safety alert Symbols

T133588-19: Safety Alert Symbols

This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert for
the potential of personal injury.

Follow the precautions and safe operating practices highlighted by this symbol.

A signal word — DANGER, WARNING, or CAUTION — is used with the safety alert symbol. DANGER identifies
the most serious hazards.

On your machine, DANGER signs are red in color, WARNING signs are orange, and CAUTION signs are yellow.
DANGER and WARNING signs are located near specific hazards. General precautions are on CAUTION labels.

Go to Section_9000:Group_01

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20
 Recognize Safety Information

Recognize Safety Information

T133555-UN: Safety alert Symbols

T133588-19: Safety Alert Symbols

This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert for
the potential of personal injury.

Follow the precautions and safe operating practices highlighted by this symbol.

A signal word — DANGER, WARNING, or CAUTION — is used with the safety alert symbol. DANGER identifies
the most serious hazards.

On your machine, DANGER signs are red in color, WARNING signs are orange, and CAUTION signs are yellow.
DANGER and WARNING signs are located near specific hazards. General precautions are on CAUTION labels.

Go to Section_9000:Group_01

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 Follow Safety Instructions

Follow Safety Instructions

T133556-UN: Follow Safety Instructions

Read the safety messages in this manual and on the machine. Follow these warnings and instructions carefully.
Review them frequently. Keep safety signs in good condition. Replace missing or damaged safety signs. Be sure
new equipment components and repair parts include the current safety signs. Replacement safety signs are
available from your John Deere dealer.

Be sure all operators of this machine understand every safety message. Replace operator's manual and safety
labels immediately if missing or damaged.

Go to Section_9000:Group_01

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22
 Operate Only If Qualified

Operate Only If Qualified

Do not operate this machine unless the operator's manual has been read carefully, and you have been qualified
by supervised training and instruction.

Operator should be familiar with the job site and surroundings before operating. Try all controls and machine
functions with the machine in an open area before starting to work.

Know and observe all safety rules that may apply to every work situation and work site.

Go to Section_9000:Group_01

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 Wear Protective Equipment

Wear Protective Equipment

TS206-UN: Protective Equipment

Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.

Wear close fitting clothing and safety equipment appropriate to the job.

Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear suitable hearing protection such
as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

Go to Section_9000:Group_01

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 Avoid Unauthorized Machine Modifications

Avoid Unauthorized Machine Modifications

John Deere recommends using only genuine John Deere replacement parts to ensure machine performance.
Never substitute genuine John Deere parts with alternate parts not intended for the application as these can
create hazardous situations or hazardous performance. Non-John Deere Parts, or any damage or failures
resulting from their use, are not covered by any John Deere warranty.

Modifications of this machine, or addition of unapproved products or attachments, may affect machine stability or
reliability, and may create a hazard for the operator or others near the machine. The installer of any modification
which may affect the electronic controls of this machine is responsible for establishing that the modification does
not adversely affect the machine or its performance.

Always contact an authorized John Deere dealer before making machine modifications that change the intended
use, weight, or balance of the machine, or that alter machine controls, performance, or reliability.

Go to Section_9000:Group_01

AM40430,00000A9-19-20150602

25
 Inspect Machine

Inspect Machine

T6607AQ-UN: Inspect Machine

Inspect machine carefully each day by walking around it before starting.

Keep all guards and shields in good condition and properly installed. Fix damage and replace worn or broken
parts immediately. Pay special attention to hydraulic hoses and electrical wiring.

Go to Section_9000:Group_01

TX03679,0001734-19-20080108

26
 Stay Clear of Moving Parts

Stay Clear of Moving Parts

T133592-UN: Stay Clear of Moving Parts

Entanglements in moving parts can cause serious injury.

Stop engine before examining, adjusting or maintaining any part of machine with moving parts.

Keep guards and shields in place. Replace any guard or shield that has been removed for access as soon as
service or repair is complete.

Go to Section_9000:Group_01

TX03679,00016D2-19-20080108

27
 Avoid High-Pressure Fluids

Avoid High-Pressure Fluids

T133509-UN: Avoid High Pressure Fluids

T133840-UN: Avoid High-Pressure Fluids

This machine uses a high-pressure hydraulic system. Escaping fluid under pressure can penetrate the skin
causing serious injury.

Never search for leaks with your hands. Protect hands. Use a piece of cardboard to find location of escaping
fluid. Stop engine and relieve pressure before disconnecting lines or working on hydraulic system.

If hydraulic fluid penetrates your skin, see a doctor immediately. Injected fluid must be removed
surgically within hours or gangrene may result. Contact a knowledgeable medical source or the Deere &
Company Medical Department in Moline, Illinois, U.S.A.

Go to Section_9000:Group_01

TX03679,00016D3-19-20060907

28
 Avoid High-Pressure Oil

Avoid High-Pressure Oil

T133509-UN: Avoid High Pressure Oils

T133840-UN: Avoid High-Pressure Oils

This machine uses a high-pressure hydraulic system. Escaping oil under pressure can penetrate the skin causing
serious injury.

Never search for leaks with your hands. Protect hands. Use a piece of cardboard to find location of escaping
oil. Stop engine and relieve pressure before disconnecting lines or working on hydraulic system.

If hydraulic oil penetrates your skin, see a doctor immediately. Injected oil must be removed surgically
within hours or gangrene may result. Contact a knowledgeable medical source or the Deere & Company
Medical Department in Moline, Illinois, U.S.A.

Go to Section_9000:Group_01

VD76477,000120C-19-20061102

29
 Beware of Exhaust Fumes

Beware of Exhaust Fumes

T133546-UN: Beware of Exhaust Fumes

Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.

If you must operate in an enclosed space, provide adequate ventilation. Use an exhaust pipe extension to remove
the exhaust fumes or open doors and windows to bring outside air into the area.

Go to Section_9000:Group_01

TX03679,00016D4-19-20080623

30
 Prevent Fires

Prevent Fires

T133552-UN: Handle Fuel Safely

T133553-UN: Clean Machine Regularly

T133554-UN: Carry A Fire Extinguisher

Handle Fuel Safely: Store flammable fluids away from fire hazards. Never refuel machine while smoking or when
near sparks or flame.

Clean Machine Regularly: Keep trash, debris, grease and oil from accumulating in engine compartment, around
fuel lines, hydraulic lines, exhaust components and electrical wiring. Never store oily rags or flammable materials
inside a machine compartment.

Maintain Hoses and Wiring: Replace hydraulic hoses immediately if they begin to leak, and clean up any oil
spills. Examine electrical wiring and connectors frequently for damage.

Keep A Fire Extinguisher Available: Always keep a multi-purpose fire extinguisher on or near the machine.
Know how to use extinguisher properly.

Go to Section_9000:Group_01

TX03679,00016F5-19-20090626

31
 Prevent Battery Explosions

Prevent Battery Explosions

TS204-UN: Battery Explosions

Battery gas can explode. Keep sparks, lighted matches, and open flame away from the top of battery.

Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

Go to Section_9000:Group_01

TX03679,000174A-19-20080108

32
 Handle Chemical Products Safely

Handle Chemical Products Safely

T133580-UN: Handle Chemical Products Safely

Exposure to hazardous chemicals can cause serious injury. Under certain conditions, lubricants, coolants, paints
and adhesives used with this machine may be hazardous.

If uncertain about safe handling or use of these chemical products, contact your authorized dealer for a Material
Safety Data Sheet (MSDS) or go to internet website http://www.jdmsds.com. The MSDS describes physical and
health hazards, safe use procedures, and emergency response techniques for chemical substances. Follow
MSDS recommendations to handle chemical products safely.

Go to Section_9000:Group_01

TX03679,00016D7-19-20070103

33
 Dispose of Waste Properly

Dispose of Waste Properly

T133567-UN: Dispose of Waste Properly

Improper disposal of waste can threaten the environment. Fuel, oils, coolants, filters and batteries used with this
machine may be harmful if not disposed of properly.

Never pour waste onto the ground, down a drain, or into any water source.

Air conditioning refrigerants can damage the atmosphere. Government regulations may require using a certified
service center to recover and recycle used refrigerants.

If uncertain about the safe disposal of waste, contact your local environmental or recycling center or your
authorized dealer for more information.

Go to Section_9000:Group_01

TX03679,0001733-19-20080108

34
 Prepare for Emergencies

Prepare for Emergencies

TS291-UN: First Aid Kit

Be prepared if an emergency occurs or a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

Go to Section_9000:Group_01

TX03679,000174B-19-20080108

35
 Add Cab Guarding For Special Uses

Add Cab Guarding For Special Uses

T139005-UN: Cab Guarding

Special work situations or machine attachments may expose the operator to intruding or flying objects. Using this
machine in a forestry application or woods environment, or with attachments such as a winch, requires added
guarding to protect the operator.

Forestry protection packages or special screens should be installed when working in areas where logs or
branches may strike the operator. A rear screen should always be used with a winch to protect against a
snapping cable. Contact your authorized dealer for information on protective guarding before operating in any
hazardous environment.

Go to Section_9000:Group_01

TX03768,0000B77-19-20080114

36
 Use Steps and Handholds Correctly

Use Steps and Handholds Correctly

T133468-UN: Use Handholds And Steps

Prevent falls by facing the machine when you get on and off. Maintain 3-point contact with steps and handrails.
Never use machine controls as handholds.

Use extra care when mud, snow, or moisture present slippery conditions. Keep steps clean and free of grease or
oil. Never jump when exiting machine. Never mount or dismount a moving machine.

Go to Section_9000:Group_01

TX03679,00016F2-19-20070212

37
 Start Only From Operator's Seat

Start Only From Operator's Seat

T133715-UN: Operate Only From Operators Seat

Avoid unexpected machine movement. Start engine only while sitting in operator's seat. Ensure all controls and
working tools are in proper position for a parked machine.

Never attempt to start engine from the ground. Do not attempt to start engine by shorting across the starter
solenoid terminals.

Go to Section_9000:Group_01

TX03679,0001799-19-20100422

38
 Use and Maintain Seat Belt

Use and Maintain Seat Belt

T133716-19: Use and Maintain Seat Belt

Use seat belt when operating machine . Remember to fasten seat belt when loading and unloading from trucks
and during other uses.

Examine seat belt frequently. Be sure webbing is not cut or torn. Replace seat belt immediately if any part is
damaged or does not function properly.

The complete seat belt assembly should be replaced every three years, regardless of appearance.

Go to Section_9000:Group_01

TX03679,00016DD-19-20070319

39
 Prevent Unintended Machine Movement

Prevent Unintended Machine Movement

T207688-19: LOCKED Position

Always move the park lock lever to the up (locked) position before leaving the operator's seat for any
reason .

Be careful not to accidentally actuate controls when coworkers are present. Engage park lock and lower work
equipment to the ground during work interruptions. Stop the engine before allowing anyone to approach the
machine. Follow these same precautions before standing up, leaving the operator's seat, or exiting the machine.

Go to Section_9000:Group_01

TX03768,0000B72-19-20101123

40
 Avoid Work Site Hazards

Avoid Work Site Hazards

T139002-UN: Contact With Gas Line

T139003-UN: Operate Only On Solid Footing

Avoid contact with gas lines, buried cables and water lines. Call utility line location services to identify all
underground utilities before starting work.

Prepare work site properly. Avoid operating near structures or objects that could fall onto the machine. Clear
away debris that could move unexpectedly if run over.

Avoid boom or attachment contact with overhead obstacles or overhead electrical lines. Never move
machine closer than 3 m (10 ft) plus twice the line insulator length to overhead wires.

Keep bystanders clear at all times. Keep bystanders away from raised booms, attachments, and unsupported
loads. Avoid swinging or raising booms, attachments, or loads over or near personnel. Use barricades or a signal
person to keep vehicles and pedestrians away. Use a signal person if moving machine in congested areas or
where visibility is restricted. Always keep signal person in view. Coordinate hand signals before starting machine.

Operate only on solid footing with strength sufficient to support machine. Be especially alert working near
embankments or excavations.

Avoid working under overhanging embankments or stockpiles that could collapse under or on machine.

Reduce machine speed when operating with tool on or near ground when obstacles may be hidden (e.g., during
snow removal or clearing mud, dirt, etc.). At high speeds, hitting obstacles (rocks, uneven concrete or manholes)

41
 Avoid Work Site Hazards
can cause a sudden stop. Always wear your seat belt.

Go to Section_9000:Group_01

VD76477,000120D-19-20080425

42
 Keep Riders Off Machine

Keep Riders Off Machine

T137580-UN: Keep Riders Off Machine

Only allow operator on machine.

Riders are subject to injury. They may fall from machine, be caught between machine parts, or be struck by
foreign objects.

Riders may obstruct operator’s view or impair the operator’s ability to operate machine safely.

Go to Section_9000:Group_01

TX03768,0000B73-19-20150603

43
 Avoid Backover Accidents

Avoid Backover Accidents

T138441-UN: Backover Warning

Before moving machine, be sure all persons are clear of the machine path. Turn around and look directly for
best visibility. Use mirror to assist in checking behind the machine. Keep windows and mirror clean and in good
repair.

Be certain backup warning alarm is working properly.

Use a signal person when backing if view is obstructed or when in close quarters. Keep signal person in
view at all times. Use prearranged hand signals to communicate.

Go to Section_9000:Group_01

TX03768,0000B69-19-20110614

44
 Avoid Machine Tip Over and Machine Damage

Avoid Machine Tip Over and Machine Damage

T133716-19: Avoid Machine Tip Over

T138416-UN: Avoid Machine Tip Over

T138415-UN: Avoid Machine Tip Over

Use seat belt at all times.

Do not jump if the machine tips. You will be unlikely to jump clear and the machine may crush you.

Load and unload from trucks or trailers carefully. Be sure truck is wide enough and secured on a firm level
surface. Use loading ramps and attach them properly to truck bed. Avoid trucks with steel beds because tracks
slip more easily on steel.

Be careful on slopes. Use extra care on soft, rocky, or frozen ground because machine may slip sideways in
these conditions. When traveling up or down steep slopes, keep the bucket or blade on uphill side and just above
ground level.

Ensure solid footing. Use extra care when operating on stockpile materials, or near banks or excavations that
may cave-in and cause machine to tip or fall.

Avoid machine damage on slopes. Use extra care to operate machine.

45
Avoid Machine Tip Over and Machine Damage

Go to Section_9000:Group_01

AM40430,00000B7-19-20070212

46
 Add and Operate Attachments Safely

Add and Operate Attachments Safely

Always verify compatibility of attachments by contacting your authorized dealer. Adding unapproved attachments
may affect machine stability or reliability and may create a hazard for others near the machine.

Ensure that a qualified person is involved in attachment installation. Add guards to machine if operator protection
is required or recommended. Verify that all connections are secure and attachment responds properly to controls.

Carefully read attachment manual and follow all instructions and warnings. In an area free of bystanders and
obstructions, carefully operate attachment to learn its characteristics and range of motion.

Go to Section_9000:Group_01

TX03679,00016F0-19-20070212

47
 Prevent Unintended Detonation of Explosive Devices

Prevent Unintended Detonation of Explosive Devices

TX1023216-UN: Prevent Unintended Detonation of Explosive Devices

Avoid serious injury or death from an explosion hazard. Deactivate all cellular or radio frequency devices on
equipment stored or operating in an area, such as a blasting zone, where the use of radio transmitting devices are
prohibited.

Go to Section_9000:Group_01

VD76477,0001543-19-20080108

48
 Park and Prepare for Service Safely

Park and Prepare for Service Safely

T133332-19: Do Not Operate Tag

TS229-UN: Support Machine Properly

Warn others of service work. Always park and prepare your machine for service or repair properly.

Park machine on a level surface and lower blade and attachments to the ground.
Place park lock lever in “up” (locked) position. Stop engine and remove key.
Attach a “Do Not Operate” tag in an obvious place in the operator's station.

Securely support machine or attachment before working under it.

Do not support machine with blade or attachments.

Do not support machine with cinder blocks or wooden pieces that may crumble or crush.
Do not support machine with a single jack or other devices that may slip out of place.

Understand service procedures before beginning repairs. Keep service area clean and dry. Use two people
whenever the engine must be running for service work.

Go to Section_9000:Group_01

TX03768,0000B6A-19-20070212

49
 Service Cooling System Safely

Service Cooling System Safely

TS281-UN: Cooling System

Explosive release of fluids from pressurized cooling system can cause serious burns.

Do not service radiator through the radiator cap. Only fill through the surge tank filler cap. Shut off engine. Only
remove surge tank filler cap when cool enough to touch with bare hands. Slowly loosen cap to relieve pressure
before removing completely.

Go to Section_9000:Group_01

TX,SURGE-19-20110119

50
 Remove Paint Before Welding or Heating

Remove Paint Before Welding or Heating

T133546-UN: Toxic Fumes

Hazardous fumes can be generated when paint is heated by welding or using a torch. Dust from sanding or
grinding paint can also be hazardous.

Remove paint to at least 76 mm (3 in.) from area to be heated. Wear an approved respirator when sanding or
grinding paint. If a solvent or paint stripper is used, wash area with soap and water. Remove solvent or paint
stripper containers from work area, and allow fumes to disperse at least 15 minutes before welding or heating.

Work outside or in a well-ventilated area. Dispose of waste, paint, and solvents properly.

Go to Section_9000:Group_01

TX03679,0001732-19-20070829

51
 Make Welding Repairs Safely

Make Welding Repairs Safely

T133547-UN: Avoid Heating Near Pressurized Fluid Lines

IMPORTANT:

Disable electrical power before welding. Turn off main battery switch or disconnect positive battery cable.
Separate harness connectors to engine and vehicle microprocessors.

Avoid welding or heating near pressurized fluid lines. Flammable spray may result and cause severe burns if
pressurized lines fail as a result of heating. Do not let heat go beyond work area to nearby pressurized lines.

Remove paint properly. Do not inhale paint dust or fumes. Use a qualified welding technician for structural repairs.
Make sure there is good ventilation. Wear eye protection and protective equipment when welding.

Go to Section_9000:Group_01

TX03679,00016D5-19-20090911

52
 Drive Metal Pins Safely

Drive Metal Pins Safely

T133738-UN: Hardened Metal Parts

Always wear protective goggles or safety glasses and other protective equipment before striking hardened parts.
Hammering hardened metal parts such as pins and bucket teeth may dislodge chips at high velocity.

Use a soft hammer or a brass bar between hammer and object to prevent chipping.

Go to Section_9000:Group_01

OUO1065,0000090-19-20160106

53
 Table of Contents

Section 9001: Diagnostic Trouble Codes (DTC)

Group 10: CAN Monitor Unit (CMU) Diagnostic Trouble Codes

CAN Monitor Unit (CMU) Diagnostic Trouble Codes

000096.03 - Fuel Level Sensor Open or Short

000096.04 - Fuel Level Sensor Short to Ground

000107.03 - Engine Air Filter Restriction Indicator Switch Short to Power

000107.04 - Engine Air Filter Restricted

000177.03 - Transmission Oil Temperature Sensor Short to Power

000177.04 - Transmission Oil Temperature Sensor Short to Ground

000177.16 - Transmission Oil Temperature High

000609.09 - CAN Communication Error, No TCU Message

001638.00 - Hydraulic Oil Temperature High

001638.03 - Hydraulic Oil Temperature Short to Power

001638.04 - Hydraulic Oil Temperature Short to Ground

1713.31 - Hydraulic Oil Filter Restricted

002000.09 - CAN Communication Error, No ECU Configuration

003156.09 - CAN Blade Mode Missing From EHC

3359.31 - Transmission Oil Filter Restricted

524227.31 - Fan Oil Filter Restricted

Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes

Engine Control Unit (ECU) Diagnostic Trouble Codes

000091.09 - CAN Throttle Missing from TCU

000091.14 - Throttle Voltage Out of Range

000100.01 - Engine Oil Pressure Signal Extremely Low

000100.03 - Eng Oil Press Short to Power

000100.04 - Engine Oil Pressure Signal Out of Range Low

000171.03 - Ambient Air Temp Open or Short

000171.04 - Ambient Air Temp Short to Gnd

000627.01 - Injector Current Incorrect

000651.00 - Cyl 1 Injector Max Cal

000651.01 - Cyl 1 Injector Min Cal

000652.00 - Cyl 2 Injector Max Cal

000652.01 - Cyl 2 Injector Min Cal

54
 Table of Contents
000653.00 - Cyl 3 Injector Max Cal

000653.01 - Cyl 3 Injector Min Cal

000654.00 - Cyl 4 Injector Max Cal

000654.01 - Cyl 4 Injector Min Cal

000655.00 - Cyl 5 Injector Max Cal

000655.01 - Cyl 5 Injector Min Cal

000656.00 - Cyl 6 Injector Max Cal

000656.01 - Cyl 6 Injector Min Cal

Group 30: Transmission Control Unit (TCU) Diagnostic Trouble Codes

Transmission Control Unit (TCU) Diagnostic Trouble Codes

000070.00 - Park Lock Lever Inputs Both ON

000070.01 - Park Lock Lever Inputs Both OFF

000091.00 - Throttle Sensor Input Greater Than Maximum Calibration Value

000091.01 - Throttle Sensor Input Less Than Minimum Calibration Value

000091.03 - Throttle Sensor Short to Power

000091.04 - Throttle Sensor Open or Short

000091.15 - Throttle Sensor Minimum Calibration Value Too High

000091.16 - Throttle Sensor Maximum Calibration Value Too High

000091.17 - Throttle Sensor Minimum Calibration Value Too Low

000091.18 - Throttle Sensor Maximum Calibration Value Too Low

000116.00 - Brake Pressure High

000116.01 - Brake Pressure Low

000116.03 - Brake Pressure Short to Power

000116.04 - Brake Pressure Open or Short

000158.03 - TCU System Voltage Too High

000158.04 - TCU System Voltage Too Low

000177.00 - Transmission Over Temp

000190.09 - CAN Communication Error No Engine Speed

000190.19 - CAN Communication Error Invalid Engine Speed

000521.00 - Decel Sensor Input Greater Than Maximum Calibration Value

000521.01 - Decel Sensor Input Less Than Minimum Calibration Value

000521.03 - Decel Sensor Short to Power

000521.04 - Decel Sensor Open or Short

55
 Table of Contents
000521.05 - Decel Sensor Brake Calibration Value Too Low

000521.06 - Decel Sensor Brake Calibration Value Too High

000521.15 - Decel Sensor Minimum Calibration Value Too High

000521.16 - Decel Sensor Maximum Calibration Value Too High

000521.17 - Decel Sensor Minimum Calibration Value Too Low

000521.18 - Decel Sensor Maximum Calibration Value Too Low

000581.00 - Speed Buttons Input Greater Than Maximum Calibration Value

000581.01 - Speed Buttons Input Less Than Minimum Calibration Value

000581.03 - Speed Buttons Short to Power

000581.04 - Speed Buttons Open or Short

000581.15 - Speed Buttons Minimum Calibration Value Too High

000581.16 - Speed Buttons Maximum Calibration Value Too High

000581.17 - Speed Buttons Minimum Calibration Value Too Low

000581.18 - Speed Buttons Maximum Calibration Value Too Low

000604.03 - FNR Neutral Switch Open Circuit

000604.04 - FNR Neutral Switch Short Circuit

000604.15 - FNR Neutral Switch Minimum Calibration Value Too High

000604.16 - FNR Neutral Switch Maximum Calibration Value Too High

000604.17 - FNR Neutral Switch Minimum Calibration Value Too Low

000604.18 - FNR Neutral Switch Maximum Calibration Value Too Low

000619.05 - Brake Solenoid No Response

000620.03 - TCU 5V Supply Short to Power

000620.04 - TCU 5V Supply Open or Short

000907.03 - Left Speed Sensor Short to Power

000907.04 - Left Speed Sensor Short

000907.07 - Left Speed Sensor No Response

000907.12 - Left Speed Sensor Open

000908.03 - Right Speed Sensor Short to Power

000908.04 - Right Speed Sensor Short

000908.07 - Right Speed Sensor No Response

000908.12 - Right Speed Sensor Open

000977.05 - Fan Reverse Solenoid No Response

001071.05 - Fan Drive Solenoid Open Circuit

56
 Table of Contents
001071.06 - Fan Drive Solenoid Short Circuit

002660.00 - Steer Sensor Input Greater Than Maximum Calibration Value

002660.01 - Steer Sensor Input Less Than Minimum Calibration Value

002660.03 - Steer Sensor Short to Power

002660.04 - Steer Sensor Open or Short

002660.15 - Steer Sensor Minimum Calibration Value Too High

002660.16 - Steer Sensor Maximum Calibration Value Too High

002660.17 - Steer Sensor Minimum Calibration Value Too Low

002660.18 - Steer Sensor Maximum Calibration Value Too Low

002661.00 - FNR Sensor Input Greater Than Maximum Calibration Value

002661.01 - FNR Sensor Input Less Than Minimum Calibration Value

002661.03 - FNR Sensor Short to Power

002661.04 - FNR Sensor Open or Short

002661.15 - FNR Sensor Minimum Calibration Value Too High

002661.16 - FNR Sensor Maximum Calibration Value Too High

002661.17 - FNR Sensor Minimum Calibration Value Too Low

002661.18 - FNR Sensor Maximum Calibration Value Too Low

522439.05 - Tank Bypass Solenoid Open Circuit

522440.05 - Blade Left Solenoid Open Circuit

522440.06 - Blade Left Solenoid Short Circuit

522441.05 - Blade Right Solenoid Open Circuit

522441.06 - Blade Right Solenoid Short Circuit

522442.00 - Blade Buttons Input Greater Than Maximum Calibration Value

522442.01 - Blade Buttons Input Less Than Minimum Calibration Value

522442.03 - Blade Buttons Short to Power

522442.04 - Blade Buttons Open or Short

522442.15 - Blade Buttons Minimum Calibration Value Too High

522442.16 - Blade Buttons Maximum Calibration Value Too High

522442.17 - Blade Buttons Minimum Calibration Value Too Low

522442.18 - Blade Buttons Maximum Calibration Value Too Low

522444.00 - Charge Pressure High

522444.01 - Charge Pressure Low

522444.03 - Charge Pressure Short to Power

57
 Table of Contents
522444.04 - Charge Pressure Open or Short

522445.00 - Right System Pressure High

522445.01 - Right System Pressure Low

522445.03 - Right System Press. Short to Power

522445.04 - Right System Press. Open or Short

522446.00 - Left System Pressure High

522446.01 - Left System Pressure Low

522446.03 - Left System Press. Short to Power

522446.04 - Left System Press. Open or Short

522447.05 - Right Forward Pump Coil Open

522447.06 - Right Forward Pump Coil Short

522447.15 - Right Forward Pump Threshold Calibration Value Too High

522447.16 - Right Forward Pump Max Speed Calibration Value Too High

522447.17 - Right Forward Pump Threshold Calibration Value Too Low

522447.18 - Right Forward Pump Max Speed Calibration Value Too Low

522448.05 - Right Reverse Pump Coil Open

522448.06 - Right Reverse Pump Coil Short

522448.15 - Right Reverse Pump Threshold Calibration Value Too High

522448.16 - Right Reverse Pump Max Speed Calibration Value Too High

522448.17 - Right Reverse Pump Thresh Calibration Value Too Low

522448.18 - Right Reverse Pump Max Speed Calibration Value Too Low

522449.05 - Left Reverse Pump Coil Open

522449.06 - Left Reverse Pump Coil Short

522449.15 - Left Reverse Pump Threshold Calibration Value Too High

522449.16 - Left Reverse Pump Max Speed Calibration Value Too High

522449.17 - Left Reverse Pump Threshold Calibration Value Too Low

522449.18 - Left Reverse Pump Max Speed Calibration Value Too Low

522450.05 - Left Forward Pump Coil Open

522450.06 - Left Forward Pump Coil Short

522450.15 - Left Forward Pump Threshold Calibration Value Too High

522450.16 - Left Forward Pump Max Speed Calibration Value Too High

522450.17 - Left Forward Pump Threshold Calibration Value Too Low

522450.18 - Left Forward Pump Max Speed Calibration Value Too Low

58
 Table of Contents
522451.05 - Cooler Bypass Solenoid No Response

523108.13 - TCU Not Calibrated High Speed Not Done

523108.14 - TCU Not Calibrated Sensor/Pump/Motor

523436.07 - TCU Watchdog Timer Exceeded

523577.05 - Left Motor Solenoid Open Circuit

523577.06 - Left Motor Solenoid Short Circuit

523577.16 - Left Motor Maximum Calibration Value Too High

523577.18 - Left Motor Maximum Calibration Value Too Low

523578.05 - Right Motor Solenoid Open Circuit

523578.06 - Right Motor Solenoid Short Circuit

523578.16 - Right Motor Maximum Calibration Value Too High

523578.18 - Right Motor Maximum Calibration Value Too Low

Group 40: Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

000158.03 - EHC System Volts Too High

000158.04 - EHC System Volts Too Low

000620.03 - Sensor Short to Power

000620.04 - Sensor Short to GND

001903.00 - Aux 1 PVE Open Circuit

001903.01 - Aux 1 PVE Low or Open Circuit

001903.03 - Aux 1 PVE Short to Power

001903.04 - Aux 1 PVE Short to GND

001903.31 - Aux 1 PVE Spool Pos Error

001915.00 - Aux 2 PVE Open Circuit

001915.01 - Aux 2 PVE Low or Open Circuit

001915.03 - Aux 2 PVE Short to Power

001915.04 - Aux 2 PVE Short to GND

001915.31 - Aux 2 PVE Spool Pos Error

002697.09 - CAN Joystick Pos Missing From BCJ

002712.00 - Hyd Enable Sw Inputs Both On

002712.01 - Hyd Enable Sw Inputs Both Off

003157.03 - Incr / Decr Buttons Short to Power

003157.04 - Incr / Decr Buttons Open or Short

59
 Table of Contents
003751.31 - Incr / Decr Buttons Invalid Output

522442.31 - Blade Buttons Invalid Output

523779.00 - Blade Rotate Current Above Max

523779.01 - Blade Rotate Current Below Min

523780.00 - Tilt PVE Open Circuit

523780.01 - Tilt PVE Low or Open Circuit

523780.03 - Tilt PVE Short to Power

523780.04 - Tilt PVE Short to GND

523780.31 - Tilt PVE Spool Pos Error

523781.00 - Height PVE Open Circuit

523781.01 - Height PVE Low or Open Circuit

523781.03 - Height PVE Short to Power

523781.04 - Height PVE Short to GND

523781.31 - Height PVE Spool Pos Error

524059.00 - Aux 2 Jstk Sensor 2 Volts High

524059.01 - Aux 2 Jstk Sensor 2 Volts Low

524059.03 - Aux 2 Jstk Sensor 2 Short to Power

524059.04 - Aux 2 Jstk Sensor 2 Short to GND

524059.31 - Aux 2 Jstk Sensor 2 Invalid Output

524062.00 - Aux 1 Jstk Sensor 2 Volts High

524062.01 - Aux 1 Jstk Sensor 2 Volts Low

524062.03 - Aux 1 Jstk Sensor 2 Short to Power

524062.04 - Aux 1 Jstk Sensor 2 Short to GND

524062.31 - Aux 1 Jstk Sensor 2 Invalid Output

524085.00 - Aux 2 Jstk Sensor 2 Volts High

524085.01 - Aux 2 Jstk Sensor 2 Volts Low

524085.03 - Aux 2 Jstk Sensor 1 Short to Power

524085.04 - Aux 2 Jstk Sensor 1 Short to GND

524085.14 - Aux 2 Jstk Sensor Mismatch

524085.31 - Aux 2 Jstk Sensor 1 Invalid Output

524086.00 - Aux 1 Jstk Sensor 1 Volts High

524086.01 - Aux 1 Jstk Sensor 1 Volts Low

524086.03 - Aux 1 Jstk Sensor 1 Short to Power

60
 Table of Contents
524086.04 - Aux 1 Jstk Sensor 1 Short to GND

524086.14 - Aux 1 Jstk Sensor Mismatch

524086.31 - Aux 1 Jstk Sensor 1 Invalid Output

Group 50: Blade Control Joystick (BCJ) Diagnostic Trouble Codes

Blade Control Joystick (BCJ) Diagnostic Trouble Codes

002697.03 - X-Axis Sensor Out of Range High

002697.04 - X-Axis Sensor Out of Range Low

002697.12 - X-Axis Joystick Internal Failure

002697.13 - X-Axis Joystick Setup Failure

002697.14 - X-Axis Joystick Sensor Failure

002698.03 - Y-Axis Sensor Out of Range High

002698.04 - Y-Axis Sensor Out of Range Low

002698.12 - Y-Axis Joystick Internal Failure

002698.13 - Y-Axis Joystick Setup Failure

002698.14 - Y-Axis Joystick Sensor Failure

61
 CAN Monitor Unit (CMU) Diagnostic Trouble Codes

CAN Monitor Unit (CMU) Diagnostic Trouble Codes

The diagnostic trouble code is indicated by a Suspect Parameter Number (SPN) and a Failure Mode Indicator
(FMI) number. In the example 000096.03 , 96 is the SPN and 03 is the FMI number.

To view diagnostic trouble codes, use one of the following methods:

Service ADVISOR™ system. See Reading Diagnostic Trouble Codes with Service ADVISOR™
Diagnostic Application . (Group 9015-20.)
CAN Monitor Unit (CMU). see CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-
20.)

NOTE:

For in-depth diagnostics on all CMU diagnostic trouble codes, see specific code diagnostic
procedure. (Group 9001-10.)

Go to Section_9001:Group_10

WS68074,0000B56-19-20070405

62
 CAN Monitor Unit (CMU) Diagnostic Trouble Codes

CAN Monitor Unit (CMU) Diagnostic Trouble Codes

The diagnostic trouble code is indicated by a Suspect Parameter Number (SPN) and a Failure Mode Indicator
(FMI) number. In the example 000096.03 , 96 is the SPN and 03 is the FMI number.

To view diagnostic trouble codes, use one of the following methods:

Service ADVISOR™ system. See Reading Diagnostic Trouble Codes with Service ADVISOR™
Diagnostic Application . (Group 9015-20.)
CAN Monitor Unit (CMU). see CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-
20.)

NOTE:

For in-depth diagnostics on all CMU diagnostic trouble codes, see specific code diagnostic
procedure. (Group 9001-10.)

Go to Section_9001:Group_10

WS68074,0000B56-19-20070405

63
 000096.03 —Fuel Level Sensor Open or Short
000096.03 —
Fuel Level Sensor Open or Short

The fuel level sensor circuit has an open or short.

Fuel Level Sensor Open or Short Diagnostic Procedure

Alarm Level:

No Service Light

Launch Close Expand List Collapse List

1 Component Check
Action:

Turn key switch OFF.

Disconnect fuel level sensor (B19). See Engine Fuel System Component Location . (Group 9010-15.)

Check resistance across sensor.

Item Measurement Specification

Fuel Level Sensor (B19) Resistance 29—36 ohms at 100% Fill (full)
62—70 ohms at 75% Fill
99—107 ohms at 50% Fill
147—157 ohms at 25% Fill
240—250 ohms at 0% Fill (empty)
Is the fuel level sensor within specifications?

Record of Actual Results:

Result:
YES:
Go to Open Circuit Check .
NO:
Replace fuel level sensor. See Engine Fuel System Component Location . (Group 9010-15.)

2 Open Circuit Check

Action:

Turn key switch OFF.

Disconnect fuel level sensor (B19). See Engine Fuel System Component Location . (Group 9015-10.)

Disconnect CMU connector (X4). See Operator's Station Harness (W7) Component Location . (Group 9015-
10.)

Check wire Y01 YEL for continuity between fuel level sensor connector and pin N on CMU connector (X4).

64
 000096.03 —Fuel Level Sensor Open or Short
Check wire R10 BLK for continuity between fuel level sensor connector and pin F on CMU connector (X4).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
NO:
Go to next step in this check.
Action:

Disconnect connector (X21) from the transmission harness. See Transmission Harness (W11) Component
Location . (Group 9015-10.)

Check wire Y01 YEL for continuity between pin 2 on connector (X21) and pin N on CMU connector (X4).

Check wire R10 BLK for continuity between pin 1 on connector (X21) and pin F on CMU connector (X4).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Open circuit in fuel tank harness. Repair or replace harness. See Transmission Harness (W11) Wiring
Diagram . (Group 9015-10.)
NO:
Go to next step in this check.
Action:

Disconnect connector (X17) from the transmission harness. See Operator's Station Harness (W7)
Component Location . (Group 9015-10.)

Check wire Y01 YEL in operator's station harness for continuity between pin 4 on connector (X17) and pin N
on CMU connector (X4).

Check wire R10 BLK in operator's station harness for continuity between pin 3 on connector (X17) and pin F
on CMU connector (X4).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Open circuit in transmission harness (W11). Repair or replace harness. See Transmission Harness (W11)
Wiring Diagram . (Group 9015-10.)
65
 000096.03 —Fuel Level Sensor Open or Short

NO:
Open circuit in operator's station harness (W7). Repair or replace harness. See Operator's Station Harness
(W7) Wiring Diagram . (Group 9015-10.)

3 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect fuel level sensor (B19). See Engine Fuel System Component Location . (Group 9010-15.)

Disconnect CMU connector (X4). See Operator's Station Harness (W7) Component Location

Turn key switch ON.

Check for voltage at fuel level sensor connector (wire R10 BLK).

Check for voltage at fuel level sensor connector (wire Y01 YEL).

Is voltage present?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Go to Reprogram Controller .
Action:

Turn key switch OFF.

Disconnect connector (X21) from the transmission harness. See Transmission Harness (W11) Component
Location . (Group 9015-10.)

Turn key switch ON.

Check for voltage at pin 1 (wire R10 BLK) on transmission harness side of connector (X21).

Check for voltage at pin 2 (wire Y01 YEL) on transmission harness side of connector (X21).

Is voltage present?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Short to power in fuel tank harness. Repair or replace harness. See Transmission Harness (W11) Wiring
66
 000096.03 —Fuel Level Sensor Open or Short
Diagram . (Group 9015-10.)
Action:

Turn key switch OFF.

Disconnect connector (X17) from the operator's station harness. See Transmission Harness (W11)
Component Location . (Group 9015-10.)

Turn key switch ON.

Check for voltage at pin 3 (wire R10 BLK) on transmission harness side of connector (X17).

Check for voltage at pin 4 (wire Y01 YEL) on transmission harness side of connector (X17).

Is voltage present?

Record of Actual Results:

Result:
YES:
Short to power in transmission harness. Repair or replace harness. See Transmission Harness (W11) Wiring
Diagram . (Group 9015-10.)
NO:
Short to power in operator's station harness. Repair or replace harness. See Operator's Station Harness
(W7) Wiring Diagram . (Group 9015-10.)

4 Reprogram Controller
Action:

Reprogram CAN monitor unit (CMU).

Check for active codes.

Is CMU code 000096.03 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_10

WS68074,0000B58-19-20070404

67
 000096.04 —Fuel Level Sensor Short to Ground
000096.04 —
Fuel Level Sensor Short to Ground

The fuel level sensor circuit has a short to ground.

Fuel Level Sensor Short to Ground Diagnostic Procedure

Alarm Level:

No Service Light

Launch Close Expand List Collapse List

1 Component Check
Action:

Turn key switch OFF.

Disconnect fuel level sensor (B19). See Engine Fuel System Component Location . (Group 9010-15.)

Check resistance across sensor.

Item Measurement Specification

Fuel Level Sensor (B19) Resistance 29—36 ohms at 100% Fill (full)
62—70 ohms at 75% Fill
99—107 ohms at 50% Fill
147—157 ohms at 25% Fill
240—250 ohms at 0% Fill (empty)
Is the fuel level sensor within specifications?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
NO:
Replace fuel level sensor.

2 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect fuel level sensor. See Engine Fuel System Component Location . (Group 9010-15.)

Disconnect CMU connector (X4). See Operator's Station Harness (W7) Component Location . (Group 9015-
10.)

Check for ground at pin N (wire Y01 YEL) on CMU connector (X4).

68
 000096.04 —Fuel Level Sensor Short to Ground
Check for ground at pin F (wire R10 BLK) on CMU connector (X4).

Is ground present?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Go to Reprogram Controller .
Action:

Disconnect connector (X21) from the transmission harness. See Transmission Harness (W11) Component
Location . (Group 9015-10.)

Check for ground at pin N (wire Y01 YEL) on CMU connector (X4).

Check for ground at pin F (wire R10 BLK) on CMU connector (X4).

Is ground present?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Short to ground in fuel tank harness. Repair or replace harness. See Transmission Harness (W11) Wiring
Diagram . (Group 9015-10.)
Action:

Disconnect connector (X17) from the transmission harness. See Operator's Station Harness (W7)
Component Location . (Group 9015-10.)

Check for ground at pin N (wire Y01 YEL) on CMU connector (X4).

Check for ground at pin F (wire R10 BLK) on CMU connector (X4).

Is ground present?

Record of Actual Results:

Result:
YES:
Short to ground in operator's station harness (W7). Repair or replace harness. See Operator's Station
Harness (W7) Wiring Diagram . (Group 9015-10.)
NO:
Short to ground in transmission harness (W11). Repair or replace harness. See Transmission Harness
69
 000096.04 —Fuel Level Sensor Short to Ground
(W11) Wiring Diagram . (Group 9015-10.)

3 Reprogram Controller
Action:

Reprogram CAN monitor unit (CMU).

Check for active codes.

Is CMU code 000096.04 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_10

WS68074,0000B59-19-20070307

70
 000107.03 —Engine Air Filter Restriction Indicator Switch Short to Power
000107.03 —
Engine Air Filter Restriction Indicator Switch Short to Power

The engine air filter restriction switch circuit has a short to power.

Engine Air Filter Restriction Indicator Switch Short to Power Diagnostic Procedure

Alarm Level:

No Service Light

Launch Close Expand List Collapse List

1 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect engine air filter restriction switch (B22). See Engine Harness (W10) Component Location .
(Group 9015-10.)

Disconnect and CMU connector (X5). See Operator's Station Harness (W7) Component Location . (Group
9015-10.)

Turn key switch ON.

Check for voltage at pin A (wire N01 YEL) on air filter restriction switch connector.

Is voltage present?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Go to Reprogram Controller .
Action:

Turn key switch OFF.

Disconnect connector (X19) from engine harness. See Transmission Harness (W11) Component Location .
(Group 9015-10.)

Turn key switch ON.

Check for voltage at pin A (wire N01 YEL) on transmission harness side of connector (X19).

Is voltage present?

Record of Actual Results:

71
 000107.03 —Engine Air Filter Restriction Indicator Switch Short to Power

Result:
YES:
Short circuit to power in engine harness (W10). Repair or replace harness. See Engine Harness (W10)
Wiring Diagram . (Group 9015-10.)
NO:
Go to next step in this check.
Action:

Turn key switch OFF.

Disconnect connector (X17) from operator's station harness. See Transmission Harness (W11) Component
Location . (Group 9015-10.)

Turn key switch ON.

Check for voltage at pin 7 (wire N01 YEL) on transmission harness side of connector (X17).

Is voltage present?

Record of Actual Results:

Result:
YES:
Short circuit to power in operator's station harness (W7). Repair or replace harness. See Operator's Station
Harness (W7) Wiring Diagram . (Group 9015-10.)
NO:
Short circuit to power in transmission harness (W11). Repair or replace harness. See Transmission Harness
(W11) Wiring Diagram . (Group 9015-10.)

2 Reprogram Controller
Action:

Reprogram CAN monitor unit (CMU).

Check for active codes.

Is CMU code 000107.03 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

72
000107.03 —Engine Air Filter Restriction Indicator Switch Short to Power

Go to Section_9001:Group_10

WS68074,0000B5A-19-20070307

73
 000107.04 —Engine Air Filter Restricted
000107.04 —
Engine Air Filter Restricted

The engine air filter is restricted.

Engine Air Filter Restricted Diagnostic Procedure

Alarm Level:

No Service Light

Launch Close Expand List Collapse List

1 Air Intake System Restriction Check

Action:

Check air filter for excessive debris or clogging.

Is debris clogging the air filter?

Record of Actual Results:

Result:
YES:
Replace air filter element. See Replace Air Filter Elements . (Operator's Manual.)
NO:
Go to Component Circuit Check .

2 Component Check

Action:

Turn key switch OFF.

Disconnect engine air filter switch (B22). See Engine Harness (W10) Component Location . (Group 9015-
10.)

Turn the key switch ON.

Check for active codes.

Is CMU code 000107.04 still present?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
NO:
Engine air filter restriction switch (B22) malfunction. Repair or replace switch. See Engine Harness (W10)

74
 000107.04 —Engine Air Filter Restricted
Component Location . (Group 9015-10.)

3 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect engine air filter restriction switch (B22). See Engine Harness (W10) Component Location .
(Group 9015-10.)

Disconnect CMU connector (X5). See Operator's Station Harness (W7) Component Location . (Group 9015-
10.)

Check for ground at pin E (wire N01 YEL) on CMU connector (X5).

Is ground present?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Go to Reprogram Controller .
Action:

Disconnect connector (X19). See Engine Harness (W10) Component Location . (Group 9015-10.)

Check for ground at pin E (wire N01 YEL) on CMU connector (X5).

Is ground present?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Short to ground in engine harness (W10). Repair or replace harness. See Engine Harness (W10) Wiring
Diagram . (Group 9015-10.)
Action:

Disconnect connector (X17). See Operator's Station Harness (W7) Component Location . (Group 9015-10.)

Check for ground at pin E (wire N01 YEL) on CMU connector (X5).

Is ground present?

Record of Actual Results:

75
 000107.04 —Engine Air Filter Restricted

Result:
YES:
Short to ground in operator's station harness (W7). Repair or replace harness. See Operator's Station
Harness (W7) Wiring Diagram . (Group 9015-10.)
NO:
Short to ground in transmission harness (W11). Repair or replace harness. See Transmission Harness
(W11) Wiring Diagram . (Group 9015-10.)

4 Reprogram Controller
Action:

Reprogram CAN monitor unit (CMU).

Check for active codes.

Is CMU code 000107.04 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_10

WS68074,0000B5B-19-20070404

76
 000177.03 —Transmission Oil Temperature Sensor Short to Power
000177.03 —
Transmission Oil Temperature Sensor Short to Power

The transmission oil temperature sensor circuit has a short to power.

Transmission Oil Temperature Sensor Short to Power Diagnostic Procedure

Alarm Level:

No Service Light

Launch Close Expand List Collapse List

1 Component Check
Action:

Turn key switch OFF.

Disconnect transmission oil temperature sensor (B21). See Transmission Harness (W11) Component
Location . (Group 9015-10.)

Check resistance across pins A and B on sensor.

Item Measurement Specification

Transmission Oil Temperature Sensor (B21) Resistance 90—108 kohms at -40°C (-40°F)
26—31 kohms at -20°C (-4°F)
8.7—10.2 kohms at 0°C (32°F)
3.3—3.8 kohms at 20°C (68°F)
1.4—1.6 kohms at 40°C (104°F)
648—708 ohms at 60°C (140°F)
317—350 ohms at 80°C (176°F)
170—186 ohms at 100°C (212°F)
97—105 ohms at 120°C (248°F)
Is the transmission oil temperature sensor within specifications?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
NO:
Transmission oil temperature sensor (B21) malfunction. Repair or replace sensor. See Transmission
Harness (W11) Component Location . (Group 9015-10.)

2 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect transmission oil temperature sensor (B21). See Transmission Harness (W11) Component

77
 000177.03 —Transmission Oil Temperature Sensor Short to Power
Location . (Group 9015-10.)

Disconnect CMU connector (X5). See Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)

Turn key switch ON.

Check for voltage at pin A (wire X01 YEL) on CMU connector (X5).

Is voltage present?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Go to Open Circuit Check .
Action:

Turn key switch OFF.

Disconnect connector (X17). See Transmission Harness (W11) Component Location . (Group 9015-10.)

Turn key switch ON.

Check for voltage at pin 5 (wire X01 YEL) on transmission harness side of connector (X17).

Is voltage present?

Record of Actual Results:

Result:
YES:
Short circuit to power in transmission harness (W11). Repair or replace harness. See Transmission Harness
(W11) Wiring Diagram . (Group 9015-10.)
NO:
Short circuit to power in operator's station harness (W7). Repair or replace harness. See Operator's Station
Harness (W7) Wiring Diagram . (Group 9015-10.)

3 Open Circuit Check

Action:

Turn key switch OFF.

Disconnect transmission oil temperature sensor (B21). See Transmission Harness (W11) Component
Location . (Group 9015-10.)

Check for ground at pin B (wire R12 BLK) on transmission oil temperature sensor connector.

Is ground present?

78
 000177.03 —Transmission Oil Temperature Sensor Short to Power

Record of Actual Results:

Result:
YES:
Go to Reprogram Controller .
NO:
Open circuit in transmission harness (W11). Repair or replace harness. See Transmission Harness (W11)
Wiring Diagram . (Group 9015-10.)

4 Reprogram Controller

Action:

Reprogram CAN monitor unit (CMU).

Check for active codes.

Is CMU code 000177.03 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_10

WS68074,0000B5C-19-20070307

79
 000177.04 —Transmission Oil Temperature Sensor Short to Ground
000177.04 —
Transmission Oil Temperature Sensor Short to Ground

The transmission oil temperature sensor circuit has a short to ground.

Transmission Oil Temperature Sensor Short to Ground Diagnostic Procedure

Alarm Level:

No Service Light

Launch Close Expand List Collapse List

1 Component Check
Action:

Turn key switch OFF.

Disconnect transmission oil temperature sensor (B21). See Transmission Harness (W11) Component
Location . (Group 9015-10.)

Check resistance across pins A and B on sensor.

Item Measurement Specification

Transmission Oil Temperature Sensor (B21) Resistance 90—108 kohms at -40°C (-40°F)
26—31 kohms at -20°C (-4°F)
8.7—10.2 kohms at 0°C (32°F)
3.3—3.8 kohms at 20°C (68°F)
1.4—1.6 kohms at 40°C (104°F)
648—708 ohms at 60°C (140°F)
317—350 ohms at 80°C (176°F)
170—186 ohms at 100°C (212°F)
97—105 ohms at 120°C (248°F)
Is the transmission oil temperature sensor within specifications?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
NO:
Transmission oil temperature sensor (B21) malfunction. Repair or replace sensor. See Transmission
Harness (W11) Component Location . (Group 9015-10.)

2 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect sensor (B21). See Transmission Harness (W11) Component Location . (9015-10.)

80
 000177.04 —Transmission Oil Temperature Sensor Short to Ground
Disconnect CMU connector (X5). See Operator's Station Harness (W7) Component Location . (Group 9015-
10.)

Check for ground at pin A (wire X01 YEL) on CMU connector (X5).

Is ground present?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Go to Reprogram Controller .
Action:

Disconnect connector (X17). See Operator's Station Harness (W7) Component Location . (Group 9015-10.)

Check for ground at pin A (wire X01 YEL) on CMU connector (X5).

Is ground present?

Record of Actual Results:

Result:
YES:
Short to ground in operator's station harness (W7). Repair or replace harness. See Operator's Station
Harness (W7) Wiring Diagram . (Group 9015-10.)
NO:
Short to ground in transmission harness (W11). Repair or replace harness. See Transmission Harness
(W11) Wiring Diagram . (Group 9015-10.)

3 Reprogram Controller

Action:

Reprogram CAN monitor unit (CMU).

Check for active codes.

Is CMU code 000177.04 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:

81
 000177.04 —Transmission Oil Temperature Sensor Short to Ground
Checks complete.

Go to Section_9001:Group_10

WS68074,0000B5D-19-20070307

82
 000177.16 —Transmission Oil Temperature High
000177.16 —
Transmission Oil Temperature High

Transmission oil temperature light turns on when the transmission oil temperature is above 99°C, 210°F. The light
shuts off when the temperature drops -15°C, 5°F below transmission high temperature for 5 seconds.

Transmission Oil Temperature High

Alarm Level:

Amber Warning Lamp On

Launch Close Expand List Collapse List

1 Check Service Codes

Action:

Is code 000177.16 set.

Record of Actual Results:

Result:
YES:
Perform Hydrostatic Oil Cooler Bypass Test . Group (9026-25.)

Clean hydrostatic oil cooler.

NO:
Check complete.

Go to Section_9001:Group_10

JW40272,0000003-19-20080811

83
 000609.09 —CAN Communication Error, No TCU Message
000609.09 —
CAN Communication Error, No TCU Message

The CAN monitor unit is not receiving a CAN message from the transmission control unit.

CAN Communication Error, No TCU Message Diagnostic Procedure

Alarm Level:

No Service Light

Launch Close Expand List Collapse List

1 Fuse Check
Action:

Turn key switch OFF.

Remove TCU fuse (F6). See Fuse and Relay Specifications . (Group 9015-15.)

Check continuity of fuse (F6).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to Voltage Check
NO:
Replace fuse (F6). See Fuse and Relay Specifications . (Group 9015-15.)

2 Voltage Check
Action:

Turn key switch OFF.

Disconnect TCU connector (X2). See Operator's Station Harness (W7) Component Location . (Group 9015-
10.)

Check for voltage at pin 18 (wire P03 RED) on TCU connector (X2).

Is system voltage (approximately 24 volts) present?

Record of Actual Results:

Result:
YES:
Go to CAN Circuit Check .

84
 000609.09 —CAN Communication Error, No TCU Message

NO:
Open circuit in operator's station harness (W7). Repair or replace harness. See Operator's Station Harness
(W7) Wiring Diagram . (Group 9015-10.)

3 CAN Circuit Check

Action:

Check CAN communication circuit. Perform CAN Circuit Test . (Group 9015-20.)

Is CAN circuit OK?

Record of Actual Results:

Result:
YES:
Go to Reprogram Controller .
NO:
CAN circuit wires short or open. Repair or replace harness. See Operator's Station Harness (W7) Wiring
Diagram . (Group 9015-10.)

4 Reprogram Controller

Action:

Reprogram CAN monitor unit (CMU).

Check for active codes.

Is CMU code 000609.09 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_10

WS68074,0000B5E-19-20070307

85
 001638.00 —Hydraulic Oil Temperature High
001638.00 —
Hydraulic Oil Temperature High

The hydraulic oil temperature is too high.

Hydraulic Oil Temperature High Diagnostic Procedure

Alarm Level:

No Service Light

Launch Close Expand List Collapse List

1 Hydraulic Oil Temperature Sensor Check

Action:

Turn key switch OFF.

Disconnect hydraulic oil temperature sensor (B20). See Transmission Harness (W11) Component Location .
(Group 9015-10.)

Check resistance across pins A and B on sensor.

Item Measurement Specification

Hydraulic Oil Temperature Sensor (B20) Resistance 90—108 kohms at -40°C (-40°F)
26—31 kohms at -20°C (-4°F)
8.7—10.2 kohms at 0°C (32°F)
3.3—3.8 kohms at 20°C (68°F)
1.4—1.6 kohms at 40°C (104°F)
648—708 ohms at 60°C (140°F)
317—350 ohms at 80°C (176°F)
170—186 ohms at 100°C (212°F)
97—105 ohms at 120°C (248°F)
Is sensor within specifications?

Record of Actual Results:

Result:
YES:
Go to Hydraulic System Diagnose Malfunctions . (Group 9025-15.)
NO:
Hydraulic oil temperature sensor (B20) malfunction. Repair or replace sensor. See Transmission Harness
(W11) Component Location . (Group 9015-10.)

Go to Section_9001:Group_10

WS68074,0000B60-19-20070305

86
 001638.03 —Hydraulic Oil Temperature Short to Power
001638.03 —
Hydraulic Oil Temperature Short to Power

The hydraulic oil temperature sensor circuit has a short to power.

Hydraulic Oil Temperature Short to Power Diagnostic Procedure

Alarm Level:

No Service Light

Launch Close Expand List Collapse List

1 Component Check
Action:

Turn key switch OFF.

Disconnect hydraulic oil temperature sensor (B21). See Transmission Harness (W11) Component Location .
(Group 9015-10.)

Check resistance across pins A and B on sensor.

Item Measurement Specification

Hydraulic Oil Temperature Sensor (B20) Resistance 90—108 kohms at -40°C (-40°F)
26—31 kohms at -20°C (-4°F)
8.7—10.2 kohms at 0°C (32°F)
3.3—3.8 kohms at 20°C (68°F)
1.4—1.6 kohms at 40°C (104°F)
648—708 ohms at 60°C (140°F)
317—350 ohms at 80°C (176°F)
170—186 ohms at 100°C (212°F)
97—105 ohms at 120°C (248°F)
Is sensor within specifications?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
NO:
Hydraulic oil temperature sensor (B20) malfunction. Repair or replace sensor. See Transmission Harness
(W11) Component Location . (Group 9015-10.)

2 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect hydraulic oil temperature sensor (B20). See Transmission Harness (W11) Component Location .

87
 001638.03 —Hydraulic Oil Temperature Short to Power
(Group 9015-10.)

Disconnect CMU connector (X5). See Operator's Station Harness (W7) Component Location . (Group 9015-
10.)

Check for voltage at pin A (wire X02 YEL) on hydraulic oil temperature sensor connector.

Is voltage present?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Go to Open Circuit Check .
Action:

Disconnect connector (X17) from operator's station harness. See Transmission Harness (W11) Component
Location . (Group 9015-10.)

Check for voltage at pin 12 (wire X02 YEL) on transmission harness side of connector (X17).

Is voltage present.

Record of Actual Results:

Result:
YES:
Short circuit to power in transmission harness (W11). Repair or replace harness. See Transmission Harness
(W11) Wiring Diagram . (Group 9015-10.)
NO:
Short circuit to power in operator's station harness (W7). Repair or replace harness. See Operator's Station
Harness (W7) Wiring Diagram . (Group 9015-10.)

3 Open Circuit Check

Action:

Turn key switch OFF.

Disconnect hydraulic oil temperature sensor (B20). See Transmission Harness (W11) Component Location .
(Group 9015-10.)

Check for ground at pin B (wire R12 BLK) on hydraulic oil temperature sensor connector.

Is ground present?

Record of Actual Results:

88
 001638.03 —Hydraulic Oil Temperature Short to Power

Result:
YES:
Go to Reprogram Controller .
NO:
Open circuit in transmission harness (W11). Repair or replace harness. See Transmission Harness (W11)
Wiring Diagram . (Group 9015-10.)

4 Reprogram Controller

Action:

Reprogram CAN monitor unit (CMU).

Check for active codes.

Is CMU code 001638.03 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_10

WS68074,0000B61-19-20070307

89
 001638.04 —Hydraulic Oil Temperature Short to Ground
001638.04 —
Hydraulic Oil Temperature Short to Ground

The hydraulic oil temperature sensor circuit has a short to ground.

Hydraulic Oil Temperature Short to Ground Diagnostic Procedure

Alarm Level:

No Service Light

Launch Close Expand List Collapse List

1 Component Check
Action:

Turn key switch OFF.

Disconnect hydraulic oil temperature sensor (B20). See Transmission Harness (W11) Component Location .
(Group 9015-10.)

Check resistance across pins A and B on sensor.

Item Measurement Specification

Hydraulic Oil Temperature Sensor (B20) Resistance 90—108 kohms at -40°C (-40°F)
26—31 kohms at -20°C (-4°F)
8.7—10.2 kohms at 0°C (32°F)
3.3—3.8 kohms at 20°C (68°F)
1.4—1.6 kohms at 40°C (104°F)
648—708 ohms at 60°C (140°F)
317—350 ohms at 80°C (176°F)
170—186 ohms at 100°C (212°F)
97—105 ohms at 120°C (248°F)
Is sensor within specifications?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
NO:
Hydraulic oil temperature sensor (B20) malfunction. Repair or replace sensor. See Transmission Harness
(W11) Component Location . (Group 9015-10.)

2 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect hydraulic temperature sensor (B20). See Transmission Harness (W11) Component Location .

90
 001638.04 —Hydraulic Oil Temperature Short to Ground
(Group 9015-10.)

Disconnect CMU connector (X5). See Operator's Station Harness (W7) Component Location . (Group 9015-
10.)

Check for ground at pin A (wire X02 YEL) on sensor connector.

Is ground present?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Go to Reprogram Controller .
Action:

Disconnect connector (X17). See Transmission Harness (W11) Component Location . (Group 9015-10.)

Check for ground at pin 12 (wire X02 YEL) on transmission harness side of connector (X17).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Short to ground in transmission harness (W11). Repair or replace harness. See Transmission Harness
(W11) Wiring Diagram . (Group 9015-10.)
NO:
Short to ground in operator's station harness (W7). Repair or replace harness. See Operator's Station
Harness (W7) Wiring Diagram . (Group 9015-10.)

3 Reprogram Controller

Action:

Reprogram CAN monitor unit (CMU).

Check for active codes.

Is CMU code 001683.04 present?

Record of Actual Results:

Result:
YES:
Replace controller.
91
 001638.04 —Hydraulic Oil Temperature Short to Ground

NO:
Checks complete.

Go to Section_9001:Group_10

WS68074,0000B62-19-20070307

92
 1713.31 —Hydraulic Oil Filter Restricted
1713.31 —
Hydraulic Oil Filter Restricted

Hydraulic Oil Filter Restricted

1 Hydraulic Oil Filter Restricted Diagnostic Procedure

Alarm Level:

Hydraulic Oil Filter Icon Illuminated

Launch Close Expand List Collapse List

1A Hydraulic Oil Filter Operational Check

Action:

Start engine and operate at slow idle, observe indicator, then increase speed to fast idle.

Is hydraulic oil indicator light on only at fast idle speed?

Record of Actual Results:

Result:
YES:
Cold oil or plugged filter will cause light to come on at fast idle only. If oil is at operating temperature replace
filter. See Change Hydrostatic Transmission Oil and Replace Hydrostatic Charge and Fan Oil Filters .
(Operator's Manual.)
NO:
Go to Oil Filter Restriction Switch Check .

1B Oil Filter Restriction Switch Check

Action:

Disconnect hydrostatic charge oil filter restriction switch (B23). See Transmission Harness (W11)
Component Location . (Group 9015-10.)

Ground (B23) switch wire to equipment frame.

Turn key switch ON.

Check for active codes.

Is CMU code 001713.31 still present?

Record of Actual Results:

Result:
YES:
Go to Open Circuit Check.

93
 1713.31 —Hydraulic Oil Filter Restricted

NO:
Hydrostatic charge oil filter restriction switch (B23) malfunction. Repair or replace switch. See Transmission
Harness (W11) Wiring Diagram . (Group 9015-10.)

1C Open Circuit Check

Action:

Turn key switch OFF.

Disconnect hydrostatic charge oil filter restriction switch (B23) from equipment frame ground.

Disconnect CMU connector (X5). See Operator's Station Harness (W7) Component Location . (Group 9015-
10.)

Check for open between hydraulic oil filter restriction switch connector (wire N02 YEL) and (X5) pin F.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Circuit is OK, Go to Reprogram Controller .
NO:
Go to Open Circuit Check—Operator's Station Harness .

1D Open Circuit Check—Operator's Station Harness

Action:

Disconnect connector (X17). See Operator's Station Harness (W7) Component Location . (Group 9015-10.)

Check for open between (X5) pin F. on operators station harness side of connector (X17) pin 8.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Operators station harness is OK, go to Open Circuit Check—Transmission Harness.
NO:
Open in operators station harness (W7). Repair or replace harness or connectors. See Operator's Station
Harness (W7) Wiring Diagram . (Group 9015-10.)

1E Open Circuit Check—Transmission Harness

Action:

Check for open between (B23) wire N02 YEL and transmission harness side of connector (X17) pin 8. See
94
 1713.31 —Hydraulic Oil Filter Restricted
Check for open between (B23) wire N02 YEL and transmission harness side of connector (X17) pin 8. See
Transmission Harness (W11) Component Location . (Group 9015-10.)

Is continuity measured?

Record of Actual Results:

Result:
YES:
Transmission harness is OK, go to next check.
NO:
Open in transmission harness (W11). Repair or replace harness or connector. See Transmission Harness
(W11) Wiring Diagram . (Group 9015-10.)

1F Open Circuit Check—Connector

Action:

Check for open in connector (X17) pin 8.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Connector is OK, Go to Reprogram Controller .
NO:
Repair or replace connector.

1G Reprogram Controller
Action:

Reprogram CAN monitor unit (CMU).

Check for active codes.

Is CMU code 001713.311 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

95
1713.31 —Hydraulic Oil Filter Restricted

Go to Section_9001:Group_10

CS33148,000097A-19-20060525

96
 002000.09 —CAN Communication Error, No ECU Configuration
002000.09 —
CAN Communication Error, No ECU Configuration

The CAN monitor unit is not receiving engine control unit configuration.

CAN Communication Error, No ECU Configuration Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Software Check
Action:

Observe the ECU software version and hardware by accessing the Machine Settings / Controller Info / ECU
menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group
9015-20.)

Is correct ECU information present?

Record of Actual Results:

Result:
YES:
Go to Reprogram Controller .
NO:
Perform CAN Circuit Test . (Group 9015-20.)

2 Reprogram Controller

Action:

Reprogram CAN monitor unit (CMU).

Check for active codes.

Is CMU code 002000.09 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

97
002000.09 —CAN Communication Error, No ECU Configuration

Go to Section_9001:Group_10

WS68074,0000B65-19-20070305

98
 003156.09 —CAN Blade Mode Missing From EHC
003156.09 —
CAN Blade Mode Missing From EHC

The CAN blade mode is missing from electrohydraulic controller (EHC).

CAN Blade Mode Missing From EHC Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Function Check
Action:

Operate blade functions in manual and auto mode.

Do blade functions operate?

Record of Actual Results:

Result:
YES:
Go to Blade Control Joystick (BCJ) Check .
NO:
Go to Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped . (Group 9015-20.)

2 Blade Control Joystick (BCJ) Check

Action:

Observe the joystick's 4-way axis movement as a percentage by accessing the Diagnostic / Live Values /
Performance menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service
Mode . (Group 9015-20.)

Slowly move the joystick handle through complete range in all four axes.

Do the joystick values in the CMU menu correspond with the joystick movements?

Record of Actual Results:

Result:
YES:
Go to Electrohydraulic Controller (EHC) Check .
NO:
Perform CAN Circuit Test .

3 Electrohydraulic Controller (EHC) Check

99
 003156.09 —CAN Blade Mode Missing From EHC

Action:

Start engine.

Observe the blade functions by accessing the Diagnostic / Live Values / Blade Angle and Blade Icr/Dcr menu
in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-
20.)

Is EHC blade information displayed?

Record of Actual Results:

Result:
YES:
Go to Reprogram Controller .
NO:
Perform CAN Circuit Test

4 Reprogram Controller
Action:

Reprogram CAN monitor unit (CMU).

Check for active codes.

Is CMU code 003156.09 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_10

WS68074,0000B66-19-20070404

100
 3359.31 —Transmission Oil Filter Restricted
3359.31 —
Transmission Oil Filter Restricted

The hydrostatic charge oil filter is restricted.

Transmission Oil Filter Restricted Diagnostic Procedure

Alarm Level:

Trans Oil Charge Filter Icon Illuminated

Launch Close Expand List Collapse List

1 Transmission Oil Filter Operational Check

Action:

Start engine and operate at slow idle, observe indicator, then increase speed to fast idle.

Is transmission oil indicator light on only at fast idle speed?

Record of Actual Results:

Result:
YES:
Cold oil or plugged filter will cause light to come on at fast idle only. If oil is at operating temperature replace
filter. See Change Hydrostatic Transmission Oil and Replace Hydrostatic Charge and Fan Oil Filters .
(Operator's Manual.)
NO:
Go to Oil Filter Restriction Switch Check .

2 Oil Filter Restriction Switch Check

Action:

Disconnect hydrostatic charge oil filter restriction switch (B25). See Transmission Harness (W11)
Component Location . (Group 9015-10.)

Ground (B25) switch wire to equipment frame.

Turn key switch ON.

Check for active codes.

Is CMU code 003359.31 still present?

Record of Actual Results:

Result:
YES:
Go to Open Circuit Check.

101
 3359.31 —Transmission Oil Filter Restricted

NO:
Hydrostatic charge oil filter restriction switch (B25) malfunction. Repair or replace switch. See Transmission
Harness (W11) Wiring Diagram . (Group 9015-10.)

3 Open Circuit Check

Action:

Turn key switch OFF.

Disconnect hydrostatic charge oil filter restriction switch (B25) from equipment frame ground.

Disconnect CMU connector (X5). See Operator's Station Harness (W7) Component Location . (Group 9015-
10.)

Check for open between hydrostatic charge oil filter restriction switch connector (wire N05 YEL) and (X5) pin
J.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Circuit is OK, Go to Reprogram Controller .
NO:
Go to Open Circuit Check—Operator's Station Harness .

4 Open Circuit Check—Operator's Station Harness

Action:

Disconnect connector (X17). See Operator's Station Harness (W7) Component Location . (Group 9015-10.)

Check for open between (X5) pin J. on operators station harness side of connector (X17) pin 11.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Operators station harness is OK, go to Open Circuit Check—Transmission Harness.
NO:
Open in operators station harness (W7). Repair or replace harness or connectors. See Operator's Station
Harness (W7) Wiring Diagram . (Group 9015-10.)

5 Open Circuit Check—Transmission Harness

Action:
102
 3359.31 —Transmission Oil Filter Restricted

Check for open between (B25) wire N05 YEL and transmission harness side of connector (X17) pin 11. See
Transmission Harness (W11) Component Location . (Group 9015-10.)

Is continuity measured?

Record of Actual Results:

Result:
YES:
Transmission harness is OK, go to next check.
NO:
Open in transmission harness (W11). Repair or replace harness or connector. See Transmission Harness
(W11) Wiring Diagram . (Group 9015-10.)

6 Open Circuit Check—Connector

Action:

Check for open in connector (X17) pin 11.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Connector is OK, Go to Reprogram Controller .
NO:
Repair or replace connector.

7 Reprogram Controller

Action:

Reprogram CAN monitor unit (CMU).

Check for active codes.

Is CMU code 003359.31 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

103
3359.31 —Transmission Oil Filter Restricted

Go to Section_9001:Group_10

LW86157,0000121-19-20090526

104
 524227.31 —Fan Oil Filter Restricted
524227.31 —
Fan Oil Filter Restricted

The hydraulic fan oil filter is restricted.

Fan Oil Filter Restricted Diagnostic Procedure

Alarm Level:

Hydraulic fan Oil Filter Icon Illuminated

Launch Close Expand List Collapse List

1 Fan Oil Filter Check

Action:

Clear codes.

Start engine and run at fast idle.

Press reverse fan switch and make fan spin at maximum speed.

Does hydraulic fan indicator light come on at maximum speed?

Record of Actual Results:

Result:
YES:
Cold oil or plugged filter will cause indicator to come on at maximum speed only. If oil is at operating
temperature replace filter. Replace filter. See Change Hydrostatic Transmission Oil and Replace Hydrostatic
Charge and Fan Oil Filters . (Operator's Manual.)
NO:
If after replacing filter code is still present, go Oil Filter Restriction Switch Check.

2 Oil Filter Restriction Switch Check

Action:

Disconnect hydraulic fan oil filter restriction switch (B24). See Transmission Harness (W11) Component
Location . (Group 9015-10.)

Ground (B24) switch wire to equipment frame.

Turn key switch ON.

Check for active codes.

Is CMU code 524227.31 still present?

Record of Actual Results:

105
 524227.31 —Fan Oil Filter Restricted

Result:
YES:
Go to Open Circuit Check.
NO:
Hydrostatic charge oil filter restriction switch (B24) malfunction. Repair or replace switch. See Transmission
Harness (W11) Wiring Diagram . (Group 9015-10.)

3 Open Circuit Check

Action:

Turn key switch OFF.

Disconnect hydraulic fan oil filter restriction switch (B24) from equipment frame ground.

Disconnect CMU connector (X5). See Operator's Station Harness (W7) Component Location . (Group 9015-
10.)

Check for open between hydraulic fan oil filter restriction switch connector (wire N03 YEL) and (X5) pin G.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Circuit is OK, Go to Reprogram Controller .
NO:
Go to Open Circuit Check—Operator's Station Harness .

4 Open Circuit Check—Operator's Station Harness

Action:

Disconnect connector (X17). See Operator's Station Harness (W7) Component Location . (Group 9015-10.)

Check for open between (X5) pin G. on operators station harness side of connector (X17) pin 9.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Operators station harness is OK, go to Open Circuit Check—Transmission Harness.
NO:
Open in operators station harness (W7). Repair or replace harness or connectors. See Operator's Station
Harness (W7) Wiring Diagram . (Group 9015-10.)

106
 524227.31 —Fan Oil Filter Restricted

5 Open Circuit Check—Transmission Harness

Action:

Check for open between (B24) wire N03 YEL and transmission harness side of connector (X17) pin 9. See
Transmission Harness (W11) Component Location . (Group 9015-10.)

Is continuity measured?

Record of Actual Results:

Result:
YES:
Transmission harness is OK, go to next check.
NO:
Open in transmission harness (W11). Repair or replace harness or connector. See Transmission Harness
(W11) Wiring Diagram . (Group 9015-10.)

6 Open Circuit Check—Connector

Action:

Check for open in connector (X17) pin 9.

Is continuity measured?

Record of Actual Results:

Result:
YES:
Connector is OK, Go to Reprogram Controller .
NO:
Repair or replace connector.

7 Reprogram Controller

Action:

Reprogram CAN monitor unit (CMU).

Check for active codes.

Is CMU code 524227.31 present?

Record of Actual Results:

Result:
YES:

107
 524227.31 —Fan Oil Filter Restricted
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_10

LW86157,0000120-19-20090526

108
 Engine Control Unit (ECU) Diagnostic Trouble Codes

Engine Control Unit (ECU) Diagnostic Trouble Codes

The diagnostic trouble code number is indicated by a Suspect Parameter Number (SPN) and a Failure Mode
Indicator (FMI) number. In the example 000091.09 , 91 is the SPN and 09 is the FMI number.

To view diagnostic trouble codes, use one of the following methods:

Service ADVISOR™ system. See Reading Diagnostic Trouble Codes with Service ADVISOR™
Diagnostic Application . (Group 9015-20.)
CAN Monitor Unit (CMU). See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-
20.)

M44215-UN: Engine Component Technical Manuals

For additional information on John Deere engines and components, see the following engine component technical
manuals (CTMs).

POWERTECH™ 4.5L and 6.8L Diesel Engines Base Engine . (CTM104.)

POWERTECH E™ 4.5L and 6.8L Diesel Engines Level 16 Electronic Fuel System with Denso HPCR .
(CTM502.)

Go to Section_9001:Group_20

AA95137,00007F0-19-20080314

109
 Engine Control Unit (ECU) Diagnostic Trouble Codes

Engine Control Unit (ECU) Diagnostic Trouble Codes

The diagnostic trouble code number is indicated by a Suspect Parameter Number (SPN) and a Failure Mode
Indicator (FMI) number. In the example 000091.09 , 91 is the SPN and 09 is the FMI number.

To view diagnostic trouble codes, use one of the following methods:

Service ADVISOR™ system. See Reading Diagnostic Trouble Codes with Service ADVISOR™
Diagnostic Application . (Group 9015-20.)
CAN Monitor Unit (CMU). See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-
20.)

M44215-UN: Engine Component Technical Manuals

For additional information on John Deere engines and components, see the following engine component technical
manuals (CTMs).

POWERTECH™ 4.5L and 6.8L Diesel Engines Base Engine . (CTM104.)

POWERTECH E™ 4.5L and 6.8L Diesel Engines Level 16 Electronic Fuel System with Denso HPCR .
(CTM502.)

Go to Section_9001:Group_20

AA95137,00007F0-19-20080314

110
 000091.09 —CAN Throttle Missing from TCU
000091.09 —
CAN Throttle Missing from TCU

The engine control unit (ECU) is not receiving an engine speed control signal from the transmission control unit
(TCU).

CAN Throttle Missing from TCU Diagnostic Procedure

Launch Close Expand List Collapse List

1 Voltage Check
Action:

Observe the input voltage from engine speed control (R10) by accessing the Diagnostic / Live Values / Input
Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode .
(Group 9015-20.)

Does voltage vary with respect to the engine speed control movement?

Record of Actual Results:

Result:
YES:
Go to Reprogram Controller .
NO:
Go to Code Check .

2 Code Check

Action:

Check for active codes.

Are any transmission control unit (TCU) codes present?

Record of Actual Results:

Result:
YES:
Correct any TCU codes.
NO:
Go to CAN Circuit Check .

3 CAN Circuit Check

Action:

Check CAN circuit. Perform CAN Circuit Test . (Group 9015-20.)

Is CAN circuit OK?

111
 000091.09 —CAN Throttle Missing from TCU

Record of Actual Results:

Result:
YES:
Go to Reprogram Controller .
NO:
Repair or replace harness. See Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)

4 Reprogram Controller
Action:

Reprogram engine control unit (ECU).

Check for active codes.

Is ECU code 000091.09 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_20

AA95137,00007F1-19-20070405

112
 000091.14 —Throttle Voltage Out of Range
000091.14 —
Throttle Voltage Out of Range

The engine speed control signal from the transmission control unit (TCU) is invalid.

Throttle Voltage Out of Range

Launch Close Expand List Collapse List

1 Voltage Check

Action:

Observe the input voltage from engine speed control (R10) by accessing the Diagnostic / Live Values / Input
Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode .
(Group 9015-20.)

Does voltage vary with respect to the engine speed control movement?

Record of Actual Results:

Result:
YES:
Go to Reprogram Controller .
NO:
Go to Code Check .

2 Code Check

Action:

Check for active codes.

Are any transmission control unit (TCU) codes present?

Record of Actual Results:

Result:
YES:
Correct any TCU codes.
NO:
Go to CAN Circuit Check .

3 CAN Circuit Check

Action:

Check CAN circuit. Perform CAN Circuit Test . (Group 9015-20.)

Is CAN circuit OK?

Record of Actual Results:

113
 000091.14 —Throttle Voltage Out of Range

Result:
YES:
Go to Reprogram Controller .
NO:
Repair or replace harness. See Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)

4 Reprogram Controller
Action:

Reprogram engine control unit (ECU).

Check for active codes.

Is ECU code 000091.14 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_20

AA95137,00007F2-19-20070605

114
 000100.01 —Engine Oil Pressure Signal Extremely Low
000100.01 —
Engine Oil Pressure Signal Extremely Low

The engine oil pressure is extremely low.

Engine Oil Pressure Diagnostic Procedure

Launch Close Expand List Collapse List

1 Engine Oil Level Check

Action:

Check engine oil. See Check Engine Oil Level . (Operator's Manual.)

Is engine oil level low?

Record of Actual Results:

Result:
YES:
Add engine oil. See Diesel Engine Oil . (Operator's Manual.)
NO:
Go to Engine Oil Pressure Check .

2 Engine Oil Pressure Check

Action:

Check oil pressure. See Check Engine Oil Pressure . (CTM104.)

Is oil pressure below specification?

Record of Actual Results:

Result:
YES:
See 4.5L/6.8L - L2 - Engine Oil Pressure Low . (CTM104.)
NO:
Go to Open Circuit Check .

3 Open Circuit Check

Action:

Turn key switch OFF.

Disconnect engine oil pressure sensor (B17) and ECU connector (X10). See Engine Harness (W10)
Component Location . (Group 9015-10.)

Check wire N06 YEL for continuity between pin C on sensor connector and pin A3 on ECU connector (X10).

115
 000100.01 —Engine Oil Pressure Signal Extremely Low
Check wire P26 RED for continuity between pin B on the sensor connector and pin F3 on ECU connector
(X10).

Check wire R15 BLK for continuity between pin A on the sensor connector and pin D2 on ECU connector
(X10).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Engine oil pressure sensor (B17) malfunction. Repair or replace sensor. See Engine Harness (W10)
Component Location . (Group 9015-10.)
NO:
Open circuit in harness. Repair or replace harness. See Engine Harness (W10) Wiring Diagram . (Group
9015-10.)

Go to Section_9001:Group_20

AA95137,000081A-19-20070605

116
 000100.03 —Eng Oil Press Short to Power
000100.03 —
Eng Oil Press Short to Power

The engine oil pressure sensor circuit has a short to power.

Engine Oil Pressure Sensor Diagnostic Procedure

Launch Close Expand List Collapse List

1 Component Check

Action:

Turn key switch OFF.

Disconnect engine oil pressure sensor (B17). See Engine Harness (W10) Component Location . (Group
9015-10.)

Turn key switch ON.

Check for active codes.

Is ECU code 000100.03 still present?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
NO:
Engine oil pressure sensor (B17) malfunction. Repair or replace sensor.

2 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect engine oil pressure sensor (B17) and ECU connector (X10). See Engine Harness (W10)
Component Location . (Group 9015-10.)

Turn key switch ON.

Check for voltage at pin C (wire N06 YEL) on sensor connector.

Is voltage present?

Record of Actual Results:

Result:
YES:
Short to power in harness. Repair or replace. See Engine Harness (W10) Wiring Diagram . (Group 9015-10.)

117
 000100.03 —Eng Oil Press Short to Power

NO:
Go to Reprogram Controller .

3 Reprogram Controller
Action:

Reprogram engine control unit (ECU).

Check for active codes.

Is ECU code 000100.03 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_20

AA95137,000081B-19-20070307

118
 000100.04 —Engine Oil Pressure Signal Out of Range Low
000100.04 —
Engine Oil Pressure Signal Out of Range Low

The engine oil pressure sensor circuit has an open or short to ground.

Engine Oil Pressure Sensor Diagnostic Procedure

Launch Close Expand List Collapse List

1 Open Circuit Check

Action:

Turn key switch OFF.

Disconnect engine oil pressure sensor connector and ECU connector (X10). See Engine Harness (W10)
Component Location . (Group 9015-10.)

Check for wire N06 YEL for continuity between pin C on sensor connector and pin A3 on ECU connector
(X10).

Check for wire P26 RED for continuity between pin B on sensor connector and pin F3 on ECU connector
(X10).

Check for wire R15 BLK for continuity between pin A on sensor connector and pin D2 on ECU connector
(X10).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
NO:
Open circuit in harness. Repair or replace harness. See Engine Harness (W10) Wiring Diagram . (Group
9015-10.)

2 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect engine oil pressure sensor (B17). See Engine Harness (W10) Component Location . (Group
9015-10.)

Turn key switch ON.

Check for voltage at pin B (wire P26 RED) on sensor connector.

Are more than 4 volts present?

Record of Actual Results:

119
 000100.04 —Engine Oil Pressure Signal Out of Range Low

Result:
YES:
Go to next step in this check.
NO:
Short to ground in harness. Repair or replace engine harness. See Engine Harness (W10) Wiring Diagram .
(Group 9015-10.)
Action:

Turn key switch OFF.

Disconnect ECU connector (X10). See Engine Harness (W10) Component Location . (Group 9015-10.)

Check for ground at pin C (wire N06 YEL) on sensor connector.

Is ground present?

Record of Actual Results:

Result:
YES:
Short to ground in harness. Repair or replace engine harness. See Engine Harness (W10) Wiring Diagram .
(Group 9015-10.)
NO:
Go to Component Check .

3 Component Check
Action:

Turn key switch OFF.

Disconnect engine oil pressure sensor (B17). See Engine Harness (W10) Component Location . (Group
9015-10.)

Install a jumper wire between pins B and C on sensor connector.

Observe the input voltage of the oil pressure sensor by accessing the Diagnostic / Live Values / Input
Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode .
(Group 9015-20.)

Is voltage below 4.95 volts?

Record of Actual Results:

Result:
YES:
Go to Reprogram Controller .
NO:
120
 000100.04 —Engine Oil Pressure Signal Out of Range Low
Engine oil pressure sensor (B17) malfunction. Repair or replace sensor.

4 Reprogram Controller
Action:

Reprogram engine control unit (ECU).

Check for active codes.

Is ECU code 000100.04 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_20

AA95137,000081C-19-20070605

121
 000171.03 —Ambient Air Temp Open or Short
000171.03 —
Ambient Air Temp Open or Short

The ambient air temperature sensor circuit has an open or short to power.

Ambient Air Temperature Sensor Diagnostic Procedure

Launch Close Expand List Collapse List

1 Component Check

Action:

Turn key switch OFF.

Disconnect ambient air temperature sensor (B16). See Engine Harness (W10) Component Location . (Group
9015-10.)

Measure resistance of sensor.

Item Measurement Specification

Ambient Air Temperature Sensor (B16) Resistance 90—108 kohms at -40°C (-40°F)
26—31 kohms at -20°C (-4°F)
8.7—10.2 kohms at 0°C (32°F)
3.3—3.8 kohms at 20°C (68°F)
1.4—1.6 kohms at 40°C (104°F)
648—708 ohms at 60°C (140°F)
317—350 ohms at 80°C (176°F)
170—186 ohms at 100°C (212°F)
97—105 ohms at 120°C (248°F)
Is sensor within specifications?

Record of Actual Results:

Result:
YES:
Go to Open Circuit Check .
NO:
Ambient air temperature sensor (B16) malfunction. Repair or replace sensor. See Engine Harness (W10)
Component Location . (Group 9015-10.)

2 Open Circuit Check

Action:

Turn key switch OFF.

Disconnect ambient air temperature sensor (B16) and ECU connector (X3). See Engine Harness (W10)
Component Location . (Group 9015-10.)

Check wire X06 YEL for continuity between pin A on sensor connector and pin G4 on ECU connector (X3).

Check wire R14 BLK for continuity between pin B on sensor connector and pin C3 on ECU connector (X3).

122
 000171.03 —Ambient Air Temp Open or Short
Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
NO:
Open circuit in harness. Repair or replace engine harness. See Engine Harness (W10) Wiring Diagram .
(Group 9015-10.)

3 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect ambient air temperature sensor (B16) and ECU connector (X3). See Engine Harness (W10)
Component Location . (Group 9015-10.)

Turn key switch ON.

Check for voltage at pin A (wire X06 YEL) on sensor connector.

Check for voltage at pin B (wire R14 BLK) on sensor connector.

Is voltage present?

Record of Actual Results:

Result:
YES:
Short to power in harness. Repair or replace engine harness. See Engine Harness (W10) Wiring Diagram .
(Group 9015-10.)
NO:
Go to Reprogram Controller .

4 Reprogram Controller

Action:

Reprogram engine control unit (ECU).

Check for active codes.

Is ECU code 000171.03 present?

Record of Actual Results:

123
 000171.03 —Ambient Air Temp Open or Short

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_20

AA95137,000081D-19-20070307

124
 000171.04 —Ambient Air Temp Short to Gnd
000171.04 —
Ambient Air Temp Short to Gnd

The ambient air temperature sensor circuit has a short to ground.

Ambient Air Temperature Sensor Diagnostic Procedure

Launch Close Expand List Collapse List

1 Component Check

Action:

Turn key switch OFF.

Disconnect ambient air temperature sensor (B16). See Engine Harness (W10) Component Location . (Group
9015-10.)

Measure resistance of sensor.

Item Measurement Specification

Ambient Air Temperature Sensor (B16) Resistance 90—108 kohms at -40°C (-40°F)
26—31 kohms at -20°C (-4°F)
8.7—10.2 kohms at 0°C (32°F)
3.3—3.8 kohms at 20°C (68°F)
1.4—1.6 kohms at 40°C (104°F)
648—708 ohms at 60°C (140°F)
317—350 ohms at 80°C (176°F)
170—186 ohms at 100°C (212°F)
97—105 ohms at 120°C (248°F)
Is sensor within specifications?

Record of Actual Results:

Result:
YES:
Go to Open Circuit Check .
NO:
Ambient air temperature sensor (B16) malfunction. Repair or replace sensor.

2 Open Circuit Check

Action:

Disconnect ambient air temperature sensor (B16) and ECU connector (X3). See Engine Harness (W10)
Component Location . (Group 9015-10.)

Check wire X06 YEL for continuity between pin A on sensor connector and pin G4 on ECU connector (X3).

Check wire R14 BLK for continuity between pin B on sensor connector and pin C3 on ECU connector (X3).

Is continuity indicated?

125
 000171.04 —Ambient Air Temp Short to Gnd

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
NO:
Open circuit in harness. Repair or replace engine harness. See Engine Harness (W10) Wiring Diagram .
(Group 9015-10.)

3 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect ambient air temperature sensor (B16) and ECU connector (X3). See Engine Harness (W10)
Component Location . (Group 9015-10.)

Check for ground at pin A (wire X06 YEL) on sensor connector.

Check for ground at pin B (wire R14 BLK) on sensor connector.

Is ground present?

Record of Actual Results:

Result:
YES:
Short to ground in harness. Repair or replace engine harness. See Engine Harness (W10) Wiring Diagram .
(Group 9015-10.)
NO:
Go to Reprogram Controller .

4 Reprogram Controller
Action:

Reprogram engine control unit (ECU).

Check for active codes.

Is ECU code 000171.04 present?

Record of Actual Results:

Result:
YES:
Replace controller.

126
 000171.04 —Ambient Air Temp Short to Gnd

NO:
Checks complete.

Go to Section_9001:Group_20

AA95137,000081E-19-20070307

127
 000627.01 —Injector Current Incorrect
000627.01 —
Injector Current Incorrect

The initial injector pull in current is too low or the hold current is incorrect.

Injector Current Incorrect Diagnostic Procedure

Launch Close Expand List Collapse List

1 Charging System Check

Action:

Check alternator output. See Alternator Test . (Group 9015-20.)

Does alternator test good?

Record of Actual Results:

Result:
YES:
Go to Battery Check .
NO:
Replace alternator.

2 Battery Check
Action:

Test batteries. See Check Battery Electrolyte Level and Terminals . (Operator's Manual.)

Do the batteries test good?

Record of Actual Results:

Result:
YES:
Go to Voltage Check .
NO:
Replace batteries.

3 Voltage Check

Action:

Turn key switch OFF.

Disconnect ECU connector (X3). See Engine Harness (W10) Component Location . (Group 9015-10.)

Turn key switch ON.

Check for voltage at the following pins on ECU connector (X3):

128
 000627.01 —Injector Current Incorrect
Pin B2 (wire P31 RED)
Pin L1 (wire P30 RED)
Pin L4 (wire P30 RED)
Pin M1 (wire P30 RED)
Pin M4 (wire P30 RED)

Is system voltage (approximately 24 volts) present?

Record of Actual Results:

Result:
YES:
Go to Reprogram Controller .
NO:
Go to next step in this check.
Action:

Turn key switch OFF.

Remove fuses (F26 and F29). See Fuse and Relay Specifications . (Group 9015-10.)

Check continuity of fuses.

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Open circuit. Repair or replace harness(es). See Engine Harness (W10) Wiring Diagram and see Operator's
Station Harness (W7) Wiring Diagram . (Group 9015-10.)
NO:
Replace fuse(s).

4 Reprogram Controller
Action:

Reprogram engine control unit (ECU).

Check for active codes.

Is ECU code 000627.01 present?

Record of Actual Results:

Result:
YES:
Replace controller.
129
 000627.01 —Injector Current Incorrect

NO:
Checks complete.

Go to Section_9001:Group_20

AA95137,00007F5-19-20070405

130
 000651.00 —Cyl 1 Injector Max Cal
000651.00 —
Cyl 1 Injector Max Cal

The injector is limited by maximum pulse duration on cylinder #1.

Cyl 1 Injector Max Cal Diagnostic Procedure

Launch Close Expand List Collapse List

1 Code Check

Action:

Re-calibrate injector #1. See Electronic Injector Calibration . (CTM502.)

Check for active codes.

Is ECU code 000651.00 still present?

Record of Actual Results:

Result:
YES:
Go to Component Check .
NO:
Check complete.

2 Component Check

Action:

Check fuel injector #1. See Engine Fuel System Component Location . (Group 9010-15.)

Is injector OK?

Record of Actual Results:

Result:
YES:
Go to Harness Check .
NO:
Injector malfunction. Replace faulty injectors.

3 Harness Check
Action:

Check wire E13 WHT [pin 1 on connector (X23 )] and wire E12 ORG [pin 7 on connector (X23)] for open
circuits and short circuits. See System Functional Schematic and Section Legend . (Group 9015-10.)

Are any opens or shorts present?

131
 000651.00 —Cyl 1 Injector Max Cal

Record of Actual Results:

Result:
YES:
Harness malfunction. Repair or replace harness. See Engine Harness (W10) Wiring Diagram . (Group 9015-
10.)
NO:
Go to Reprogram Controller .

4 Reprogram Controller

Action:

Reprogram engine control unit (ECU).

Check for active codes.

Is ECU code 000651.00 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Check complete.

Go to Section_9001:Group_20

AA95137,00007F6-19-20070307

132
 000651.01 —Cyl 1 Injector Min Cal
000651.01 —
Cyl 1 Injector Min Cal

The injector is limited by minimum pulse duration on cylinder #1.

Cyl 1 Injector Min Cal Diagnostic Procedure

Launch Close Expand List Collapse List

1 Code Check

Action:

Re-calibrate injector #1. See Electronic Injector Calibration . (CTM502)

Check for active codes.

Is ECU code 000651.01 still present?

Record of Actual Results:

Result:
YES:
Go to Component Check .
NO:
Check complete.

2 Component Check

Action:

Check fuel injector #1. See Engine Fuel System Component Location . (Group 9010-15.)

Is injector OK?

Record of Actual Results:

Result:
YES:
Go to Harness Check .
NO:
Injector malfunction. Replace injector.

3 Harness Check
Action:

Check wire E13 WHT [pin 1 on connector (X23 )] and wire E12 ORG [pin 7 on connector (X23)] for open
circuits and short circuits. See Engine Harness (W10) Wiring Diagram . (Group 9015-10.)

Are any opens or shorts present?

133
 000651.01 —Cyl 1 Injector Min Cal

Record of Actual Results:

Result:
YES:
Harness malfunction. Repair or replace harness. See Engine Harness (W10) Wiring Diagram . (Group 9015-
10.)
NO:
Go to Reprogram Controller .

4 Reprogram Controller

Action:

Reprogram engine control unit (ECU).

Check for active codes.

Is ECU code 000651.01 present?

Record of Actual Results:

Result:
YES:
Controller malfunction. Replace ECU.
NO:
Checks complete.

Go to Section_9001:Group_20

AA95137,00007F7-19-20070307

134
 000652.00 —Cyl 2 Injector Max Cal
000652.00 —
Cyl 2 Injector Max Cal

The injector is limited by maximum pulse duration on cylinder #2.

Cyl 2 Injector Max Cal Diagnostic Procedure

Launch Close Expand List Collapse List

1 Code Check

Action:

Re-calibrate injector #2. See Electronic Injector Calibration . (CTM502.)

Check for active codes.

Is ECU code 000652.00 still present?

Record of Actual Results:

Result:
YES:
Go to Component Check .
NO:
Check complete.

2 Component Check

Action:

Check fuel injector #2. See Engine Fuel System Component Location . (Group 9010-15.)

Is injector OK?

Record of Actual Results:

Result:
YES:
Go to Harness Check .
NO:
Injector malfunction. Replace injector.

3 Harness Check
Action:

Check wire E14 GRY [pin 2 on connector (X23)] and wire E12 ORG [pin 7 on connector (X23 )] for open
circuits and short circuits. See Engine Harness (W10) Wiring Diagram . (Group 9015-10.)

Are any opens or shorts present?

135
 000652.00 —Cyl 2 Injector Max Cal

Record of Actual Results:

Result:
YES:
Harness malfunction. Repair or replace harness. See Engine Harness (W10) Wiring Diagram . (Group 9015-
10.)
NO:
Go to Reprogram Controller .

4 Reprogram Controller

Action:

Reprogram engine control unit (ECU).

Check for active codes.

Is ECU code 000652.00 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_20

AA95137,00007F8-19-20070307

136
 000652.01 —Cyl 2 Injector Min Cal
000652.01 —
Cyl 2 Injector Min Cal

The injector is limited by minimum pulse duration on cylinder #2.

Cyl 2 Injector Min Cal Diagnostic Procedure

Launch Close Expand List Collapse List

1 Code Check

Action:

Re-calibrate injector #2. See Electronic Injector Calibration . (CTM502.)

Check for active codes.

Is ECU code 000652.01 still present?

Record of Actual Results:

Result:
YES:
Go to Component Check .
NO:
Check complete.

2 Component Check

Action:

Check fuel injector #2. See Engine Fuel System Component Location . (Group 9010-15.)

Is injector OK?

Record of Actual Results:

Result:
YES:
Go to Harness Check .
NO:
Injector malfunction. Replace injector.

3 Harness Check
Action:

Check wire E14 GRY [pin 2 on connector (X23 )] and wire E12 ORG [pin 7 on connector (X23)] for open
circuits and short circuits. See Engine Harness (W10) Wiring Diagram . (Group 9015-10.)

Are any opens or shorts present?

137
 000652.01 —Cyl 2 Injector Min Cal

Record of Actual Results:

Result:
YES:
Harness malfunction. Repair or replace harness. See Engine Harness (W10) Wiring Diagram . (Group 9015-
10.)
NO:
Go to Reprogram Controller .

4 Reprogram Controller

Action:

Reprogram engine control unit (ECU).

Check for active codes.

Is ECU code 000652.01 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_20

AA95137,00007F9-19-20070307

138
 000653.00 —Cyl 3 Injector Max Cal
000653.00 —
Cyl 3 Injector Max Cal

The injector is limited by maximum pulse duration on cylinder #3.

Cyl 3 Injector Max Cal Diagnostic Procedure

Launch Close Expand List Collapse List

1 Code Check

Action:

Re-calibrate injector #3. See Electronic Injector Calibration . (CTM502)

Check for active codes.

Is ECU code 000653.00 still present?

Record of Actual Results:

Result:
YES:
Go to Component Check .
NO:
Check complete.

2 Component Check

Action:

Check fuel injector #3. See Engine Fuel System Component Location . (Group 9010-15.)

Is injector OK?

Record of Actual Results:

Result:
YES:
Go to Harness Check .
NO:
Injector malfunction. Replace injector.

3 Harness Check
Action:

Check wire E15 GRN [pin 3 on connector (X23)] and wire E12 ORG [pin 7 on connector (X23)] for open
circuits and short circuits. See Engine Harness (W10) Wiring Diagram . (Group 9015-10.)

Are any opens or shorts present?

139
 000653.00 —Cyl 3 Injector Max Cal

Record of Actual Results:

Result:
YES:
Harness malfunction. Repair or replace harness. See Engine Harness (W10) Wiring Diagram . (Group 9015-
10.)
NO:
Go to Reprogram Controller .

4 Reprogram Controller

Action:

Reprogram engine control unit (ECU).

Check for active codes.

Is ECU code 000653.00 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_20

AA95137,00007FA-19-20070307

140
 000653.01 —Cyl 3 Injector Min Cal
000653.01 —
Cyl 3 Injector Min Cal

The injector is limited by minimum pulse duration on cylinder #3.

Cyl 3 Injector Min Cal Diagnostic Procedure

Launch Close Expand List Collapse List

1 Code Check

Action:

Re-calibrate injector #3. See Electronic Injector Calibration . (CTM502.)

Check for active codes.

Is ECU code 000653.01 still present?

Record of Actual Results:

Result:
YES:
Go to Component Check .
NO:
Check complete.

2 Component Check

Action:

Check fuel injector #3. See Engine Fuel System Component Location . (Group 9010-15.)

Is injector OK?

Record of Actual Results:

Result:
YES:
Go to Harness Check .
NO:
Injector malfunction. Replace injector.

3 Harness Check
Action:

Check wire E15 GRN [pin 3 on connector (X23)] and wire E12 ORG [pin 7 on connector (X23)] for open
circuits and short circuits. See Engine Harness (W10) Wiring Diagram . (Group 9015-10.)

Are any opens or shorts present?

141
 000653.01 —Cyl 3 Injector Min Cal

Record of Actual Results:

Result:
YES:
Harness malfunction. Repair or replace harness. See Engine Harness (W10) Wiring Diagram . (Group 9015-
10.)
NO:
Go to Reprogram Controller .

4 Reprogram Controller

Action:

Reprogram engine control unit (ECU).

Check for active codes.

Is ECU code 000653.01 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_20

AA95137,00007FB-19-20070307

142
 000654.00 —Cyl 4 Injector Max Cal
000654.00 —
Cyl 4 Injector Max Cal

The injector is limited by maximum pulse duration on cylinder #4.

Cyl 4 Injector Max Cal Diagnostic Procedure

Launch Close Expand List Collapse List

1 Code Check

Action:

Re-calibrate injector #4. See Electronic Injector Calibration . (CTM502.)

Check for active codes.

Is ECU code 000654.00 still present?

Record of Actual Results:

Result:
YES:
Go to Component Check .
NO:
Check complete.

2 Component Check

Action:

Check fuel injector #4. See Engine Fuel System Component Location . (Group 9010-15.)

Is injector OK?

Record of Actual Results:

Result:
YES:
Go to Harness Check .
NO:
Injector malfunction. Replace injector.

3 Harness Check
Action:

Check wire E16 VLT [pin 4 on connector (X23)] and wire E11 RED [pin 8 on connector (X23)] for open
circuits and short circuits. See Engine Harness (W10) Wiring Diagram . (Group 9015-10.)

Are any opens or shorts present?

143
 000654.00 —Cyl 4 Injector Max Cal

Record of Actual Results:

Result:
YES:
Harness malfunction. Repair or replace harness. See Engine Harness (W10) Wiring Diagram . (Group 9015-
10.)
NO:
Go to Reprogram Controller .

4 Reprogram Controller

Action:

Reprogram engine control unit (ECU).

Check for active codes.

Is ECU code 000654.00 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_20

AA95137,00007FC-19-20070307

144
 000654.01 —Cyl 4 Injector Min Cal
000654.01 —
Cyl 4 Injector Min Cal

The injector is limited by minimum pulse duration on cylinder #4.

Cyl 4 Injector Min Cal Diagnostic Procedure

Launch Close Expand List Collapse List

1 Code Check

Action:

Re-calibrate injector #4. See Electronic Injector Calibration . (CTM502)

Check for active codes.

Is ECU code 000654.01 still present?

Record of Actual Results:

Result:
YES:
Go to Component Check .
NO:
Check complete.

2 Component Check

Action:

Check fuel injector #4. See Engine Fuel System Component Location . (Group 9010-15.)

Is injector OK?

Record of Actual Results:

Result:
YES:
Go to Harness Check .
NO:
Injector malfunction. Replace injector.

3 Harness Check
Action:

Check wire E16 VLT [pin 4 on connector (X23)] and wire E11 RED [pin 8 on connector (X23)] for open
circuits and short circuits. See Engine Harness (W10) Wiring Diagram . (Group 9015-10.)

Are any opens or shorts present?

145
 000654.01 —Cyl 4 Injector Min Cal

Record of Actual Results:

Result:
YES:
Harness malfunction. Repair or replace harness. See Engine Harness (W10) Wiring Diagram . (Group 9015-
10.)
NO:
Go to Reprogram Controller .

4 Reprogram Controller

Action:

Reprogram engine control unit (ECU).

Check for active codes.

Is ECU code 000654.01 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_20

AA95137,00007FD-19-20070307

146
 000655.00 —Cyl 5 Injector Max Cal
000655.00 —
Cyl 5 Injector Max Cal

The injector is limited by maximum pulse duration on cylinder #5.

Cyl 5 Injector Max Cal Diagnostic Procedure

Launch Close Expand List Collapse List

1 Code Check

Action:

Re-calibrate injector #5. See Electronic Injector Calibration . (CTM502.)

Check for active codes.

Is ECU code 000655.00 still present?

Record of Actual Results:

Result:
YES:
Go to Component Check .
NO:
Check complete.

2 Component Check

Action:

Check fuel injector #5. See Engine Fuel System Component Location . (Group 9010-15.)

Is injector OK?

Record of Actual Results:

Result:
YES:
Go to Harness Check .
NO:
Injector malfunction. Replace injector.

3 Harness Check
Action:

Check wire E17 YEL [pin 5 on connector (X23)] and wire E11 RED [pin 8 on connector (X23)] for open
circuits and short circuits. See Engine Harness (W10) Wiring Diagram . (Group 9015-10.)

Are any opens or shorts present?

147
 000655.00 —Cyl 5 Injector Max Cal

Record of Actual Results:

Result:
YES:
Harness malfunction. Repair or replace harness. See Engine Harness (W10) Wiring Diagram . (Group 9015-
10.)
NO:
Go to Reprogram Controller .

4 Reprogram Controller

Action:

Reprogram engine control unit (ECU).

Check for active codes.

Is ECU code 000655.00 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_20

AA95137,00007FE-19-20070307

148
 000655.01 —Cyl 5 Injector Min Cal
000655.01 —
Cyl 5 Injector Min Cal

The injector is limited by minimum pulse duration on cylinder #5.

Cyl 5 Injector Min Cal Diagnostic Procedure

Launch Close Expand List Collapse List

1 Code Check

Action:

Re-calibrate injector #5. See Electronic Injector Calibration . (CTM502.)

Check for active codes.

Is ECU code 000655.01 still present?

Record of Actual Results:

Result:
YES:
Go to Component Check .
NO:
Check complete.

2 Component Check

Action:

Check fuel injector #5. See Engine Fuel System Component Location . (Group 9010-15.)

Is injector OK?

Record of Actual Results:

Result:
YES:
Go to Harness Check .
NO:
Injector malfunction. Replace injector.

3 Harness Check
Action:

Check wire E17 YEL [pin 5 on connector (X23)] and wire E11 RED [pin 8 on connector (X23)] for open
circuits and short circuits. See Engine Harness (W10) Wiring Diagram . (Group 9015-10.)

Are any opens or shorts present?

149
 000655.01 —Cyl 5 Injector Min Cal

Record of Actual Results:

Result:
YES:
Harness malfunction. Repair or replace harness. See Engine Harness (W10) Wiring Diagram . (Group 9015-
10.)
NO:
Go to Reprogram Controller .

4 Reprogram Controller

Action:

Reprogram engine control unit (ECU).

Check for active codes.

Is ECU code 000655.01 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_20

AA95137,00007FF-19-20070307

150
 000656.00 —Cyl 6 Injector Max Cal
000656.00 —
Cyl 6 Injector Max Cal

The injector is limited by maximum pulse duration on cylinder #6.

Cyl 6 Injector Max Cal Diagnostic Procedure

Launch Close Expand List Collapse List

1 Code Check

Action:

Re-calibrate injector #5. See Electronic Injector Calibration . (CTM502.)

Check for active codes.

Is ECU code 000656.00 still present?

Record of Actual Results:

Result:
YES:
Go to Component Check .
NO:
Check complete.

2 Component Check

Action:

Check fuel injector #6. See Engine Fuel System Component Location . (Group 9010-15.)

Is injector OK?

Record of Actual Results:

Result:
YES:
Go to Injector #6 Harness Check .
NO:
Injector malfunction. Replace injector.

3 Harness Check
Action:

Check wire E18 BLU [pin 6 on connector (X23)] and wire E11 RED [pin 8 on connector (X23)] for open
circuits and short circuits. See Engine Harness (W10) Wiring Diagram . (Group 9015-10.)

Are any opens or shorts present?

151
 000656.00 —Cyl 6 Injector Max Cal

Record of Actual Results:

Result:
YES:
Harness malfunction. Repair or replace harness. See Engine Harness (W10) Wiring Diagram . (Group 9015-
10.)
NO:
Go to Reprogram Controller .

4 Reprogram Controller

Action:

Reprogram engine control unit (ECU).

Check for active codes.

Is ECU code 000656.00 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_20

AA95137,0000800-19-20070307

152
 000656.01 —Cyl 6 Injector Min Cal
000656.01 —
Cyl 6 Injector Min Cal

The injector is limited by minimum pulse duration on cylinder #6.

Cyl 6 Injector Min Cal Diagnostic Procedure

Launch Close Expand List Collapse List

1 Code Check

Action:

Re-calibrate injector #5. See Electronic Injector Calibration . (CTM502.)

Check for active codes.

Is ECU code 000656.01 still present?

Record of Actual Results:

Result:
YES:
Go to Component Check .
NO:
Check complete.

2 Component Check

Action:

Check fuel injector #6. See Engine Fuel System Component Location . (Group 9010-15.)

Is injector OK?

Record of Actual Results:

Result:
YES:
Go to Harness Check .
NO:
Injector malfunction. Replace injector.

3 Harness Check
Action:

Check wire E18 BLU [pin 6 on connector (X23)] and wire E11 RED [pin 8 on connector (X23)] for open
circuits and short circuits. See Engine Harness (W10) Wiring Diagram . (Group 9015-10.)

Are any opens or shorts present?

153
 000656.01 —Cyl 6 Injector Min Cal

Record of Actual Results:

Result:
YES:
Harness malfunction. Repair or replace harness. See Engine Harness (W10) Wiring Diagram . (Group 9015-
10.)
NO:
Go to Reprogram Controller .

4 Reprogram Controller

Action:

Reprogram engine control unit (ECU).

Check for active codes.

Is ECU code 000656.01 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_20

AA95137,0000801-19-20070307

154
 Transmission Control Unit (TCU) Diagnostic Trouble Codes

Transmission Control Unit (TCU) Diagnostic Trouble Codes

The diagnostic trouble code is indicated by a Suspect Parameter Number (SPN) and a Failure Mode Indicator
(FMI) number. In the example 000070.00 , 70 is the SPN and 00 is the FMI number.

To view diagnostic trouble codes, use one of the following methods:

Service ADVISOR™ system. See Reading Diagnostic Trouble Codes with Service ADVISOR™
Diagnostic Application . (Group 9015-20.)
CAN Monitor Unit (CMU). See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-
20.)

NOTE:

For in-depth diagnostics on all TCU diagnostic trouble codes, see specific code diagnostic
procedure. (Group 9001-30.)

Go to Section_9001:Group_30

WS68074,0001124-19-20070405

155
 Transmission Control Unit (TCU) Diagnostic Trouble Codes

Transmission Control Unit (TCU) Diagnostic Trouble Codes

The diagnostic trouble code is indicated by a Suspect Parameter Number (SPN) and a Failure Mode Indicator
(FMI) number. In the example 000070.00 , 70 is the SPN and 00 is the FMI number.

To view diagnostic trouble codes, use one of the following methods:

Service ADVISOR™ system. See Reading Diagnostic Trouble Codes with Service ADVISOR™
Diagnostic Application . (Group 9015-20.)
CAN Monitor Unit (CMU). See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-
20.)

NOTE:

For in-depth diagnostics on all TCU diagnostic trouble codes, see specific code diagnostic
procedure. (Group 9001-30.)

Go to Section_9001:Group_30

WS68074,0001124-19-20070405

156
 000070.00 —Park Lock Lever Inputs Both ON
000070.00 —
Park Lock Lever Inputs Both ON

Park Lock Lever Inputs Both ON

Park Lock Lever Inputs Both ON Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Component Check
Action:

Turn key switch OFF.

Disconnect park lock lever switch (S18). See Operator's Station Harness (W7) Component Location . (Group
9015-10.)

Turn key switch ON.

Is code 000070.00 active?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
NO:
Replace switch.

2 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect park lock switch (S18) and TCU connector (X1). See Operator's Station Harness (W7)
Component Location . (Group 9015-10.)

Check for continuity between pin B ( T16 BLU) and pin C (wire E05 WHT) on switch connector.

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Check for short circuit between wires T16 BLU and E05 WHT. Repair or replace harness. See Operator's
157
 000070.00 —Park Lock Lever Inputs Both ON
Station Harness (W7) Wiring Diagram . (Group 9015-10.)
NO:
Go to next step in this check.
Action:

Check for ground at pin B (wire T16 BLU) on park lock switch connector.

Is ground present?

Record of Actual Results:

Result:
YES:
Check for short circuit between wire T16 BLU and ground. Repair or replace harness. See Operator's
Station Harness (W7) Wiring Diagram . (Group 9015-10.)
NO:
Go to next step in this check.
Action:

Check for ground at pin C (wire E05 WHT) on park lock switch connector.

Is ground present?

Record of Actual Results:

Result:
YES:
Check for short circuit between wire E05 WHT and ground. Repair or replace harness. See Operator's
Station Harness (W7) Wiring Diagram . (Group 9015-10.)
NO:
Go to Replace Controller .

3 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 000070.00 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:

158
 000070.00 —Park Lock Lever Inputs Both ON
Checks complete.

Go to Section_9001:Group_30

CS33148,0002294-19-20080610

159
 000070.01 —Park Lock Lever Inputs Both OFF
000070.01 —
Park Lock Lever Inputs Both OFF

Machine will intermittently not move or come to abrupt stop. Transmission control unit (TCU) code 000070.01
appears and machine will not move forward or reverse. Unable to get into calibration. This diagnostic trouble code
indicates that both park lock lever switch (S18) wires (T16 BLU and E05 WHT) are open. Both wires from park
lock switch cannot have open circuits at the same time or the TCU will generate this code and prevent forward
and reverse movement of machine.

Park Lock Lever Inputs Both OFF Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Connector Check

Action:

Check park lock lever switch (S18) connector, transmission control unit (TCU) connector (X1) for corrosion,
loose fit, bent/pushed out terminals or crimp malfunctions. See Operator's Station Harness (W7) Component
Location . (Group 9015-10.)

Are connectors in good condition?

Record of Actual Results:

Result:
YES:
Go to Park Lock Lever Switch (S18) Check.
NO:
Repair or replace connector(s) or terminal(s) as needed.

2 Park Lock Lever Switch (S18) Check

Action:

Turn key switch OFF.

Disconnect park lock lever switch (S18). See Operator's Station Harness (W7) Wiring Diagram . (Group
9015-10.)

Check park lock lever switch (S18).

When park lock lever is in the LOCK position, check for continuity between pins A and C on park
lock lever switch (S18).
When park lock lever is in the UNLOCK position, check for continuity between pins A and B on
park lock lever switch (S18).

Is continuity indicated?

Record of Actual Results:

160
 000070.01 —Park Lock Lever Inputs Both OFF

Result:
YES:
Go to Open Circuit Check.
NO:
Replace switch.

3 Open Circuit Check

Action:

Verify that ground wire (G02 BLK) has a good connection and good continuity (low resistance) from park
lock lever switch (S18) to ground location.

Turn key switch OFF.

Disconnect park lock lever switch (S18). See Operator's Station Harness (W7) Wiring Diagram . (Group
9015-10.)

Check for ground at pin A on park lock lever switch (S18) connector (wire G02 BLK).

Is ground present at pin A?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Open circuit on wire G02 BLK. Repair or replace harness.
Action:

Disconnect transmission control unit (TCU) connector (X1). See Operator's Station Harness (W7) Wiring
Diagram . (Group 9015-10.)

Check continuity between pin B (wire T16 BLU) on park lock lever switch (S18) connector and pin 11 on
TCU connector (X1).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Open circuit on wire T16 BLU. Repair or replace harness.
Action:

161
 000070.01 —Park Lock Lever Inputs Both OFF

Disconnect transmission control unit (TCU) connector (X1). See Operator's Station Harness (W7) Wiring
Diagram . (Group 9015-10.)

Check continuity between pin C (wire E05 WHT) on park lock lever switch (S18) connector and pin 12 on
TCU connector (X1).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Checks complete.
NO:
Open circuit on wire E05 WHT. Repair or replace harness.

Go to Section_9001:Group_30

CS33148,0002295-19-20100415

162
 000091.00 —Throttle Sensor Input Greater Than Maximum Calibration Value
000091.00 —
Throttle Sensor Input Greater Than Maximum Calibration Value

The Input From Engine Speed Control Is Greater Than the Stored Maximum Calibration Value.

Throttle Sensor Input Greater Than Maximum Calibration Value Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Perform Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Check for active codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 000091.15 or 000091.16 active?

Record of Actual Results:

Result:
YES:
See code 000091.15— Throttle Sensor Minimum Calibration Value Too High or 000091.16— Throttle
Sensor Maximum Calibration Value Too High
NO:
Go to next step in this check.
Action:

Is code 000091.00 active?

Record of Actual Results:

Result:
YES:
Go to Replace Controller.
NO:
Checks complete.

2 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

163
 000091.00 —Throttle Sensor Input Greater Than Maximum Calibration Value
Is code 000091.00 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

CS33148,0002296-19-20091202

164
 000091.01 —Throttle Sensor Input Less Than Minimum Calibration Value
000091.01 —
Throttle Sensor Input Less Than Minimum Calibration Value

The Input From Engine Speed Control Is Less Than the Stored Minimum Calibration Value.

Throttle Sensor Input Less Than Minimum Calibration Value Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Perform Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 000091.17 or 000091.18 active?

Record of Actual Results:

Result:
YES:
See code 000091.17— Throttle Sensor Minimum Calibration Value Too Low or 000091.18— Throttle Sensor
Maximum Calibration Value Too Low
NO:
Checks complete.
Action:

Is code 000091.01 active?

Record of Actual Results:

Result:
YES:
Go to Replace Controller.
NO:
Checks complete.

2 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 000091.01 active?

165
 000091.01 —Throttle Sensor Input Less Than Minimum Calibration Value

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

CS33148,0002297-19-20091202

166
 000091.03 —Throttle Sensor Short to Power
000091.03 —
Throttle Sensor Short to Power

The Signal Voltage From the Engine Speed Control Is More Than 4.95 Volts

Throttle Sensor Short to Power Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Code Check
Action:

Check for active codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 000620.03 active?

Record of Actual Results:

Result:
YES:
See code 000620.03— TCU 5V Supply Short to Power . (Group 9001-30.)
NO:
Go to Component Check .

2 Component Check

Action:

Turn key switch OFF.

Disconnect engine speed control (R10) connector. See Operator's Station Harness (W7) Component
Location . (Group 9015-10.)

Turn key switch ON.

Is code 000091.03 active?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
NO:
Replace engine speed control (R10). Perform TCU calibration. See Transmission Control Unit (TCU)
Calibration . (Group 9015-20.)

167
 000091.03 —Throttle Sensor Short to Power
3 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect engine speed control (R10) connector. See Operator's Station Harness (W7) Component
Location . (Group 9015-10.)

Turn key switch ON.

Check voltage at pin B (wire E02 WHT) on engine speed control connector. See Operator's Station Harness
(W7) Wiring Diagram . (Group 9015-10.)

Is voltage present?

Record of Actual Results:

Result:
YES:
Check for a short to power between pin B on engine speed control connector and pin 14 on TCU connector
(X1). Repair or replace harness. See Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)
NO:
Go to Replace Controller .

4 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 000091.03 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

CS33148,0002298-19-20080610

168
 000091.04 —Throttle Sensor Open or Short
000091.04 —
Throttle Sensor Open or Short

Engine Speed Control Input Voltage Is Less Than 0.5 Volts

Throttle Sensor Open or Short Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Code Check
Action:

Check for active codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 000620.04 active?

Record of Actual Results:

Result:
YES:
See code 000620.04— TCU 5V Supply Open or Short . (Group 9001-30.)
NO:
Go to Component Check .

2 Component Check

Action:

Turn key switch OFF.

Disconnect engine speed control (R10) connector. See Operator's Station Harness (W7) Component
Location . (Group 9015-10.)

Check resistance of engine speed control (R10).

Item Measurement Specification

Engine Speed Control (R10) Resistance (between pins A and C) 980—1020 ohms

Is resistance within specifications?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
NO:
169
 000091.04 —Throttle Sensor Open or Short
Replace engine speed control (R10). Calibrate TCU, See Transmission Control Unit (TCU) Calibration .
(Group 9015-20.)

3 Short Circuit Check

Action:

Turn key switch OFF.

Engine speed control (R10) disconnected.

Disconnect TCU connector (X1). See Operator's Station Harness (W7) Component Location . (Group 9015-
10.)

Check for ground at pin B (wire E02 WHT) on engine speed control (R10) connector. See Operator's Station
Harness (W7) Wiring Diagram . (Group 9015-10.)

Is ground present?

Record of Actual Results:

Result:
YES:
Check for a short to ground between pin B on engine speed control (R10) connector and pin 14 on TCU
connector (X1).
NO:
Go to Open Circuit Check .

4 Open Circuit Check

Action:

Turn key switch OFF.

Disconnect engine speed control (R10) connector. (Group 9015-10.)

Check for voltage at pin A (wire T15 BLU) on engine speed control (R10) connector.

Is voltage approximately 5 volts?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check wire E02 WHT for an open circuit between pin B on engine speed control connector and pin 9 on
bussed 5 volt sensor connector. Repair or replace harness. See Operator's Station Harness (W7) Wiring
Diagram . (Group 9015-10.)
Action:

170
 000091.04 —Throttle Sensor Open or Short

Check for ground at pin C (wire R08 BLK) on engine speed control (R10) connector.

Is ground present?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check wire R08 BLK for an open circuit between pin C on engine speed control connector and pin 8 on
bussed ground sensor connector. Repair or replace harness. See Operator's Station Harness (W7) Wiring
Diagram . (Group 9015-10.)
Action:

Check continuity of wire E02 WHT between pin B on engine speed control (R10) connector and pin 14 on
TCU connector (X1).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Check wire E02 WHT for an open circuit between pin B on engine speed control connector and pin 14 on
TCU connector (X1). Repair or replace harness. See Operator's Station Harness (W7) Wiring Diagram .
(Group 9015-10.)

5 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 000091.04 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

171
000091.04 —Throttle Sensor Open or Short

Go to Section_9001:Group_30

CS33148,00022A8-19-20080610

172
 000091.15 —Throttle Sensor Minimum Calibration Value Too High
000091.15 —
Throttle Sensor Minimum Calibration Value Too High

Throttle Sensor Minimum Calibration Value Too High

Throttle Sensor Minimum Calibration Value Too High Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Observe the input voltage from engine speed control (R10) by accessing the Diagnostic / Live Values / Input
Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode .
(Group 9015-20.)

Record voltage with engine speed control at fast idle.

Item Measurement Specification

Engine Speed Control (R10) Calibration Limits 0.44—1.07 V at Fast Idle

Is voltage reading greater than 1.07 volts?

Record of Actual Results:

Result:
YES:
Go to Component Check .
NO:
Go to Replace Controller .

2 Component Check

Action:

Turn key switch OFF.

Disconnect engine speed control (R10) connector. See Operator's Station Harness (W7) Component
Location . (Group 9015-10.)

Check resistance of engine speed control (R10).

Item Measurement Specification

Engine Speed Control (R10) Resistance Between Pins A and C 980—1020 ohms

Is resistance within specifications?

Record of Actual Results:

173
 000091.15 —Throttle Sensor Minimum Calibration Value Too High

Result:
YES:
Go to next check in this step.
NO:
Replace engine speed control (R10). Perform TCU calibration. See Transmission Control Unit (TCU)
Calibration . (Group 9015-20.)
Action:

Engine speed control sensor disconnected.

Check resistance between pins A and B while turning engine speed control.

Is resistance change proportional to rotation of speed control?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Replace engine speed control (R10). Perform TCU calibration. See Transmission Control Unit (TCU)
Calibration . (Group 9015-20.)

3 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 000091.15 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

AH91621,0000261-19-20080610

174
 000091.16 —Throttle Sensor Maximum Calibration Value Too High
000091.16 —
Throttle Sensor Maximum Calibration Value Too High

The Engine Speed Control Stored Calibration Voltage for Slow Idle Position Is Greater Than 4.15 Volts

Throttle Sensor Maximum Calibration Value Too High Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Turn key switch ON.

Observe the input voltage from engine speed control (R10) by accessing the Diagnostic / Live Values / Input
Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode .
(Group 9015-20.)

Record voltage with engine speed control at slow idle.

Item Measurement Specification

Engine Speed Control Switch (R10) Calibration Limits 2.53—3.59 V at Slow Idle

Is voltage reading greater than 3.59 volts?

Record of Actual Results:

Result:
YES:
Go to Component Check .
NO:
Go to Replace Controller . (Group 9015-20.)

2 Component Check

Action:

Turn key switch OFF.

Disconnect engine speed control (R10) connector. See Operator's Station Harness (W7) Component
Location . (Group 9015-10.)

Check resistance of engine speed control (R10).

Item Measurement Specification

Engine Speed Control Switch (R10) Resistance Between Pins A and C 980—1020 ohms

Is resistance within specifications?

175
 000091.16 —Throttle Sensor Maximum Calibration Value Too High

Record of Actual Results:

Result:
YES:
Go to next check in this step.
NO:
Replace engine speed control (R10). Perform TCU calibration. See Transmission Control Unit (TCU)
Calibration . (Group 9015-20.)
Action:

Engine speed control sensor disconnected.

Check resistance between pins A and B while turning engine speed control sensor.

Is resistance change proportional to rotation of speed control?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Replace engine speed control (R10). Perform TCU calibration. See Transmission Control Unit (TCU)
Calibration . (Group 9015-20.)

3 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 000091.16 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

AH91621,0000262-19-20080610

176
 000091.17 —Throttle Sensor Minimum Calibration Value Too Low
000091.17 —
Throttle Sensor Minimum Calibration Value Too Low

The Engine Speed Control Stored Calibration Voltage for Fast Idle Position Is Less Than 0.45 Volts

Throttle Sensor Minimum Calibration Value Too Low Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Observe the input voltage from engine speed control (R10) by accessing the Diagnostic / Live Values / Input
Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode .
(Group 9015-20.)

Record voltage with engine speed control at fast idle.

Item Measurement Specification

Engine Speed Control (R10) Calibration Limits 0.44—1.07 V at Fast Idle

Is voltage reading less than 0.44 volts?

Record of Actual Results:

Result:
YES:
Go to Replace Controller . (Group 9015-20.)
NO:
Go to Component Check .

2 Component Check

Action:

Turn key switch OFF.

Disconnect engine speed control (R10) connector. See Operator's Station Harness (W7) Component
Location . (Group 9015-10.)

Check resistance of engine speed control (R10).

Item Measurement Specification

Engine Speed Control Switch (R10) Resistance Between Pins A and C 980—1020 ohms

Is resistance within specifications?

Record of Actual Results:

177
 000091.17 —Throttle Sensor Minimum Calibration Value Too Low

Result:
YES:
Go to next check in this step.
NO:
Replace engine speed control (R10). Perform TCU calibration. See Transmission Control Unit (TCU)
Calibration . (Group 9015-20.)
Action:

Engine speed control sensor disconnected.

Check resistance between pins A and B while turning engine speed control sensor.

Is resistance change proportional to rotation of speed control?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Replace engine speed control (R10). Perform TCU calibration. See Transmission Control Unit (TCU)
Calibration . (Group 9015-20.)

3 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 000091.00 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

AH91621,0000263-19-20080610

178
 000091.18 —Throttle Sensor Maximum Calibration Value Too Low
000091.18 —
Throttle Sensor Maximum Calibration Value Too Low

The Engine Speed Control Stored Calibration Voltage for Slow Idle Position Is Less Than 2.96 Volts

Throttle Sensor Maximum Calibration Value Too Low Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Observe the input voltage from engine speed control (R10) by accessing the Diagnostic / Live Values / Input
Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode .
(Group 9015-20.)

Record voltage with engine speed control at slow idle.

Item Measurement Specification

Engine Speed Control Switch (R10) Calibration Limits 2.53—3.59 V at Slow Idle

Is voltage reading less than 2.53 volts?

Record of Actual Results:

Result:
YES:
Go to Component Check .
NO:
Go to Replace Controller .

2 Component Check

Action:

Turn key switch OFF.

Disconnect engine speed control (R10) connector. See Operator's Station Harness (W7) Component
Location . (Group 9015-10.)

Check resistance of engine speed control (R10).

Item Measurement Specification

Engine Speed Control Switch (R10) Resistance Between Pins A and C 980—1020 ohms

Is resistance within specifications?

Record of Actual Results:

179
 000091.18 —Throttle Sensor Maximum Calibration Value Too Low

Result:
YES:
Go to next check in this step.
NO:
Replace engine speed control (R10). Perform TCU calibration. See Transmission Control Unit (TCU)
Calibration . (Group 9015-20.)
Action:

Engine speed control sensor disconnected.

Check resistance between pins A and B while turning engine speed control sensor.

Is resistance change proportional to rotation of speed control?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Replace engine speed control (R10). Perform TCU calibration. See Transmission Control Unit (TCU)
Calibration . (Group 9015-20.)

3 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 000091.18 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

AH91621,0000264-19-20080610

180
 000116.00 —Brake Pressure High
000116.00 —
Brake Pressure High

Park brake pressure high. Pressure is greater than 345 kPa (3.4 bar) (50 psi) with park brake ON and engine
running above 800 rpm.

Brake Pressure High Diagnostic Procedure

Alarm Level:

No Warning Lamp

Launch Close Expand List Collapse List

1 Code Check
Action:

NOTE:

The brake pressure sensor is B35 for machines (S.N. —173641) and B42 for machines
(S.N. 173642— ).

Pressure sensor harness (W27) is used with B42 (S.N. 173642— ).

Check for active codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 000116.04 active?

Record of Actual Results:

Result:
YES:
See code 000116.04— Brake Pressure Open or Short . (Group 9001-30.)
NO:
Go to Component Check.

2 Component Check

Action:

CAUTION:
To avoid injury from escaping fluid under pressure, stop engine and relieve the
pressure in the system before disconnecting or connecting hydraulic or other lines.
Tighten all connections before applying pressure.

Turn key switch OFF.

Remove park brake pressure sensor (B35 or B42)

Install JT02156A Digital Pressure/Temperature Analyzer in place of park brake sensor using XPD341 Quick
181
 000116.00 —Brake Pressure High
Coupler and JT02161 Transducer.

Start the engine.

Record pressure on the digital pressure analyzer with the brake off and on.

Item Measurement Specification

Brake Off Pressure 2482—2620 kPa
24.8—26.2 bar
360—380 psi
Brake On Pressure 0—207 kPa
0—2.1 bar
0—30 psi

Is park brake pressure within specifications?

Record of Actual Results:

Result:
YES:
Replace park brake pressure sensor (B35 or B42). Perform TCU calibration. See Transmission Control Unit
(TCU) Calibration . (Group 9015-20.)
NO:
Diagnose cause of high park brake pressure. See Park Brake Test . (Group 9026-25.)

Go to Section_9001:Group_30

CS33148,00022A0-19-20100709

182
 000116.01 —Brake Pressure Low
000116.01 —
Brake Pressure Low

Park brake pressure low. Pressure is less than 1400 kPa (14 bar) (200 psi) with park brake OFF (released),
engine running above 800 rpm, and charge pressure greater than 1700 kPa (17 bar) (250 psi).

Brake Pressure Low Diagnostic Procedure

Alarm Level:

No Warning Lamp

Launch Close Expand List Collapse List

1 Code Check
Action:

NOTE:

The brake pressure sensor is B35 for machines (S.N. —173641) and B42 for machines
(S.N. 173642— ).

Pressure sensor harness (W27) is used with B42 (S.N. 173642— ).

Check for active codes.

Is code 619.05 active?

Record of Actual Results:

Result:
YES:
See code 000619.05— Brake Solenoid No Response . (Group 9001-30.)
NO:
Go to next step in this check.
Action:

Is code 000116.03 or 000116.04 active?

Record of Actual Results:

Result:
YES:
See code 000116.04— Brake Pressure Open or Short or 000116.03— Brake Pressure Short to Power .
(Group 9001-30.)
NO:
Go to Component Check.

183
 000116.01 —Brake Pressure Low

2 Component Check

Action:

CAUTION:
To avoid injury from escaping fluid under pressure, stop engine and relieve the
pressure in the system before disconnecting or connecting hydraulic or other lines.
Tighten all connections before applying pressure.

Turn key switch OFF.

Remove park brake pressure sensor (B35 or B42).

Install JT02156A Digital Pressure/Temperature Analyzer in place of park brake sensor using XPD341 Quick
Coupler and JT02161 Transducer.

Start the engine.

Record pressure on the digital pressure analyzer with the brake off and on.

Item Measurement Specification

Brake Off Pressure 2482—2620 kPa
24.8—26.2 bar
360—380 psi
Brake On Pressure 0—207 kPa
0—2.1 bar
0—30 psi

Is park brake pressure within specifications?

Record of Actual Results:

Result:
YES:
Replace park brake pressure sensor (B35 or B42). Perform TCU calibration. See Transmission Control Unit
(TCU) Calibration . (Group 9015-20.)
NO:
Diagnose cause of incorrect park brake pressure. See Park Brake Test . (Group 9026-25.)

Go to Section_9001:Group_30

CS33148,00022A1-19-20100709

184
 000116.03 —Brake Pressure Short to Power
000116.03 —
Brake Pressure Short to Power

Brake Pressure Short to Power

Brake Pressure Short to Power Diagnostic Procedure

Alarm Level:

No Warning Lamp

Launch Close Expand List Collapse List

1 Component Check
Action:

NOTE:

The brake pressure sensor is B35 for (S.N. —173641) and B42 for (S.N. 173642— ).

Pressure sensor harness (W27) is used with B42 (S.N. 173642— ).

Turn key switch OFF.

Disconnect brake pressure sensor (B35 or B42). See Transmission Harness (W11) Component Location .
(Group 9015-10.)

Turn key switch ON.

Is code 000116.03 active?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check.
NO:
Replace brake pressure sensor (B35 or B42).

2 Short Circuit Check

Action:

Turn key switch OFF.

Brake pressure sensor (B35 or B42) disconnected.

Turn key switch ON.

Check voltage at pin C (wire T13 BLU) on brake pressure sensor (B35 or B42) connector. See Transmission
Harness (W11) Wiring Diagram . (Group 9015-10.)

185
 000116.03 —Brake Pressure Short to Power
Is voltage greater than 1 volt?

Record of Actual Results:

Result:
YES:
If voltage is approximately 5 volts, check wire T13 BLU for a short circuit between pin C on brake pressure
sensor (B35 or B42) connector and pin 3 on TCU connector (X1). Repair or replace harness(es). See
Transmission Harness (W11) Wiring Diagram and see Operator's Station Harness (W7) Wiring Diagram .
(Group 9015-10.)

If voltage is approximately system voltage (24 volts), check wire T13 BLU for a short circuit to system
voltage. See Transmission Harness (W11) Wiring Diagram and see Operator's Station Harness (W7) Wiring
Diagram . (Group 9015-10.)

NO:
Go to Replace Controller.

3 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 000116.03 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

CS33148,00022A4-19-20090924

186
 000116.04 —Brake Pressure Open or Short
000116.04 —
Brake Pressure Open or Short

Brake Pressure Open or Short

Brake Pressure Open or Short Diagnostic Procedure

Alarm Level:

No Warning Lamp

Launch Close Expand List Collapse List

1 Voltage Check
Action:

NOTE:

The brake pressure sensor is B35 for (S.N. —173641) and B42 for (S.N. 173642— ).

Pressure sensor harness (W27) is used with B42 (S.N. 173642— ).

Turn key switch OFF.

Disconnect brake pressure sensor (B35 or B42). See Transmission Harness (W11) Component Location .
(Group 9015-10.)

Turn key switch ON.

Check voltage between pin B (wire T12 BLU) and pin C (wire R07 BLK) on brake pressure sensor (B35 or
B42) connector. See Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)

Is voltage approximately 5 volts?

Record of Actual Results:

Result:
YES:
Go to Open Circuit Check.
NO:
Go to next step in this check.
Action:

Turn key switch OFF.

Brake pressure sensor (B35 or B42) disconnected.

Disconnect connector (X16) from operator's station harness (W7). See Transmission Harness (W11)
Component Location (Group 9015-10.)

Check the following wires for continuity:

Check wire T12 BLU for continuity between pin B on brake pressure sensor (B35 or B42)
187
 000116.04 —Brake Pressure Open or Short
connector and pin 7 on transmission harness side of connector (X16).

See Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)

Check wire R07 BLK for continuity between pin A on brake pressure sensor (B35 or B42)
connector and pin 9 on transmission harness side of connector (X16). See Transmission Harness
(W11) Wiring Diagram . (Group 9015-10.)

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Repair or replace harness. See Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)
Action:

Key switch OFF.

Connector (X16) disconnected from transmission harness (W11).

Disconnect bussed 5-volt connector (X6) and bussed ground connector (X7). See Operator's Station
Harness (W7) Component Location (Group 9015-10.)

Check the following wires for continuity:

Check wire T12 BLU for continuity between pin 7 on connector (X16) and pin 7 on bussed 5-volt
connector (X6). See Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)
Check wire R07 BLK for continuity between pin 9 on connector (X16) and pin 7 on bussed ground
connector (X7). See Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Repair or replace harness. See Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)
Action:

Key switch OFF.

Connector (X16) disconnected from transmission harness (W11).

Connectors bussed 5-volt connector (X6) and bussed ground connector (X7) disconnected.

Disconnect TCU connector (X1). See Operator's Station Harness (W7) Component Location (Group 9015-
10.)

188
 000116.04 —Brake Pressure Open or Short
Check the following wires for continuity:

Check wire T01 BLU for continuity between pin 1 on bussed 5-volt connector (X6) and pin 3 on
TCU connector (X1). See Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)
Check wire R01 BLK for continuity between pin 1 on bussed ground connector (X7) and pin 22 on
TCU connector (X1). See Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Repair or replace connector (X6) or (X7).
NO:
Repair or replace harness. See Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)

2 Open Circuit Check

Action:

Turn key switch OFF.

Disconnect brake pressure sensor (B35 or B42) and TCU connector (X1). See Operator's Station Harness
(W7) Component Location and See Transmission Harness (W11) Component Location . (Group 9015-10.)

Check wire T13 BLU for continuity between pin C on brake pressure sensor (B35 or B42) connector and pin
16 on TCU connector (X1). See Operator's Station Harness (W7) Wiring Diagram and see Transmission
Harness (W11) Wiring Diagram . (Group 9015-10.)

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check T13 BLU for an open circuit between pin C on brake pressure sensor (B35 or B42) connector and pin
16 on TCU connector (X1). Repair or replace harness(es). See Operator's Station Harness (W7) Wiring
Diagram and see Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)
Action:

Key switch OFF.

Brake pressure sensor (B35 or B42) and TCU connector (X1) disconnected.

Check for continuity between pin C (wire R07 BLK) on brake pressure sensor (B35 or B42) connector and
pin 22 (R01 BLK) on TCU connector (X1). See Operator's Station Harness (W7) Wiring Diagram and see
Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)

189
 000116.04 —Brake Pressure Open or Short
Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check.
NO:
Check for an open circuit between pin C (wire R07 BLK) on brake pressure sensor (B35 or B42) connector
and pin 22 on TCU connector (X1). Repair or replace harness(es). See Operator's Station Harness (W7)
Wiring Diagram and see Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)

3 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect brake pressure sensor (B35 or B42) and TCU connector (X1). See Operator's Station Harness
(W7) Component Location and See Transmission Harness (W11) Component Location . (Group 9015-10.)

Check for ground at pin C (wire T13 BLU) on brake pressure sensor (B35 or B42) connector.

Is ground present?

Record of Actual Results:

Result:
YES:
Check wire T13 BLU for a short circuit to ground. Repair or replace harness(es). See Operator's Station
Harness (W7) Wiring Diagram and see Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)
NO:
Go to Replace Controller.

4 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 000116.04 active?

Record of Actual Results:

Result:
YES:
Replace brake pressure sensor (B35 or B42). If code 000116.04 is active after replacing sensor, replace
190
 000116.04 —Brake Pressure Open or Short
controller.
NO:
Checks complete.

Go to Section_9001:Group_30

CS33148,00022A5-19-20090924

191
 000158.03 —TCU System Voltage Too High
000158.03 —
TCU System Voltage Too High

TCU System Voltage Too High

TCU System Voltage Too High Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Component Check
Action:

Perform Alternator Test . (Group 9015-20.)

Does alternator pass test?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Repair or replace alternator.
Action:

Test batteries. See Handling, Checking And Servicing Batteries Carefully and see Check Battery Electrolyte
Level and Terminals . (Operator's Manual.)

Do batteries past test?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Replace batteries.

2 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

192
 000158.03 —TCU System Voltage Too High
Is code 000158.03 active?

Record of Actual Results:

Result:
YES:
Controller malfunction. Replace TCU.
NO:
Checks complete.

Go to Section_9001:Group_30

CS33148,00022A6-19-20080610

193
 000158.04 —TCU System Voltage Too Low
000158.04 —
TCU System Voltage Too Low

TCU System Voltage Too Low

TCU System Voltage Too Low Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Component Check
Action:

Turn key switch OFF.

Remove fuse F6. See Fuse and Relay Specifications . (Group 9015-20.)

Check fuse F6 for continuity.

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Replace fuse.
Action:

Test batteries. See Handling, Checking And Servicing Batteries Carefully and see Check Battery Electrolyte
Level and Terminals . (Operator's Manual.)

Do the batteries pass test?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Replace batteries.
Action:

Perform Alternator Test . (Group 9015-20.)

Does alternator pass test?

194
 000158.04 —TCU System Voltage Too Low

Record of Actual Results:

Result:
YES:
Go to Open Circuit Check .
NO:
Replace alternator.

2 Open Circuit Check

Action:

Turn key switch OFF.

Disconnect TCU connector (X2). See Operator's Station Harness (W7) Component Location . (Group 9015-
10.)

Turn key switch ON.

Check for voltage at pins 1 and 18 (wire P03 RED) on connector (X2). See Operator's Station Harness (W7)
Wiring Diagram . (Group 9015-10.)

Is system voltage present?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Check wire P03 RED for an open circuit on operator's harness. Repair or replace harness if necessary. See
Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10).

3 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 000158.04 active?

Record of Actual Results:

Result:
YES:
Replace controller.

195
 000158.04 —TCU System Voltage Too Low

NO:
Checks complete.

Go to Section_9001:Group_30

CS33148,00022AB-19-20080610

196
 000177.00 —Transmission Over Temp
000177.00 —
Transmission Over Temp

Transmission Over Temp

Transmission Over Temp Diagnostic Procedure

Alarm Level:

No Warning Lamp

Launch Close Expand List Collapse List

1 Component Check
Action:

See Overheating Malfunctions . (Group 9026-15.)

Is code 000177.00 active?

Record of Actual Results:

Result:
YES:
Go to Code Check .
NO:
Repair complete.

2 Code Check

Action:

Check for active codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 000177.03 or code 000177.04 present?

Record of Actual Results:

Result:
YES:
See 000177.03— Transmission Oil Temperature Sensor Short to Power or 000177.04— Transmission Oil
Temperature Sensor Short to Ground . (Group 9001-10.)
NO:
Go to Replace Controller .

3 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

197
 000177.00 —Transmission Over Temp
Check for active codes.

Is code 000177.00 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

CS33148,00022A7-19-20080610

198
 000190.09 —CAN Communication Error No Engine Speed
000190.09 —
CAN Communication Error No Engine Speed

CAN Communication Error, No Engine Speed Message Received from ECU

CAN Communication Error No Engine Speed Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Component Check
Action:

Start engine.

Observe the engine speed by accessing the Diagnostic / Live Values / Speeds menu in the CMU menu
structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is engine speed displayed?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Go to Code Check .
Action:

Perform CAN Circuit Test . (Group 9015-20.)

Is code 000190.09 active?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Check complete.

2 Code Check

Action:

Check for active engine control unit (ECU) codes. See CAN Monitor Unit (CMU) Menu Structure—Service
Mode . (Group 9015-20.)

199
 000190.09 —CAN Communication Error No Engine Speed
Are any ECU codes active?

Record of Actual Results:

Result:
YES:
Resolve ECU codes. See Diagnostic Trouble Code (DTC) Quick Reference List—Engine Control Unit (ECU)
. (Group 9001-20.)
NO:
Perform CAN Circuit Test . (Group 9015-20.)

3 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 000190.09 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

CS33148,00022AA-19-20080610

200
 000190.19 —CAN Communication Error Invalid Engine Speed
000190.19 —
CAN Communication Error Invalid Engine Speed

CAN Communication Error Invalid Engine Speed

CAN Communication Error Invalid Engine Speed Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Component Check
Action:

Start engine.

Observe the engine speed by accessing the Diagnostic / Live Values / Speeds menu in the CMU menu
structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is engine speed displayed?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Go to Code Check .
Action:

Perform CAN Circuit Test . (Group 9015-20.)

Is code 000190.19 active?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Check complete.

2 Code Check

Action:

Check for active engine control unit (ECU) codes. See CAN Monitor Unit (CMU) Menu Structure—Service
Mode . (Group 9015-20.)

201
 000190.19 —CAN Communication Error Invalid Engine Speed
Are any ECU codes active?

Record of Actual Results:

Result:
YES:
Resolve ECU codes. See Diagnostic Trouble Code (DTC) Quick Reference List—Engine Control Unit (ECU)
. (Group 9001-20.)
NO:
Perform CAN Circuit Test . (Group 9015-20.)

3 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 000190.19 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

CS33148,00022AC-19-20091217

202
 000521.00 —Decel Sensor Input Greater Than Maximum Calibration Value
000521.00 —
Decel Sensor Input Greater Than Maximum Calibration Value

Decelerator Sensor Input Greater Than Maximum Calibration Value

Decelerator Sensor Input Greater Than Maximum Calibration Value Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Perform Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Check for active codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 000521.06, 000521.15, or 000521.16 active?

Record of Actual Results:

Result:
YES:
See 000521.06— Decel Sensor Brake Calibration Value Too High , 000521.15— Decel Sensor Minimum
Calibration Value Too High , or 000521.16— Decel Sensor Maximum Calibration Value Too High . (Group
9001-30.)
NO:
Go to next step in this check..
Action:

Is code 000521.00 active?

Record of Actual Results:

Result:
YES:
Go to Replace Controller.
NO:
Checks complete.

2 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

203
 000521.00 —Decel Sensor Input Greater Than Maximum Calibration Value
Check for active codes.

Is code 000521.00 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

CS33148,00022AE-19-20091202

204
 000521.01 —Decel Sensor Input Less Than Minimum Calibration Value
000521.01 —
Decel Sensor Input Less Than Minimum Calibration Value

Decelerator Sensor Input Less Than Minimum Calibration Value

Decelerator Sensor Input Less Than Minimum Calibration Value Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Perform Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Check for active codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 000521.05, 000521.17, or 000521.18 active?

Record of Actual Results:

Result:
YES:
See 000521.05— Decel Sensor Brake Calibration Value Too Low , 000521.17— Decel Sensor Minimum
Calibration Value Too Low , or 000521.18— Decel Sensor Maximum Calibration Value Too Low . (Group
9001-30.)
NO:
Go to next step in this check..
Action:

Is code 000521.01 active?

Record of Actual Results:

Result:
YES:
Go to Replace Controller.
NO:
Checks complete.

2 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

205
 000521.01 —Decel Sensor Input Less Than Minimum Calibration Value
Check for active codes.

Is code 000521.01 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

CS33148,00022AD-19-20091202

206
 000521.03 —Decel Sensor Short to Power
000521.03 —
Decel Sensor Short to Power

Decelerator Sensor Short to Power

Decelerator Sensor Short to Power Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Code Check
Action:

Check for active codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 000620.03 active?

Record of Actual Results:

Result:
YES:
See 000620.03— TCU 5V Supply Short to Power . (Group 9001-30.)
NO:
Go to Component Check .

2 Component Check

Action:

Turn key switch OFF.

Disconnect decelerator sensor (B1). See Operator's Station Harness (W7) Component Location . (Group
9015-10.)

Turn key switch ON.

Is code 000521.03 active?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
NO:
Replace decelerator sensor (B1). Perform TCU calibration. See Transmission Control Unit (TCU) Calibration
. (Group 9015-20.)

207
 000521.03 —Decel Sensor Short to Power
3 Short Circuit Check

Action:

Decelerator sensor (B1) disconnected.

Turn key switch ON.

Check voltage at pin B (wire T03 BLU) on decelerator sensor (B1) connector. See Transmission Harness
(W11) Wiring Diagram . (Group 9015-10.)

Is voltage present?

Record of Actual Results:

Result:
YES:
Check wire T03 BLU for a short circuit between pins B on decelerator sensor (B1) connector and pin 18 on
TCU connector (X1). See Transmission Harness (W11) Wiring Diagram
NO:
Go to Replace Controller .

4 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 000521.03 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

CS33148,00022AF-19-20080610

208
 000521.04 —Decel Sensor Open or Short
000521.04 —
Decel Sensor Open or Short

Decelerator Sensor Open or Short

Decelerator Sensor Open or Short Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Code Check
Action:

NOTE:

The brake pressure sensor is B35 for (S.N. —173641) and B42 for (S.N. 173642— ).

Pressure sensor harness (W27) is used with B42 (S.N. 173642— ).

Check for active codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 000620.04 active?

Record of Actual Results:

Result:
YES:
See 000620.04— TCU 5V Supply Open or Short . (Group 9001-30.)
NO:
Go to Open Circuit Check .

2 Open Circuit Check

Action:

Turn key switch OFF.

Disconnect decelerator sensor (B1). See Transmission Harness (W11) Component Location . (Group 9015-
10.)

Turn key switch ON.

Check voltage at pin A (wire T02 BLU) on decelerator sensor (B1) connector. See Transmission Harness
(W11) Wiring Diagram . (Group 9015-10.)

Is voltage approximately 5 volts?

Record of Actual Results:

209
 000521.04 —Decel Sensor Open or Short

Result:
YES:
Go to next step in this check.
NO:
Check for an open circuit between pin A on decelerator sensor (B1) connector and pin 2 on 5 volt bussed
sensor connector (X6). Repair or replace harness. See Operator's Station Harness (W7) Wiring Diagram .
(Group 9015-10.)
Action:

Turn key switch OFF.

Decelerator sensor (B1) disconnected.

Check ground at pin C (wire R02 BLK) on decelerator sensor (B1) connector). See Operator's Station
Harness (W7) Wiring Diagram . (Group 9015-10.)

Is ground present?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check for an open circuit between pin C on decelerator sensor (B35 or B42) connector and pin 6 on 5 volt
bussed sensor connector (X6). Repair or replace harness. See Operator's Station Harness (W7) Wiring
Diagram . (Group 9015-10.)
Action:

Key switch OFF.

Disconnect TCU connector (X1). See Operator's Station Harness (W7) Component Location . (Group 9015-
10.)

Decelerator sensor (B1) disconnected.

Check for continuity between pin B (wire T03 BLU) on brake pressure sensor (B1) connector and pin 18 on
TCU connector (X1). See Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check.
NO:
Check for an open circuit between pin B on decelerator sensor (B1) connector and pin 18 on TCU connector
210
 000521.04 —Decel Sensor Open or Short
(X1). Repair or replace harness. See Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)

3 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect decelerator sensor (B1) and TCU connector (X1). See Operator's Station Harness (W7)
Component Location . (Group 9015-10.)

Check for ground at pin B (wire T03 BLU) on decelerator sensor (B1) connector.

Is ground present?

Record of Actual Results:

Result:
YES:
Check for a short circuit to ground between pin B decelerator sensor (B1) connector and pin 18 on TCU
connector X1. Repair or replace harness. See Operator's Station Harness (W7) Wiring Diagram . (Group
9015-10.)
NO:
Go to Replace Controller.

4 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Clear codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 000521.04 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000F19-19-20090924

211
 000521.05 —Decel Sensor Brake Calibration Value Too Low
000521.05 —
Decel Sensor Brake Calibration Value Too Low

Decelerator Sensor Brake Calibration Value Too Low

Decelerator Sensor Brake Calibration Value Too Low Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Observe the input voltage from decelerator sensor (B1) by accessing the Diagnostic / Live Values / Input
Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode .
(Group 9015-20.)

Record voltage with decelerator pedal at brake position.

Item Measurement Specification

Decelerator Sensor (B1) Calibration Limits 3.79—3.99 V at Brake Position

Is voltage less than 3.79 volts?

Record of Actual Results:

Result:
YES:
Go to Component Adjustment
NO:
Go to Replace Controller .

2 Component Adjustment

Action:

Adjust decelerator sensor (B1). See Decelerator/Brake Pedal Adjustment . (Group 9015-20.)

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 000521.05 active?

Record of Actual Results:

Result:
YES:
Go to Component Check .

212
 000521.05 —Decel Sensor Brake Calibration Value Too Low

NO:
Repair complete.

3 Component Check
Action:

Remove the decelerator sensor (B1).

Verify the shaft is turning.

Does shaft on decelerator sensor turn?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Replace sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

4 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 000521.05 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FC6-19-20080610

213
 000521.06 —Decel Sensor Brake Calibration Value Too High
000521.06 —
Decel Sensor Brake Calibration Value Too High

The Decelerator Sensor Stored Calibration Value for Brake Position Is More Than 3.99 Volts

Decelerator Sensor Brake Calibration Value Too High Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Observe the input voltage from decelerator sensor (B1) by accessing the Diagnostic / Live Values / Input
Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode .
(Group 9015-20.)

Record decelerator voltage with decelerator at brake position.

Item Measurement Specification

Decelerator Sensor (B1) Calibration Limits 3.79—3.99 V at Brake Position

Is voltage reading greater than 3.99 volts?

Record of Actual Results:

Result:
YES:
Go to Component Adjustment .
NO:
Go to Replace Controller .

2 Component Adjustment

Action:

Adjust decelerator sensor (B1). See Decelerator/Brake Pedal Adjustment . (Group 9015-20.)

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 000521.06 active?

Record of Actual Results:

Result:
YES:
Go to Component Check .

214
 000521.06 —Decel Sensor Brake Calibration Value Too High

NO:
Repair complete.

3 Component Check
Action:

Remove the decelerator sensor (B1).

Verify the shaft is turning.

Does shaft on decelerator sensor turn?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Replace sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

4 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 000521.06 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FC5-19-20080610

215
 000521.15 —Decel Sensor Minimum Calibration Value Too High
000521.15 —
Decel Sensor Minimum Calibration Value Too High

Decelerator Sensor Stored Minimum Calibration Value for Pedal Up Position Is Greater Than 1.75 Volts

Decelerator Sensor Minimum Calibration Value Too High Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Observe the input voltage from decelerator sensor (B1) by accessing the Diagnostic / Live Values / Input
Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode .
(Group 9015-20.)

Record decelerator voltage at high decelerator position.

Item Measurement Specification

Decelerator Sensor (B1) Calibration Limits 1.40—1.60 V at High Decel Position (pedal up)

Is the voltage reading greater than 1.75 volts?

Record of Actual Results:

Result:
YES:
Go to Component Adjustment .
NO:
Go to Replace Controller .

2 Component Adjustment

Action:

Adjust decelerator sensor (B1). See Decelerator/Brake Pedal Adjustment . (Group 9015-20.)

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 000521.15 active?

Record of Actual Results:

Result:
YES:
Go to Component Check .

216
 000521.15 —Decel Sensor Minimum Calibration Value Too High

NO:
Repair complete.

3 Component Check
Action:

Remove the decelerator sensor (B1).

Verify the shaft is turning.

Does shaft on decelerator sensor turn?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Replace sensor and calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

4 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 000521.15 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FC9-19-20080610

217
 000521.16 —Decel Sensor Maximum Calibration Value Too High
000521.16 —
Decel Sensor Maximum Calibration Value Too High

Decelerator Sensor Stored Maximum Calibration Value for Pedal Down Position Is Greater Than 3.75 Volts High

Decelerator Sensor Maximum Calibration Value Too High Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Observe the input voltage from decelerator sensor (B1) by accessing the Diagnostic / Live Values / Input
Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode .
(Group 9015-20.)

Record decelerator voltage with decelerator pedal at low decelerator position.

Item Measurement Specification

Decelerator Sensor (B1) Calibration Limits 3.40—3.60 V at Low Decel Position

Is voltage reading greater than 3.75 volts?

Record of Actual Results:

Result:
YES:
Go to Component Adjustment .
NO:
Go to Replace Controller .

2 Component Adjustment

Action:

Adjust decelerator sensor (B1). See Decelerator/Brake Pedal Adjustment . (Group 9015-20.)

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 000521.16 active?

Record of Actual Results:

Result:
YES:
Go to Component Check .

218
 000521.16 —Decel Sensor Maximum Calibration Value Too High

NO:
Repair complete.

3 Component Check
Action:

Remove the decelerator sensor (B1).

Verify the shaft is turning.

Does shaft on decelerator sensor turn?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Replace sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

4 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 000521.16 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FC2-19-20080610

219
 000521.17 —Decel Sensor Minimum Calibration Value Too Low
000521.17 —
Decel Sensor Minimum Calibration Value Too Low

The Decelerator Sensor Stored Minimum Calibration Value for Pedal Up Position Is Less Than 1.40 Volts

Decelerator Sensor Minimum Calibration Value Too Low Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Observe the input voltage from decelerator sensor (B1) by accessing the Diagnostic / Live Values / Input
Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode .
(Group 9015-20.)

Record decelerator voltage with decelerator at high decelerator position.

Item Measurement Specification

Decelerator Sensor (B1) Calibration Limits 1.40—1.60 V at High Decel Position

Is the voltage reading less than 1.40 volts?

Record of Actual Results:

Result:
YES:
Go to Component Adjustment .
NO:
Go to Replace Controller .

2 Component Adjustment

Action:

Adjust decelerator sensor (B1). See Decelerator/Brake Pedal Adjustment . (Group 9015-20.)

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 000521.17 active?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .

220
 000521.17 —Decel Sensor Minimum Calibration Value Too Low

NO:
Repair complete.

3 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 000521.17 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FC3-19-20080610

221
 000521.18 —Decel Sensor Maximum Calibration Value Too Low
000521.18 —
Decel Sensor Maximum Calibration Value Too Low

The Decelerator Sensor Stored Maximum Calibration Value for Pedal Down Position Is Less Than 3.25 Volts

Decelerator Sensor Maximum Calibration Value Too Low Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Observe the input voltage from decelerator sensor (B1) by accessing the Diagnostic / Live Values / Input
Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode .
(Group 9015-20.)

Record voltage with decelerator pedal at low decel position.

Item Measurement Specification

Decelerator Sensor (B1) Calibration Limits 3.40—3.60 V at Low Decel Position

Is the voltage reading less than 3.25 volts?

Record of Actual Results:

Result:
YES:
Go to Component Adjustment .
NO:
Go to Replace Controller .

2 Component Adjustment

Action:

Adjust decelerator sensor (B1). See Decelerator/Brake Pedal Adjustment . (Group 9015-20.)

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 000521.18 active?

Record of Actual Results:

Result:
YES:
Go to Component Check .

222
 000521.18 —Decel Sensor Maximum Calibration Value Too Low

NO:
Repair complete.

3 Component Check
Action:

Remove the decelerator sensor (B1).

Verify the shaft is turning.

Does shaft on decelerator sensor turn?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Replace sensor and calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

4 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 000521.18 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FC4-19-20080610

223
 000581.00 —Speed Buttons Input Greater Than Maximum Calibration Value
000581.00 —
Speed Buttons Input Greater Than Maximum Calibration Value

The Transmission Speed Control Sensor Input Voltage Is Greater Than 3.50 Volts

Transmission Speed Control Sensor Input Greater Than Maximum Calibration Value
Diagnostic Procedure

Alarm Level:

No Warning Lamp

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Perform Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Check for active codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 000581.15 or 000581.16 active?

Record of Actual Results:

Result:
YES:
See 000581.15— Speed Buttons Minimum Calibration Value Too High or 000581.16— Speed Buttons
Maximum Calibration Value Too High
NO:
Go to next check in this step.
Action:

Is code 000581.00 active?

Record of Actual Results:

Result:
YES:
Go to Replace Controller.
NO:
Checks complete.

2 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

224
 000581.00 —Speed Buttons Input Greater Than Maximum Calibration Value
Check for active codes.

Is code 000581.00 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000F20-19-20091202

225
 000581.01 —Speed Buttons Input Less Than Minimum Calibration Value
000581.01 —
Speed Buttons Input Less Than Minimum Calibration Value

The Transmission Speed Control Sensor Voltage Is Less Than 0.50 Volts

Transmission Speed Control Sensor Input Less Than Minimum Calibration Value
Diagnostic Procedure
Launch Close Expand List Collapse List

1 Calibration Check

Action:

Perform Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Check for active codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 000581.17 or 000581.18 active?

Record of Actual Results:

Result:
YES:
See 000581.17— Speed Buttons Minimum Calibration Value Too Low or 000581.18— Speed Buttons
Maximum Calibration Value Too Low
NO:
Go to next check in this step.
Action:

Is code 000581.01 active?

Record of Actual Results:

Result:
YES:
Go to Replace Controller.
NO:
Checks complete.

2 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 000581.01 active?

Record of Actual Results:

226
 000581.01 —Speed Buttons Input Less Than Minimum Calibration Value

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FBE-19-20091202

227
 000581.03 —Speed Buttons Short to Power
000581.03 —
Speed Buttons Short to Power

Transmission Speed Control Switch Short to Power

Transmission Speed Control Switch Short to Power Diagnostic Procedure

Alarm Level:

No Warning Lamp

Launch Close Expand List Collapse List

1 Code Check
Action:

Check for active codes, see CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 000620.03 active?

Record of Actual Results:

Result:
YES:
See 000620.03— TCU 5V Supply Short to Power . (Group 9001-30.)
NO:
Go to Component Check .

2 Component Check

Action:

Turn key switch OFF.

Disconnect transmission speed control switch (B34). See Operator's Station Harness (W7) Component
Location . (Group 9015-10.)

Turn key switch ON.

Is code 000581.03 active?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
NO:
Replace transmission speed control switch (B34).

228
 000581.03 —Speed Buttons Short to Power

3 Short Circuit Check

Action:

Transmission speed control switch (B34) disconnected.

Turn key switch ON.

Check voltage at pin B (wire T33 BLU) on transmission speed control switch (B34) connector. See
Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)

Is voltage present?

Record of Actual Results:

Result:
YES:
Check wire for short to power between pins B on transmission speed control switch (B34) connector and pin
17 on TCU connector (X1).
NO:
Go to Replace Controller .

4 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 000581.03 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FCD-19-20080610

229
 000581.04 —Speed Buttons Open or Short
000581.04 —
Speed Buttons Open or Short

Transmission Speed Control Sensor Open or Short

Transmission Speed Control Sensor Open or Short Diagnostic Procedure

Alarm Level:

No Warning Lamp

Launch Close Expand List Collapse List

1 Code Check
Action:

Check for active codes, see CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 000620.04 active?

Record of Actual Results:

Result:
YES:
See 000620.04— TCU 5V Supply Open or Short . (Group 9001-30.)
NO:
Go to Open Circuit Check .

2 Open Circuit Check

Action:

Turn key switch OFF.

Disconnect transmission speed control switch (B34). See Transmission Harness (W11) Component Location
. (Group 9015-10.)

Turn key switch ON.

Check voltage at pin A (wire T30 BLU) on transmission speed control switch (B34) connector. See
Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)

Is voltage approximately 5 volts?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:

230
 000581.04 —Speed Buttons Open or Short
Check for an open circuit between pin A on transmission speed control switch (B34) connector and pin 12 on
5 volt bussed sensor connector (X6). Repair or replace harness. See Operator's Station Harness (W7)
Wiring Diagram . (Group 9015-10.)
Action:

Turn key switch OFF.

Transmission speed control switch (B34) disconnected.

Check ground at pin C (wire R21 BLK) on transmission speed control switch (B34) connector. See
Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)

Is ground present?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check for an open circuit between pin C on decelerator sensor (B1) connector and pin 10 on bussed ground
sensor connector (X7). Repair or replace harness. See Operator's Station Harness (W7) Wiring Diagram .
(Group 9015-10.)
Action:

Key switch OFF.

Transmission speed control switch (B34) disconnected.

Disconnect TCU connector (X1). See Operator's Station Harness (W7) Component Location . (Group 9015-
10.)

Check or continuity between pin B (wire T33 BLU) on transmission speed control switch (B34) connector and
pin 17 on TCU connector (X1). See Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
NO:
Check for an open circuit between pin B on brake pressure sensor (B1) connector and pin 17 on TCU
connector (X1). Repair or replace harness. See Operator's Station Harness (W7) Wiring Diagram . (Group
9015-10.)

3 Short Circuit Check

Action:

Turn key switch OFF. 231

 000581.04 —Speed Buttons Open or Short
Turn key switch OFF.

Disconnect decelerator sensor (B1) and TCU connector (X1). See Operator's Station Harness (W7)
Component Location . (Group 9015-10.)

Check for ground at pin B (wire T33 BLU) on decelerator sensor (B1) connector.

Is ground present?

Record of Actual Results:

Result:
YES:
Check for a short to ground between pin B on brake pressure sensor (B1) connector and pin 17 on TCU
connector (X1). Repair or replace harness. See Operator's Station Harness (W7) Wiring Diagram . (Group
9015-10.)
NO:
Go to Replace Controller .

4 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 000581.04 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FCC-19-20080610

232
 000581.15 —Speed Buttons Minimum Calibration Value Too High
000581.15 —
Speed Buttons Minimum Calibration Value Too High

The Stored Minimum Calibration Value for the Transmission Speed Control Sensor Is Greater Than 1.22 Volts

Transmission Speed Control Sensor Minimum Calibration Value Too High Diagnostic
Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Observe the input voltage from transmission speed control sensor (B34) by accessing the Diagnostic / Live
Values / Input Voltages menu in the CMU menu structure. see CAN Monitor Unit (CMU) Menu Structure—
Service Mode . (Group 9015-20.)

Record voltage with up button pressed on transmission speed control sensor.

Item Measurement Specification

Transmission Speed Control Sensor (B34) Calibration Limits 0.50—1.22 V w/ Up button pressed

Is the voltage greater than 1.22 volts?

Record of Actual Results:

Result:
YES:
Go to Component Check.
NO:
Go to Replace Controller .

2 Component Check

Action:

Disconnect transmission speed control sensor. see CAN Monitor Unit (CMU) Menu Structure—Service Mode
. (Group 9015-10.)

Check resistance between pins A and C on sensor connector while pressing button up and down.

Item Measurement Specification

Transmission Speed Control Sensor (B34) Resistance 194.10—214.60 ohms (Button up)
248.90—275.10 ohms (button down)
344—380 ohms (neutral position)

Is sensor within specifications?

233
 000581.15 —Speed Buttons Minimum Calibration Value Too High

Record of Actual Results:

Result:
YES:
Go to Replace Controller.
NO:
Replace sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

3 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 000581.15 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FBD-19-20120816

234
 000581.16 —Speed Buttons Maximum Calibration Value Too High
000581.16 —
Speed Buttons Maximum Calibration Value Too High

The Stored Maximum Calibration Value for the Transmission Speed Control Sensor Is Greater Than 3.50 Volts

Transmission Speed Control Sensor Maximum Calibration Value Too High Diagnostic
Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Observe the input voltage from transmission speed control Sensor (B34) by accessing the Diagnostic / Live
Values / Input Voltages menu in the CMU menu structure. see CAN Monitor Unit (CMU) Menu Structure—
Service Mode . (Group 9015-20.)

Record voltage with down button pressed on the transmission speed control sensor.

Item Measurement Specification

Transmission Speed Control Sensor (B34) Calibration Limits 2.66—3.50 V w/ Down button pressed

Is the voltage reading greater than 3.50 volts?

Record of Actual Results:

Result:
YES:
Go to Component Check.
NO:
Go to Replace Controller .

2 Component Check

Action:

Disconnect transmission speed control sensor. See CAN Monitor Unit (CMU) Menu Structure—Service
Mode . (Group 9015-10.)

Check resistance between pins A and C on sensor connector while pressing button up and down.

Item Measurement Specification

Transmission Speed Control Sensor (B34) Resistance 194.10—214.60 ohms (Button up)
248.90—275.10 ohms (button down)
344—380 ohms (neutral position)

Is sensor within specifications?

235
 000581.16 —Speed Buttons Maximum Calibration Value Too High

Record of Actual Results:

Result:
YES:
Go to Replace Controller.
NO:
Replace sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

3 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 000581.16 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FBC-19-20120816

236
 000581.17 —Speed Buttons Minimum Calibration Value Too Low
000581.17 —
Speed Buttons Minimum Calibration Value Too Low

The Stored Minimum Calibration Value for the Transmission Speed Control Sensor Is Less Than 0.50 Volts

Transmission Speed Control Sensor Minimum Calibration Value Too Low Diagnostic
Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Observe the input voltage from transmission speed control Sensor (B34) by accessing the Diagnostic / Live
Values / Input Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—
Service Mode . (Group 9015-20.)

Record voltage with the up button pressed on the transmission speed control Sensor.

Item Measurement Specification

Transmission Speed Control Sensor (B34) Calibration Limits 0.50—1.22 V w/ Up button pressed

Is the voltage reading less than 0.50 volts?

Record of Actual Results:

Result:
YES:
Go to Component Check.
NO:
Go to Replace Controller .

2 Component Check

Action:

Disconnect transmission speed control Sensor. See CAN Monitor Unit (CMU) Menu Structure—Service
Mode . (Group 9015-10.)

Check resistance between pins A and C on Sensor connector while pressing button up and down.

Item Measurement Specification

Transmission Speed Control Sensor (B34) Resistance 194.10—214.60 ohms (Button up)
248.90—275.10 ohms (button down)
344—380 ohms (neutral position)

Is Sensor within specifications?

237
 000581.17 —Speed Buttons Minimum Calibration Value Too Low

Record of Actual Results:

Result:
YES:
Go to Replace Controller.
NO:
Replace Sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

3 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 000581.17 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FBB-19-20120816

238
 000581.18 —Speed Buttons Maximum Calibration Value Too Low
000581.18 —
Speed Buttons Maximum Calibration Value Too Low

The Stored Maximum Calibration Value for the Transmission Speed Control Sensor Is Less Than 2.66 Volts

Transmission Speed Control Sensor Maximum Calibration Value Too Low Diagnostic
Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Observe the input voltage from transmission speed control Sensor (B34) by accessing the Diagnostic / Live
Values / Input Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—
Service Mode . (Group 9015-20.)

Record voltage with the down button pressed on the transmission speed control sensor.

Item Measurement Specification

Transmission Speed Control Sensor (B34) Calibration Limits 2.66—3.50 V w/ Down button pressed

Is the voltage reading less than 2.66 volts?

Record of Actual Results:

Result:
YES:
Go to Component Check.
NO:
Go to Replace Controller .

2 Component Check

Action:

Disconnect transmission speed control sensor. See Operator's Station Harness (W7) Component Location .
(Group 9015-10.)

Check resistance between pins A and C on sensor connector while pressing button up and down.

Item Measurement Specification

Transmission Speed Control Sensor (B34) Resistance 194.10—214.60 ohms (Button up)
248.90—275.10 ohms (button down)
344—380 ohms (neutral position)

Is sensor within specifications?

239
 000581.18 —Speed Buttons Maximum Calibration Value Too Low

Record of Actual Results:

Result:
YES:
Go to Replace Controller.
NO:
Replace sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

3 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 000581.18 active?

Record of Actual Results:

Result:
YES:
Replace transmission speed control Sensor (B34). If code 000581.18 is active after replacing Sensor,
replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FBA-19-20120816

240
 000604.03 —FNR Neutral Switch Open Circuit
000604.03 —
FNR Neutral Switch Open Circuit

Neutral start switch (S20) input circuit is open or mismatch exists between neutral start switch and TCL sensor
(B32). Neutral start switch indicates out of neutral and TCL sensor output voltage indicates neutral.

NOTE:

The FNR switch is also referred to as the TCL.

Neutral Start Switch Open Circuit Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Code Check
Action:

Check for active codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 002661.03 or 0002661.04 active?

Record of Actual Results:

Result:
YES:
Diagnose 002661.03 and 0002661.04 first. See Diagnostic Trouble Code (DTC) Quick Reference List—
Transmission Control Unit (TCU) . (Group 9001-30.)
NO:
Go to Component Check.

2 Component Check

Action:

Disconnect neutral start switch (S20). See Operator's Station Harness (W7) Component Location . (Group
9015-10.)

Check switch continuity at pins A and B while moving TCL.

Is continuity indicated in the neutral state only?

Record of Actual Results:

Result:
YES:
Go to TCL Sensor Check.
241
 000604.03 —FNR Neutral Switch Open Circuit

NO:
Replace neutral start switch (S20).

3 TCL Sensor Check

Action:

Check function of TCL sensor (B32) in transmission control lever (TCL). See Transmission Control Lever
(TCL) Adjustment . (Group 9015-20.)

Are TCL sensor output voltages within specifications for all TCL positions?

Record of Actual Results:

Result:
YES:
Go to Open Circuit Check.
NO:
Adjust TCL sensor linkage or replace TCL sensor.

4 Open Circuit Check

Action:

Turn key switch OFF.

Neutral start switch (S20) disconnect.

Disconnect TCU connector (X1). See Operator's Station Harness (W7) Component Location . (Group 9015-
10.)

Check continuity (wire T34 BLU) at pin A of neutral start switch (S20) and pin 14 of TCU connector (X1).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check for an open circuit between pin A on neutral start switch (S20) connector and pin 14 on TCU
connector (X1). Repair or replace harness. See Operator's Station Harness (W7) Wiring Diagram . (Group
9015-10.)
Action:

Key switch OFF.

Decelerator sensor (B1) disconnected.

242
 000604.03 —FNR Neutral Switch Open Circuit
Check ground at pin B (wire G03 BLK) on neutral start switch (S20) connector. See Operator's Station
Harness (W7) Wiring Diagram . (Group 9015-10.)

Is ground present?

Record of Actual Results:

Result:
YES:
Checks complete.
NO:
Check for an open circuit between pin B on neutral start switch (S20) connector and ground. Repair or
replace harness. See Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)

Go to Section_9001:Group_30

WS68074,0000F28-19-20130503

243
 000604.04 —FNR Neutral Switch Short Circuit
000604.04 —
FNR Neutral Switch Short Circuit

Neutral start switch (S20) input has short circuit or mismatch exists between neutral start switch and TCL sensor
(B32). Neutral start switch indicates neutral and TCL sensor voltage indicates out of neutral.

NOTE:

The FNR switch is also referred to as the TCL.

Neutral Start Switch Open Circuit Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Connector Check
Action:

Check neutral start switch (S20) connector and TCU 18-pin connector (X1) for corrosion, loose fit,
bent/pushed out terminals, or crimp malfunctions. See Operator's Station Harness (W7) Component
Location . (Group 9015-10.)

Are connectors in good condition?

Record of Actual Results:

Result:
YES:
Go to Component Check.
NO:
Repair or replace connector(s) or terminal(s) as needed.

2 Component Check
Action:

Disconnect neutral start switch (S20). See Operator's Station Harness (W7) Component Location . (Group
9015-10.)

Check switch continuity at pins A and B while moving TCL.

Is continuity indicated in the neutral state only?

Record of Actual Results:

Result:
YES:
244
 000604.04 —FNR Neutral Switch Short Circuit
Go to TCL Sensor Check.
NO:
Replace neutral start switch (S20).

3 TCL Sensor Check

Action:

Check function of TCL sensor (B32) in transmission control lever (TCL). See Transmission Control Lever
(TCL) Adjustment . (Group 9015-20.)

Are TCL sensor output voltages within specifications for all TCL positions?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check.
NO:
Adjust TCL sensor linkage or replace TCL sensor.

4 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect neutral start switch (S20). See Operator's Station Harness (W7) Component Location . (Group
9015-10.)

Check for ground (wire T34 BLU) at pin A of neutral start switch (S20).

Is ground present?

Record of Actual Results:

Result:
YES:
Short to ground between pin A on neutral start switch (S20) connector and pin 14 on TCU connector (X1).
Repair or replace harness. See Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000F29-19-20130503

245
 000604.15 —FNR Neutral Switch Minimum Calibration Value Too High
000604.15 —
FNR Neutral Switch Minimum Calibration Value Too High

Neutral Start Switch Stored Calibration Value Too High (Reverse)

NOTE:

The FNR switch is also referred to as the TCL.

Neutral Start Switch Minimum Calibration Value Too High Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Record stored forward SW calibration voltage from TCL sensor by accessing the Diagnostic / Calibrated
Values / Input Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—
Service Mode . (Group 9015-20.).

Record the neutral input voltage from TCL sensor by accessing the Diagnostic / Calibrated Values / Input
Voltages menu in the CMU menu structure.

Subtract 0.074 from the TCL sensor live neutral voltage.

Is subtracted value less than stored calibration voltage?

Record of Actual Results:

Result:
YES:
Go to Component Check.
NO:
Go to Replace Controller .

2 Component Check

Action:

Disconnect neutral start switch (S20). See Operator's Station Harness (W7) Component Location . (Group
9015-10.)

Check switch continuity at pins A and B while moving TCL.

Is continuity indicated in the neutral state only?

Record of Actual Results:

246
 000604.15 —FNR Neutral Switch Minimum Calibration Value Too High

Result:
YES:
Go to Component Adjustment .
NO:
Replace neutral start switch (S20). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration .
(Group 9015-20.)

3 Component Adjustment

Action:

Adjust TCL linkage. See Transmission Control Lever (TCL) Adjustment . (Group 90215-20.)

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 000604.15 active?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Repair complete.

4 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Is code 000604.15 still active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FB9-19-20120816

247
 000604.16 —FNR Neutral Switch Maximum Calibration Value Too High
000604.16 —
FNR Neutral Switch Maximum Calibration Value Too High

Neutral Start Switch Stored Calibration Value Too High (Forward)

NOTE:

The FNR switch is also referred to as the TCL.

Neutral Start Switch Maximum Calibration Value Too High Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Record stored forward SW calibration voltage from TCL sensor by accessing the Diagnostic / Calibrated
Values / Input Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—
Service Mode . (Group 9015-20.).

Record the neutral input voltage from TCL sensor by accessing the Diagnostic / Calibrated Values / Input
Voltages menu in the CMU menu structure.

Add 0.354 to the TCL sensor live neutral voltage.

Is added value less than stored calibration voltage?

Record of Actual Results:

Result:
YES:
Go to Component Check .
NO:
Go to Replace Controller .

2 Component Check

Action:

Disconnect neutral start switch (S20). See Operator's Station Harness (W7) Component Location . (Group
9015-10.)

Check switch continuity at pins A and B while moving TCL.

Is continuity indicated in the neutral state?

Record of Actual Results:

248
 000604.16 —FNR Neutral Switch Maximum Calibration Value Too High

Result:
YES:
Go to Component Adjustment .
NO:
Replace neutral start switch (S20). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration .
(Group 9015-20.)

3 Component Adjustment

Action:

Adjust TCL linkage. See Transmission Control Lever (TCL) Adjustment . (Group 90215-20.)

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 000604.16 active?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Repair complete.

4 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Is code 000604.16 still active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FB8-19-20120816

249
 000604.17 —FNR Neutral Switch Minimum Calibration Value Too Low
000604.17 —
FNR Neutral Switch Minimum Calibration Value Too Low

Neutral Start Switch Stored Calibration Value Too Low (Reverse)

NOTE:

The FNR switch is also referred to as the TCL.

Neutral Start Switch Minimum Calibration Value Too Low Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Record stored forward SW calibration voltage from TCL sensor by accessing the Diagnostic / Calibrated
Values / Input Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—
Service Mode . (Group 9015-20.).

Record the neutral input voltage from TCL sensor by accessing the Diagnostic / Calibrated Values / Input
Voltages menu in the CMU menu structure.

Subtract 0.354 from the TCL sensor live neutral voltage.

Is subtracted value greater than stored calibration voltage?

Record of Actual Results:

Result:
YES:
Go to Component Check .
NO:
Go to Replace Controller .

2 Component Check

Action:

Disconnect neutral start switch (S20). See Operator's Station Harness (W7) Component Location . (Group
9015-10.)

Check switch continuity at pins A and B while moving TCL.

Is continuity indicated in the neutral state?

Record of Actual Results:

250
 000604.17 —FNR Neutral Switch Minimum Calibration Value Too Low

Result:
YES:
Go to Component Adjustment .
NO:
Replace neutral start switch (S20). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration .
(Group 9015-20.)

3 Component Adjustment

Action:

Adjust TCL linkage. See Transmission Control Lever (TCL) Adjustment . (Group 90215-20.)

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 000604.15 active?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Repair complete.

4 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Is code 000604.17 still active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FB7-19-20120816

251
 000604.18 —FNR Neutral Switch Maximum Calibration Value Too Low
000604.18 —
FNR Neutral Switch Maximum Calibration Value Too Low

Neutral Start Switch Stored Calibration Value Too Low (Forward)

NOTE:

The FNR switch is also referred to as the TCL.

Neutral Start Switch Maximum Calibration Value Too Low Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Record stored forward SW calibration voltage from TCL sensor by accessing the Diagnostic / Calibrated
Values / Input Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—
Service Mode . (Group 9015-20.).

Record the neutral input voltage from TCL sensor by accessing the Diagnostic / Calibrated Values / Input
Voltages menu in the CMU menu structure.

Add 0.074 to the TCL sensor live neutral voltage.

Is added value greater than stored calibration voltage?

Record of Actual Results:

Result:
YES:
Go to Component Check .
NO:
Go to Replace Controller .

2 Component Check

Action:

Disconnect neutral start switch (S20). See Operator's Station Harness (W7) Component Location . (Group
9015-10.)

Check switch continuity at pins A and B while moving TCL.

Is continuity indicated in the neutral state?

Record of Actual Results:

252
 000604.18 —FNR Neutral Switch Maximum Calibration Value Too Low

Result:
YES:
Go to Component Adjustment .
NO:
Replace neutral start switch (S3). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration .
(Group 9015-20.)

3 Component Adjustment

Action:

Adjust TCL linkage. See Transmission Control Lever (TCL) Adjustment . (Group 90215-20.)

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 000604.18 active?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Repair complete.

4 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Is code 000604.18 still active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FB6-19-20120816

253
 000619.05 —Brake Solenoid No Response
000619.05 —
Brake Solenoid No Response

Park Brake Solenoid No Response

Park Brake Solenoid No Response Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Component Check
Action:

Disconnect park brake solenoids (Y2 and Y15). See Transmission Harness (W11) Component Location .
(Group 9015-10.)

Check resistance of park brake solenoids.

Item Measurement Specification

Park Brake Solenoid—Y2 and Y15 Resistance 17.3—19.5 ohms at -40°C (-40°F)
19.0—21.5 ohms at -20°C (-4°F)
20.8—23.5 ohms at 0°C (32°F)
22.7—25.6 ohms at 20°C (68°F)
24.4—27.6 ohms at 40°C (104°F)

Are the park brake solenoids within specifications?

Record of Actual Results:

Result:
YES:
Go to Open Circuit Check .
NO:
Replace faulty solenoid(s). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group
9015-20.)

2 Open Circuit Check

Action:

Turn key switch OFF.

Disconnect brake solenoid (Y15) and TCU connector (X2). See Transmission Harness (W11) Component
Location . (Group 9015-10.)

Check continuity (wire T24 BLU) between pin 1 on brake solenoid (Y15) connector and pin 15 on TCU
connector (X2). See Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)

Repeat check with pin 1 on brake solenoid (Y2) and pin 15 on TCU connector (X2).

254
 000619.05 —Brake Solenoid No Response
Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check for an open circuit between pin 1 on brake solenoids (Y2 and Y15) connector and pin 15 on TCU
connector (X2). Repair or replace harness. See Operator's Station Harness (W7) Wiring Diagram and see
Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)
Action:

Key switch OFF.

Brake solenoid (Y15) disconnected.

Check continuity (wire G10 BLK) between pin B on brake solenoid (Y15) connector and ground. See
Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)

Repeat check with pin 2 on brake solenoid (Y2) and ground.

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check G10 BLK for an open circuit between pin B on brake solenoids (Y2 and Y15) connector and ground.
Repair or replace harness. See Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)

3 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect brake solenoid (Y15) and TCU connector (X1). See Transmission Harness (W11) Component
Location . (Group 9015-10.)

Check for ground at pin 1 (wire T24 BLU) on brake solenoid (Y15) connector. See Transmission Harness
(W11) Wiring Diagram . (Group 9015-10.)

Repeat step at pin 1 on brake solenoid (Y2).

Is ground present?

Record of Actual Results:

255
 000619.05 —Brake Solenoid No Response

Result:
YES:
Check wire T24 BLU for a short circuit to ground. Repair or replace harness. See Engine Harness (W10)
Wiring Diagram and see Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)
NO:
Go to Replace Controller .

4 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 000619.05 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000F2E-19-20090527

256
 000620.03 —TCU 5V Supply Short to Power
000620.03 —
TCU 5V Supply Short to Power

TCU 5V Supply Short to Power

TCU 5V Supply Short to Power Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Short Circuit Check

Action:

Disconnect bussed sensor (X6) connector. see Operator's Station Harness (W7) Component Location .
(Group 9015-10.)

Turn key switch ON.

Check voltage at pin 1 (T01 BLU) on bussed sensor (X6) connector. See Operator's Station Harness (W7)
Wiring Diagram and Connectors X6-X7 Trouble Shooting Guide . (Group 9015-20.)

Is system voltage present?

Record of Actual Results:

Result:
YES:
Repair short to power between pin 1 on connector (X6) and TCU connector (X1). See Operator's Station
Harness (W7) Wiring Diagram . (Group 9015-10.)
NO:
Go to next step in this check.
Action:

Check voltage on the following pins on bussed sensor (X6) connector:

Pin 2 (wire T02)

Pin 3 (wire T04)
Pin 4 (wire T06)
Pin 5 (wire T08)
Pin 6 (wire T10)
Pin 7 (wire T12)
Pin 8 (wire T14)
Pin 9 (wire T15)
Pin 10 (wire T28)
Pin 11 (wire T29)
Pin 12 (wire T30)

Is voltage approximately 0 volts?

Record of Actual Results:

257
 000620.03 —TCU 5V Supply Short to Power

Result:
YES:
Repair short to power on wire that has voltage present. See Transmission Harness (W11) Wiring Diagram
and see Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)
NO:
Go to Replace Controller .

2 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Is code 000620.03 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000F2F-19-20080610

258
 000620.04 —TCU 5V Supply Open or Short
000620.04 —
TCU 5V Supply Open or Short

TCU 5V Supply Open or Short

TCU 5V Supply Open or Short Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Open Circuit Check

Action:

Turn key switch OFF.

Disconnect bussed sensor (X6) connector and TCU connector (X1). See Operator's Station Harness (W7)
Component Location . (Group 9015-10.)

Check continuity (wire T02 BLU) at pin 1 on connector (X6) and pin 3 on TCU connector (X1). See
Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check for an open circuit between pin 1 on bussed sensor (X6) connector and pin 3 on TCU connector (X1).
Repair or replace harness. See Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)

2 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect bussed sensor (X6) connector and TCU connector (X1). See Operator's Station Harness (W7)
Component Location . (Group 9015-10.)

Check for resistance between pins X6 and X7. See Connectors X6-X7 Trouble Shooting Guide . (Group
9015-20.)

Pin 2 (wire T02)

Pin 3 (wire T04)
Pin 4 (wire T06)
Pin 5 (wire T08)
Pin 6 (wire T10)
Pin 7 (wire T12)

259
 000620.04 —TCU 5V Supply Open or Short
Pin 8 (wire T14)
Pin 9 (wire T15)
Pin 10 (wire T28)
Pin 11 (wire T29)
Pin 12 (wire T30)

Is ground present?

Record of Actual Results:

Result:
YES:
Repair short to ground on wire that has ground present. See Transmission Harness (W11) Wiring Diagram
and see Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)
NO:
Go to Replace Controller .

3 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Is code 000620.04 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

JW40272,0000042-19-20080610

260
 000907.03 —Left Speed Sensor Short to Power
000907.03 —
Left Speed Sensor Short to Power

Left Speed Sensor Short to Power

Left Speed Sensor Short to Power Diagnostic Procedure

Alarm Level:

No Warning Lamp

Launch Close Expand List Collapse List

1 Code Check
Action:

Check for active codes, see CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 000620.03 active?

Record of Actual Results:

Result:
YES:
See 000620.03— TCU 5V Supply Short to Power . (Group 9001-30.)
NO:
Go to Component Check .

2 Component Check

Action:

Turn key switch OFF.

Disconnect left speed sensor (B2). See Transmission Harness (W11) Component Location . (Group 9015-
10.)

Turn key switch ON.

Is code 000907.03 active?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
NO:
Replace left speed sensor (B2). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration .
(Group 9015-20.)

261
 000907.03 —Left Speed Sensor Short to Power
3 Short Circuit Check

Action:

Left speed sensor (B2) disconnected.

Turn key switch ON.

Check voltage at pin B (wire T05 BLU) on left speed sensor (B2) connector. See Transmission Harness
(W11) Wiring Diagram . (Group 9015-10.)

Is voltage approximately 0 volts?

Record of Actual Results:

Result:
YES:
Checks complete.
NO:
Check wire T05 BLU for short to power between pins B on left speed sensor (B2) connector and pin 20 on
TCU connector (X1). See Transmission Harness (W11) Wiring Diagram and see Operator's Station Harness
(W7) Wiring Diagram . (Group 9015-10.)

Go to Section_9001:Group_30

WS68074,0000FCE-19-20110912

262
 000907.04 —Left Speed Sensor Short
000907.04 —
Left Speed Sensor Short

Left Speed Sensor Short

Left Speed Sensor Short Diagnostic Procedure

Alarm Level:

No Warning Lamp

Launch Close Expand List Collapse List

1 Code Check
Action:

Check for active codes, see CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 000620.04 active?

Record of Actual Results:

Result:
YES:
See 000620.04— TCU 5V Supply Open or Short . (Group 9001-30.)
NO:
Go to Short Circuit Check .

2 Short Circuit Check

Action:

Left speed sensor (B2) disconnected.

Turn key switch ON.

Check ground at pin B (wire T05 BLU) on left speed sensor (B2) connector. See Transmission Harness
(W11) Wiring Diagram . (Group 9015-10.)

Is ground present?

Record of Actual Results:

Result:
YES:
Check wire T05 BLU for short to ground between pins B on left speed sensor (B2) connector and pin 20 on
TCU connector (X1). See Transmission Harness (W11) Wiring Diagram and see Operator's Station Harness
(W7) Wiring Diagram . (Group 9015-10.)
NO:
Checks complete.

263
000907.04 —Left Speed Sensor Short

Go to Section_9001:Group_30

WS68074,0000FD0-19-20110912

264
 000907.07 —Left Speed Sensor No Response
000907.07 —
Left Speed Sensor No Response

Left Speed Sensor No Response

Left Speed Sensor No Response Diagnostic Procedure

Alarm Level:

No Warning Lamp

Launch Close Expand List Collapse List

1 Circuit Check
Action:

Disconnect left speed sensor (B2). See Transmission Harness (W11) Component Location . (Group 9015-
10.)

Check voltage at pin A (wire T04 BLU) on left speed sensor (B2) connector. See Transmission Harness
(W11) Wiring Diagram . (Group 9015-10.)

Is voltage approximately 5 volts?

Record of Actual Results:

Result:
YES:
Go to next step in check.
NO:
Check wire T04 BLU for short to ground or open circuit between pin A on left speed sensor (B2) connector
and pin 3 on TCU connector (X1). See Transmission Harness (W11) Wiring Diagram and see Operator's
Station Harness (W7) Wiring Diagram . (Group 9015-10.)
Action:

Left speed sensor (B2) disconnected.

Check ground at pin C (wire R03 BLK) on left speed sensor (B2) connector. See Transmission Harness
(W11) Wiring Diagram . (Group 9015-10.)

Is ground present?

Record of Actual Results:

Result:
YES:
Go to next step in check.
NO:
Check wire R03 BLU for short to ground or open circuit between pin C on left speed sensor (B2) connector
and pin 22 on TCU connector (X1). See Transmission Harness (W11) Wiring Diagram and see Operator's
Station Harness (W7) Wiring Diagram . (Group 9015-10.)
265
 000907.07 —Left Speed Sensor No Response

Action:

Left speed sensor (B2) disconnected.

Disconnect TCU connector (X1). See Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)

Check continuity (wire T05 BLU) at pin B on left speed sensor (B2) connector and pin 20 on TCU connector
(X1).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Replace left speed sensor (B2). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration .
(Group 9015-20.)
NO:
Check wire T05 BLU for open circuit between pin C on left speed sensor (B2) connector and pin 20 on TCU
connector (X1). See Transmission Harness (W11) Wiring Diagram and see Operator's Station Harness (W7)
Wiring Diagram . (Group 9015-10.)

Go to Section_9001:Group_30

WS68074,0000FDA-19-20110912

266
 000907.12 —Left Speed Sensor Open
000907.12 —
Left Speed Sensor Open

Left Speed Sensor Open

Left Speed Sensor Open Diagnostic Procedure

Alarm Level:

No Warning Lamp

Launch Close Expand List Collapse List

1 Open Circuit Check

Action:

Turn key switch OFF.

Disconnect left speed sensor (B2). See Transmission Harness (W11) Component Location . (Group 9015-
10.)

Turn key switch ON.

Check voltage at pin A (wire T04 BLU) on left speed sensor (B2) connector. See Transmission Harness
(W11) Wiring Diagram . (Group 9015-10.)

Is voltage approximately 5 volts?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check for an open circuit between pin A (wire T04 BLU) on left speed sensor (B2) connector and pin 3 (wire
T01 BLU) on TCU connector (X1). Repair or replace harness. See Operator's Station Harness (W7) Wiring
Diagram . (Group 9015-10.)
Action:

Key switch OFF.

Left speed sensor (B2) disconnected.

Disconnect TCU connector (X1). See Operator's Station Harness (W7) Component Location . (Group 9015-
10.)

Check wire T05 BLU for continuity between pin B on left speed sensor (B2) connector and pin 20 on TCU
connector (X1). See Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)

Is continuity indicated?

Record of Actual Results:

267
 000907.12 —Left Speed Sensor Open

Result:
YES:
Go to next step in this check.
NO:
Check T05 BLU for an open circuit between pin B on left speed sensor (B2) connector and pin 20 on TCU
connector (X1). Repair or replace harness. See Operator's Station Harness (W7) Wiring Diagram . (Group
9015-10.)
Action:

Key switch OFF.

Left speed sensor (B2) disconnected.

TCU connector (X1) disconnected.

Check for continuity between pin C (wire R03 BLK) on left speed sensor (B2) connector and pin 22 (R01
BLK) on TCU connector (X1). See Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Replace left speed sensor (B2). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration .
(Group 9015-20.)
NO:
Check for an open circuit between pin C (wire R03 BLK) on left speed sensor (B2) connector and pin 22 on
TCU connector (X1). Repair or replace harness. See Operator's Station Harness (W7) Wiring Diagram .
(Group 9015-10.)

Go to Section_9001:Group_30

WS68074,0000FD1-19-20110912

268
 000908.03 —Right Speed Sensor Short to Power
000908.03 —
Right Speed Sensor Short to Power

Right Speed Sensor Short to Power

Right Speed Sensor Short to Power Diagnostic Procedure

Alarm Level:

No Warning Lamp

Launch Close Expand List Collapse List

1 Code Check
Action:

Check for active codes, see CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 000620.03 active?

Record of Actual Results:

Result:
YES:
See 000620.03— TCU 5V Supply Short to Power . (Group 9001-30.)
NO:
Component Check .

2 Component Check

Action:

Turn key switch OFF.

Disconnect right speed sensor (B3). See Transmission Harness (W11) Component Location . (Group 9015-
10.)

Turn key switch ON.

Is code 000908.03 active?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
NO:
Replace right speed sensor (B3). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration .
(Group 9015-20.)

269
 000908.03 —Right Speed Sensor Short to Power
3 Short Circuit Check

Action:

Right speed sensor (B3) disconnected.

Turn key switch ON.

Check voltage at pin B (wire T07 BLU) on right speed sensor (B3) connector. See Transmission Harness
(W11) Wiring Diagram . (Group 9015-10.)

Is voltage approximately 0 volts?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Check wire T07 BLU for short to power between pins B on right speed sensor (B3) connector and pin 21 on
TCU connector (X1). See Transmission Harness (W11) Wiring Diagram and see Operator's Station Harness
(W7) Wiring Diagram . (Group 9015-10.)

4 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Is code 000908.03 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FCF-19-20080610

270
 000908.04 —Right Speed Sensor Short
000908.04 —
Right Speed Sensor Short

Right Speed Sensor Short

Right Speed Sensor Short Diagnostic Procedure

Alarm Level:

No Warning Lamp

Launch Close Expand List Collapse List

1 Code Check
Action:

Check for active codes, see CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 000620.04 active?

Record of Actual Results:

Result:
YES:
See code 000620.04— TCU 5V Supply Open or Short . (Group 9001-30.)
NO:
Go to Short Circuit Check .

2 Short Circuit Check

Action:

Right speed sensor (B3) disconnected.

Turn key switch ON.

Check ground at pin B (wire T07 BLU) on right speed sensor (B3) connector. See Transmission Harness
(W11) Wiring Diagram . (Group 9015-10.)

Is ground present?

Record of Actual Results:

Result:
YES:
Check wire T07 BLU for short to ground between pins B on right speed sensor (B3) connector and pin 21 on
TCU connector (X1). See Transmission Harness (W11) Wiring Diagram and see Operator's Station Harness
(W7) Wiring Diagram . (Group 9015-10.)
NO:
Go to Replace Controller .

271
 000908.04 —Right Speed Sensor Short

3 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Is code 000908.04 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FD9-19-20080610

272
 000908.07 —Right Speed Sensor No Response
000908.07 —
Right Speed Sensor No Response

Right Speed Sensor No Response

Right Speed Sensor No Response Diagnostic Procedure

Alarm Level:

No Warning Lamp

Launch Close Expand List Collapse List

1 Circuit Check
Action:

Disconnect right speed sensor (B3). See Transmission Harness (W11) Component Location . (Group 9015-
10.)

Check voltage at pin A (wire T06 BLU) on right speed sensor (B3) connector. See Transmission Harness
(W11) Wiring Diagram . (Group 9015-10.)

Is voltage approximately 5 volts?

Record of Actual Results:

Result:
YES:
Go to next step in check.
NO:
Check wire T06 BLU for short to ground or open circuit between pins A on right speed sensor (B3)
connector and pin 3 on TCU connector (X1). See Transmission Harness (W11) Wiring Diagram and see
Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)
Action:

Right speed sensor (B3) disconnected.

Check ground at pin C (wire R04 BLK) on right speed sensor (B3) connector. See Transmission Harness
(W11) Wiring Diagram . (Group 9015-10.)

Is ground present?

Record of Actual Results:

Result:
YES:
Go to next step in check.
NO:
Check wire R04 BLU for short to ground or open circuit between pins C on right speed sensor (B3)
connector and pin 22 on TCU connector (X1). See Transmission Harness (W11) Wiring Diagram and see
Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)
273
 000908.07 —Right Speed Sensor No Response

Action:

Right speed sensor (B3) disconnected.

Disconnect TCU connector (X1). see Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)

Check continuity (wire T07 BLU) at pin B on right speed sensor (B3) connector and pin 21 on TCU connector
(X1).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Replace right speed sensor (B3). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration .
(Group 9015-20.) If code 000908.07 is still active after repair, Go to Replace Controller .
NO:
Check wire T07 BLU for open circuit between pins C on right speed sensor (B3) connector and pin 21 on
TCU connector (X1). See Transmission Harness (W11) Wiring Diagram and see Operator's Station Harness
(W7) Wiring Diagram . (Group 9015-10.)

2 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Is code 000908.07 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FDB-19-20080610

274
 000908.12 —Right Speed Sensor Open
000908.12 —
Right Speed Sensor Open

Right Speed Sensor Open

Right Speed Sensor Open Diagnostic Procedure

Alarm Level:

No Warning Lamp

Launch Close Expand List Collapse List

1 Open Circuit Check

Action:

Turn key switch OFF.

Disconnect right speed sensor (B3). See Transmission Harness (W11) Component Location . (Group 9015-
10.)

Turn key switch ON.

Check voltage at pin A (wire T06 BLU) on right speed sensor (B3) connector. See Transmission Harness
(W11) Wiring Diagram . (Group 9015-10.)

Is voltage approximately 5 volts?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check for an open circuit between pin A (wire T06 BLU) on right speed sensor (B3) connector and pin 3
(wire T01 BLU) on TCU connector (X1). Repair or replace harness. See Operator's Station Harness (W7)
Wiring Diagram . (Group 9015-10.)
Action:

Key switch OFF.

Right speed sensor (B3) disconnected.

Disconnect TCU connector (X1). See Operator's Station Harness (W7) Component Location . (Group 9015-
10.)

Check wire T07 BLU for continuity between pin B on right speed sensor (B3) connector and pin 21 on TCU
connector (X1). See Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)

Is continuity indicated?

Record of Actual Results:

275
 000908.12 —Right Speed Sensor Open

Result:
YES:
Go to next step in this check.
NO:
Check T07 BLU for an open circuit between pin B on right speed sensor (B3) connector and pin 21 on TCU
connector (X1). Repair or replace harness. See Operator's Station Harness (W7) Wiring Diagram . (Group
9015-10.)
Action:

Key switch OFF.

Right speed sensor (B3) and TCU connector (X1) disconnected.

Check for continuity between pin C (wire R04 BLK) on right speed sensor (B3) connector and pin 22 (R01
BLK) on TCU connector (X1). See Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Replace right speed sensor (B3). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration .
(Group 9015-20.) If code 000908.07 is still active after repair, Go to Replace Controller .
NO:
Check for an open circuit between pin C on right speed sensor (B3) connector and pin 22 on TCU connector
(X1). Repair or replace harness. See Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)

2 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Is code 000907.12 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FDC-19-20080610

276
000908.12 —Right Speed Sensor Open

277
 000977.05 —Fan Reverse Solenoid No Response
000977.05 —
Fan Reverse Solenoid No Response

Hydraulic fan reversing solenoid (Y6) is not responding.

Fan Reverse Solenoid No Response Diagnostic Procedure

Alarm Level:

No Warning Lamp

NOTE:

This DTC is only declared when the solenoid is energized.

Launch Close Expand List Collapse List

1 Component Check
Action:

Disconnect hydraulic fan reversing solenoid (Y6). See Engine Harness (W10) Component Location . (Group
9015-10.)

Check resistance of solenoid. See Electrical Component Specifications . (Group 9015-20.)

Is solenoid resistance within specifications?

Record of Actual Results:

Result:
YES:
Go to Open Circuit Check.
NO:
Replace solenoid.

2 Open Circuit Check

Action:

Turn key switch OFF.

Hydraulic fan reversing solenoid (Y6) disconnected.

Disconnect TCU connector (X2). See Operator's Station Harness (W7) Component Location . (Group 9015-
10.)

Check continuity (wire H03 GRN) between pin 1 of hydraulic fan reversing solenoid (Y6) connector and pin
13 of TCU connector (X2).

Is there continuity indicated?

Record of Actual Results:

278
 000977.05 —Fan Reverse Solenoid No Response

Result:
YES:
Go to next step in this check.
NO:
Check for an open circuit between pin 1 of hydraulic fan reversing solenoid (Y6) connector and pin 13 of
TCU connector (X2). Repair or replace harness.
Action:

Check continuity (wire G11 BLK) between pin 2 of hydraulic fan reversing solenoid (Y6) connector and
ground.

Is there continuity indicated?

Record of Actual Results:

Result:
YES:
Checks complete.
NO:
Check for an open circuit between pin 2 of hydraulic fan reversing solenoid (Y6) connector and ground.
Repair or replace harness.

Go to Section_9001:Group_30

WS68074,0000FD8-19-20130806

279
 001071.05 —Fan Drive Solenoid Open Circuit
001071.05 —
Fan Drive Solenoid Open Circuit

Hydraulic Fan Proportional Relief Solenoid Open Circuit

Hydraulic Fan Proportional Relief Solenoid Open Circuit Diagnostic Procedure

Alarm Level:

No Warning Lamp

Launch Close Expand List Collapse List

1 Component Check
Action:

Disconnect hydraulic fan proportional relief solenoid (Y5). See Transmission Harness (W11) Component
Location . (Group 9015-10.)

Check resistance of solenoid across pins 1 and 2.

Item Measurement Specification

Hydraulic Fan Proportional Relief Solenoid (Y5 and Y5A) Resistance 27—30 ohms at 20°C (68°F)

Is solenoid within specifications?

Record of Actual Results:

Result:
YES:
Go to Open Circuit Check.
NO:
Replace solenoid.

2 Open Circuit Check

Action:

Turn key switch OFF.

Hydraulic fan proportional relief solenoid (Y5) disconnectd.

Disconnect TCU connector (X2). See Operator's Station Harness (W7) Component Location . (Group 9015-
10.)

Check continuity (wire H02 GRN) between pin 1 of hydraulic fan proportional relief solenoid (Y5) connector
and pin 14 of TCU connector (X2). See Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)

Is there continuity indicated?

Record of Actual Results:

280
 001071.05 —Fan Drive Solenoid Open Circuit

Result:
YES:
Go to next step in this check.
NO:
Check for an open circuit between pin 1 of hydraulic fan proportional relief solenoid (Y5) connector and pin
14 of TCU connector (X2). Repair or replace harness. See Operator's Station Harness (W7) Wiring Diagram
and see Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)
Action:

Check continuity (wire G11 BLK) between pin 2 of hydraulic fan proportional relief solenoid (Y5) connector
and ground. See Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)

Is there continuity indicated?

Record of Actual Results:

Result:
YES:
Checks complete.
NO:
Check for an open circuit between pin 2 of hydraulic fan proportional relief solenoid (Y5) connector and
ground. Repair or replace harness. See Engine Harness (W10) Wiring Diagram and see Transmission
Harness (W11) Wiring Diagram . (Group 9015-10.)

Go to Section_9001:Group_30

WS68074,0000FD7-19-20130806

281
 001071.06 —Fan Drive Solenoid Short Circuit
001071.06 —
Fan Drive Solenoid Short Circuit

Hydraulic Fan Proportional Relief Solenoid Short Circuit

Hydraulic Fan Proportional Relief Solenoid Short Circuit Diagnostic Procedure

Alarm Level:

No Warning Lamp

Launch Close Expand List Collapse List

1 Component Check
Action:

Turn key switch OFF.

Disconnect hydraulic fan proportional relief solenoid (Y5). See Transmission Harness (W11) Component
Location . (Group 9015-10.)

Check resistance of solenoid across pins 1 and 2.

Item Measurement Specification

Hydraulic Fan Proportional Relief Solenoid (Y5 and Y5A) Resistance 27—30 ohms at 20°C (68°F)

Is solenoid within specifications?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check.
NO:
Replace solenoid.

2 Short Circuit Check

Action:

Turn key switch OFF.

Hydraulic fan proportional relief solenoid (Y5) diconnected.

Check for ground (wire H02 GRN) at pin 1 of hydraulic fan proportional relief solenoid (Y5) connector. See
Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)

Is there ground present?

Record of Actual Results:

282
 001071.06 —Fan Drive Solenoid Short Circuit

Result:
YES:
Check for a short to ground between pin 1 of hydraulic fan proportional relief solenoid (Y5) connector and pin
14 of TCU connector (X2). Repair or replace harness. See Operator's Station Harness (W7) Wiring Diagram
and see Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FD6-19-20130806

283
 002660.00 —Steer Sensor Input Greater Than Maximum Calibration Value
002660.00 —
Steer Sensor Input Greater Than Maximum Calibration Value

Left Steer Sensor Input Greater Than Maximum Calibration Value

Left Steer Sensor Input Greater Than Maximum Calibration Value Diagnostic Procedure

Alarm Level:

No Warning Lamp

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Observe the input voltage from steer sensor (B33) by accessing the Diagnostic / Live Values / Input Voltages
menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group
9015-20.)

Record voltage readings while moving TCL lever to right and left steer positions.

Item Measurement Specification

Steer Sensor (B33) Calibration Limits 2.3—2.7 V at Neutral Position
1.52—1.94 V at Right Steer Position
1.40—1.78 V at Right Counter Rotate Position
3.06—3.48 V at Left Steer Position
3.22—3.60 V at Left Counter Rotate Position

Are readings within specifications?

Record of Actual Results:

Result:
YES:
Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)
NO:
Go to Code Check.

2 Code Check
Action:

Check for active codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 002660.03 or code 002660.04 present?

Record of Actual Results:

Result:

284
 002660.00 —Steer Sensor Input Greater Than Maximum Calibration Value

YES:
See code 002660.03— Steer Sensor Short to Power or 002660.04— Steer Sensor Open or Short . (Group
9001-30.)
NO:
Go to Replace Controller.

3 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Is code 002660.00 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FB5-19-20090909

285
 002660.01 —Steer Sensor Input Less Than Minimum Calibration Value
002660.01 —
Steer Sensor Input Less Than Minimum Calibration Value

Steer Sensor Input Less Than Minimum Calibration Value

Steer Sensor Input Less Than Minimum Calibration Value Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Observe the input voltage from steer sensor (B33) by accessing the Diagnostic / Live Values / Input Voltages
menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group
9015-20.)

Record voltage readings while moving TCL lever to right and left steer positions.

Item Measurement Specification

Steer Sensor (B33) Calibration Limits 2.3—2.7 V at Neutral Position
1.52—1.94 V at Right Steer Position
1.40—1.78 V at Right Counter Rotate Position
3.06—3.48 V at Left Steer Position
3.22—3.60 V at Left Counter Rotate Position

Are readings within specifications?

Record of Actual Results:

Result:
YES:
Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)
NO:
Go to Code Check.

2 Code Check
Action:

Check for active codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 002660.03 or code 002660.04 present?

Record of Actual Results:

Result:

286
 002660.01 —Steer Sensor Input Less Than Minimum Calibration Value

YES:
See code 002660.03— Steer Sensor Short to Power or 002660.04— Steer Sensor Open or Short . (Group
9001-30.)
NO:
Go to Replace Controller.

3 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Is code 002660.01 still active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FB4-19-20090909

287
 002660.03 —Steer Sensor Short to Power
002660.03 —
Steer Sensor Short to Power

Steer Sensor Short to Power

Steer Sensor Short to Power Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Code Check
Action:

Check for active codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 000620.03 active?

Record of Actual Results:

Result:
YES:
See 000620.03— TCU 5V Supply Short to Power . (Group 9001-30.)
NO:
Go to Component Check .

2 Component Check

Action:

Turn key switch OFF.

Disconnect steer sensor (B33). See Operator's Station Harness (W7) Component Location . (Group 9015-
10.)

Turn key switch ON.

Is code 002660.03 active?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
NO:
Replace steer sensor (B33). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group
9015-20.)

288
 002660.03 —Steer Sensor Short to Power
3 Short Circuit Check

Action:

Steer sensor (B33) disconnected.

Turn key switch ON.

Check voltage at pin B (wire T32 BLU) on steer sensor (B33) connector. See Transmission Harness (W11)
Wiring Diagram . (Group 9015-10.)

Is voltage approximately 0 volts?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Check wire T32 BLU for short to power between pins B on steer sensor (B33) connector and pin 24 on TCU
connector (X1).

4 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Is code 002660.03 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FD5-19-20080610

289
 002660.04 —Steer Sensor Open or Short
002660.04 —
Steer Sensor Open or Short

Steer Sensor Open or Short

Steer Sensor Open or Short Diagnostic Procedure

Launch Close Expand List Collapse List

1 Code Check

Action:

Check for active codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 000620.04 active?

Record of Actual Results:

Result:
YES:
See 000620.04— TCU 5V Supply Open or Short . (Group 9001-30.)
NO:
Go to Open Circuit Check .

2 Open Circuit Check

Action:

Disconnect steer sensor (B33). See Operator's Station Harness (W7) Component Location . (Group 9015-
10.)

Turn key switch ON.

Check for voltage at pin A (wire T28 BLU) of steer sensor (B33) connector.

Is voltage approximately 5 volts?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Repair open circuit between pin A of steer sensor (B33) connector and pin 11 of 5 volt bussed sensor
connector (X6). Repair or replace harness.
Action:

Turn key switch OFF.

Steer sensor (B33) disconnected.

290
 002660.04 —Steer Sensor Open or Short
Check for ground at pin C (wire R23 BLK) of steer sensor (B33) connector.

Is ground present?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Repair open circuit between pin C of steer sensor (B33) connector and pin 12 of bussed ground sensor
connector (X7). Repair or replace harness.
Action:

Key switch OFF.

Steer sensor (B33) disconnected.

Disconnect TCU connector (X1). See Operator's Station Harness (W7) Component Location . (Group 9015-
10.)

Check continuity between pin B (wire T32 BLU) of steer sensor (B33) connector and pin 24 of TCU
connector (X1).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
NO:
Repair open circuit between pin B of steer sensor (B33) connector and pin 24 of TCU connector (X1). Repair
or replace harness.

3 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect steer sensor (B33). See Transmission Harness (W11) Component Location and see Operator's
Station Harness (W7) Component Location . (Group 9015-10.)

Check ground at pin (T32 BLU) of steer sensor (B33) connector. See Operator's Station Harness (W7)
Wiring Diagram . (Group 9015-10.)

Is ground present?

Record of Actual Results:

291
 002660.04 —Steer Sensor Open or Short

Result:
YES:
Repair short to ground between pin B of steer sensor (B33) connector and pin 24 of TCU connector (X1).
Repair or replace harness.
NO:
Replace steer sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-
20.) If code 002660.04 is still active after sensor replacement, Go to Replace Controller .

4 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 002660.04 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000F3F-19-20080610

292
 002660.15 —Steer Sensor Minimum Calibration Value Too High
002660.15 —
Steer Sensor Minimum Calibration Value Too High

Right Steer Sensor Minimum Calibration Value Too High

Right Steer Sensor Minimum Calibration Value Too High Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Observe the input voltage from steer sensor (B33) by accessing the Diagnostic / Live Values / Input Voltages
menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group
9015-20.)

Record voltage readings while moving TCL lever to right and left steer positions.

Item Measurement Specification

Steer Sensor (B33) Calibration Limits 2.3—2.7 V at Neutral Position
1.52—1.94 V at Right Steer Position
1.40—1.78 V at Right Counter Rotate Position
3.06—3.48 V at Left Steer Position
3.22—3.60 V at Left Counter Rotate Position

Are readings within specifications?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Go to Sensor Adjustment.

2 Sensor Adjustment
Action:

Adjust TCL sensor linkage. See Transmission Control Lever (TCL) Adjustment . (Group 9015-20.)

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 002661.15 still active?

Record of Actual Results:

293
 002660.15 —Steer Sensor Minimum Calibration Value Too High

Result:
YES:
Go to Component Check .
NO:
Repair complete.

3 Component Check
Action:

Remove the steer sensor and verify the shaft is turning.

Is steer sensor shaft turning?

Record of Actual Results:

Result:
YES:
Go to Replace Controller.
NO:
Replace steer sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-
20.)

4 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Is code 002660.15 still active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FB3-19-20090909

294
 002660.16 —Steer Sensor Maximum Calibration Value Too High
002660.16 —
Steer Sensor Maximum Calibration Value Too High

Steer Sensor Maximum Calibration Value Too High

Steer Sensor Maximum Calibration Value Too High Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Observe the input voltage from steer sensor (B33) by accessing the Diagnostic / Live Values / Input Voltages
menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group
9015-20.)

Record voltage readings while moving TCL lever to right and left steer positions.

Item Measurement Specification

Steer Sensor (B33) Calibration Limits 2.3—2.7 V at Neutral Position
1.52—1.94 V at Right Steer Position
1.40—1.78 V at Right Counter Rotate Position
3.06—3.48 V at Left Steer Position
3.22—3.60 V at Left Counter Rotate Position

Are readings within specifications?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Go to Sensor Adjustment.

2 Sensor Adjustment
Action:

Adjust TCL sensor linkage. See Transmission Control Lever (TCL) Adjustment . (Group 9015-20.)

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 002661.16 still active?

Record of Actual Results:

295
 002660.16 —Steer Sensor Maximum Calibration Value Too High

Result:
YES:
Go to Component Check .
NO:
Repair complete.

3 Component Check
Action:

Remove the steer sensor and verify the shaft is turning.

Is steer sensor shaft turning?

Record of Actual Results:

Result:
YES:
Go to Replace Controller.
NO:
Replace steer sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-
20.)

4 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Is code 002660.16 still active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FB2-19-20090909

296
 002660.17 —Steer Sensor Minimum Calibration Value Too Low
002660.17 —
Steer Sensor Minimum Calibration Value Too Low

Steer Sensor Minimum Calibration Value Too Low

Steer Sensor Minimum Calibration Value Too Low Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Observe the input voltage from steer sensor (B33) by accessing the Diagnostic / Live Values / Input Voltages
menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group
9015-20.)

Record voltage readings while moving TCL lever to right and left steer positions.

Item Measurement Specification

Steer Sensor (B33) Calibration Limits 2.3—2.7 V at Neutral Position
1.52—1.94 V at Right Steer Position
1.40—1.78 V at Right Counter Rotate Position
3.06—3.48 V at Left Steer Position
3.22—3.60 V at Left Counter Rotate Position

Are readings within specifications?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Go to Sensor Adjustment.

2 Sensor Adjustment
Action:

Adjust TCL sensor linkage. See Transmission Control Lever (TCL) Adjustment . (Group 9015-20.) Calibrate
the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 002661.07 still active?

Record of Actual Results:

297
 002660.17 —Steer Sensor Minimum Calibration Value Too Low

Result:
YES:
Go to Component Check.
NO:
Repair complete.

3 Component Check
Action:

Remove the steer sensor and verify the shaft is turning.

Is steer sensor shaft turning?

Record of Actual Results:

Result:
YES:
Go to Replace Controller.
NO:
Replace steer sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-
20.)

4 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Is code 002660.17 still active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FB1-19-20090909

298
 002660.18 —Steer Sensor Maximum Calibration Value Too Low
002660.18 —
Steer Sensor Maximum Calibration Value Too Low

Steer Sensor Maximum Calibration Value Too Low

Steer Sensor Maximum Calibration Value Too Low Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Observe the input voltage from steer sensor (B33) by accessing the Diagnostic / Live Values / Input Voltages
menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group
9015-20.)

Record voltage readings while moving TCL lever to right and left steer positions.

Item Measurement Specification

Steer Sensor (B33) Calibration Limits 2.3—2.7 V at Neutral Position
1.52—1.94 V at Right Steer Position
1.40—1.78 V at Right Counter Rotate Position
3.06—3.48 V at Left Steer Position
3.22—3.60 V at Left Counter Rotate Position

Are readings within specifications?

Record of Actual Results:

Result:
YES:
Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)
NO:
Go to Sensor Adjustment.

2 Sensor Adjustment
Action:

Adjust TCL sensor linkage. See Transmission Control Lever (TCL) Adjustment . (Group 9015-20.) Calibrate
the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 002661.00 still active?

Record of Actual Results:

299
 002660.18 —Steer Sensor Maximum Calibration Value Too Low

Result:
YES:
Go to Replace Controller.
NO:
Repair complete.

3 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Is code 002660.18 still active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FB0-19-20090909

300
 002661.00 —FNR Sensor Input Greater Than Maximum Calibration Value
002661.00 —
FNR Sensor Input Greater Than Maximum Calibration Value

TCL Sensor Input Greater Than Maximum Calibration Value

NOTE:

FNR is also referred to as the TCL.

FNR Sensor Input Greater Than Maximum Calibration Value Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Perform Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 002661.15 or 002661.16 active?

Record of Actual Results:

Result:
YES:
See code 002661.15— FNR Sensor Minimum Calibration Value Too High or 002661.16— FNR Sensor
Maximum Calibration Value Too High
NO:
Go to next step in this check.
Action:

Is code 002661.00 active?

Record of Actual Results:

Result:
YES:
Go to Replace Controller.
NO:
Checks complete.

2 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

301
 002661.00 —FNR Sensor Input Greater Than Maximum Calibration Value
Replace transmission control unit (TCU) (A1).

Is code 002661.00 still active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FAF-19-20091202

302
 002661.01 —FNR Sensor Input Less Than Minimum Calibration Value
002661.01 —
FNR Sensor Input Less Than Minimum Calibration Value

TCL Sensor Input Less Than Minimum Calibration Value

NOTE:

FNR is also referred to as the TCL.

FNR Sensor Input Less Than Minimum Calibration Value Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Perform Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 002661.17 or 002661.18 active?

Record of Actual Results:

Result:
YES:
See code 002661.17— FNR Sensor Minimum Calibration Value Too Low or 002661.18— FNR Sensor
Maximum Calibration Value Too Low
NO:
Go to next step in this check.
Action:

Is code 002661.01 active?

Record of Actual Results:

Result:
YES:
Go to Replace Controller.
NO:
Checks complete.

2 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

303
 002661.01 —FNR Sensor Input Less Than Minimum Calibration Value
Replace transmission control unit (TCU) (A1).

Is code 002661.01 still active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FAE-19-20091202

304
 002661.03 —FNR Sensor Short to Power
002661.03 —
FNR Sensor Short to Power

TCL Sensor Short to Power

NOTE:

FNR is also referred to as the TCL.

TCL Sensor Short to Power Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Code Check
Action:

Check for active codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 000620.03 active?

Record of Actual Results:

Result:
YES:
See 000620.03— TCU 5V Supply Short to Power . (group 9001-30.)
NO:
Go to Component Check .

2 Component Check

Action:

Turn key switch OFF.

Disconnect TCL sensor (B32). See Operator's Station Harness (W7) Component Location . (Group 9015-
10.)

Turn key switch ON.

Is code 002661.03 active?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
305
 002661.03 —FNR Sensor Short to Power

NO:
Replace TCL sensor (B32). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group
9015-20.)

3 Short Circuit Check

Action:

TCL sensor (B32) disconnected.

Turn key switch ON.

Check voltage at pin B (wire T31 BLU) on TCL sensor (B32) connector. See Transmission Harness (W11)
Wiring Diagram . (Group 9015-10.)

Is voltage approximately 0 volts?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Check wire T31 BLU for short to power between pins B on TCL sensor (B32) connector and pin 23 on TCU
connector (X1).

4 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Is code 002661.03 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FD4-19-20080610

306
 002661.04 —FNR Sensor Open or Short
002661.04 —
FNR Sensor Open or Short

TCL Sensor Open or Short

NOTE:

FNR is also referred to as the TCL.

TCL Sensor Open or Short Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Code Check
Action:

Check for active codes, see CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 000620.04 active?

Record of Actual Results:

Result:
YES:
See 000620.04— TCU 5V Supply Open or Short . (Group 9001-30.)
NO:
Go to Open Circuit Check .

2 Open Circuit Check

Action:

Turn key switch OFF.

Disconnect TCL sensor (B32) connector. See Transmission Harness (W11) Component Location . (Group
9015-10.)

Turn key switch ON.

Check voltage at pin A (wire T28 BLU) on TCL sensor (B32) connector. See Transmission Harness (W11)
Wiring Diagram . (Group 9015-10.)

Is voltage approximately 5 volts?

Record of Actual Results:

307
 002661.04 —FNR Sensor Open or Short

Result:
YES:
Go to next step in this check.
NO:
Check for an open circuit between pin A (wire T28 BLU) on TCL sensor (B32) connector and pin 3 (wire T01
BLU) on TCU connector (X1). Repair or replace harness. See Transmission Harness (W11) Wiring Diagram
and see Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)
Action:

Key switch OFF.

TCL sensor (B32) disconnected.

Disconnect TCU connector (X1). See Operator's Station Harness (W7) Component Location . (Group 9015-
10.)

Check continuity (wire T31 BLU) between pin B on TCL sensor (B32) connector and pin 23 on TCU
connector (X1). See Transmission Harness (W11) Wiring Diagram and see Operator's Station Harness (W7)
Wiring Diagram . (Group 9015-10.)

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check for an open circuit between pin B on TCL sensor (B32) connector and pin 23 on TCU connector (X1).
Repair or replace harness. See Transmission Harness (W11) Wiring Diagram and see Operator's Station
Harness (W7) Wiring Diagram . (Group 9015-10.)
Action:

Key switch OFF.

TCL sensor (B32) and TCU connector (X1) disconnected.

Check for continuity between pin C (wire R22 BLK) on TCL sensor (B32) connector and pin 22 (R01 BLK) on
TCU connector (X1). See Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
NO:
Check for an open circuit between pin C (wire R22 BLK) on TCL sensor (B32) connector and pin 22 on TCU
connector (X1). Repair or replace harness. See Operator's Station Harness (W7) Wiring Diagram . (Group

308
 002661.04 —FNR Sensor Open or Short
9015-10.)

3 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect TCL sensor (B32) and TCU connector (X1). See Operator's Station Harness (W7) Component
Location and see Transmission Harness (W11) Component Location . (Group 9015-10.)

Check for ground at pin B (wire T31 BLU) on TCL sensor (B32) connector. See Transmission Harness
(W11) Wiring Diagram . (Group 9015-10.)

Is ground present?

Record of Actual Results:

Result:
YES:
Check for a short to ground (wire T31 BLU) between pin B on TCL sensor (B32) connector and ground. See
Transmission Harness (W11) Wiring Diagram and see Operator's Station Harness (W7) Wiring Diagram .
(Group 9015-10.)
NO:
Replace TCL sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-
20.) If code 002661.04 is active after sensor replacement, Go to Replace Controller .

4 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Is code 002661.04 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FD3-19-20091217

309
 002661.15 —FNR Sensor Minimum Calibration Value Too High
002661.15 —
FNR Sensor Minimum Calibration Value Too High

TCL Sensor Minimum Calibration Value Too High

NOTE:

FNR is also referred to as the TCL.

TCL Sensor Minimum Calibration Value Too High Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Record stored reverse calibration voltage from TCL sensor by accessing the Diagnostic / Calibrated Values /
Input Voltages menu in the CMU menu structure. see CAN Monitor Unit (CMU) Menu Structure—Service
Mode . (Group 9015-20.).

Record the neutral input voltage from TCL sensor by accessing the Diagnostic / Calibrated Values / Input
Voltages menu in the CMU menu structure.

Subtract 0.667 from the TCL sensor live neutral voltage.

Is subtracted value less than stored calibration voltage?

Record of Actual Results:

Result:
YES:
Go to Sensor Adjustment.
NO:
Go to next check in this step.

2 Sensor Adjustment

Action:

Adjust TCL sensor linkage. See Transmission Control Lever (TCL) Adjustment . (Group 9015-20.)

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 002661.15 still active?

Record of Actual Results:

310
 002661.15 —FNR Sensor Minimum Calibration Value Too High

Result:
YES:
Go to Component Check .
NO:
Repair complete.

3 Component Check
Action:

Remove the TCL sensor (B32) and verify the shaft is turning.

Is TCL sensor shaft turning?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Replace TCL sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-
20.)

4 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Is code 002661.15 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FAD-19-20091217

311
 002661.16 —FNR Sensor Maximum Calibration Value Too High
002661.16 —
FNR Sensor Maximum Calibration Value Too High

TCL Sensor Maximum Calibration Value Too High

NOTE:

FNR is also referred to as the TCL.

TCL Sensor Maximum Calibration Value Too High Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Record stored forward calibration voltage from TCL sensor by accessing the Diagnostic / Calibrated Values /
Input Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service
Mode . (Group 9015-20.).

Record the neutral input voltage from TCL sensor by accessing the Diagnostic / Calibrated Values / Input
Voltages menu in the CMU menu structure.

Add 1.408 to the TCL sensor live neutral voltage.

Is Added value less than stored calibration voltage?

Record of Actual Results:

Result:
YES:
Go to Sensor Adjustment .
NO:
Go to next check in this step.

2 Sensor Adjustment

Action:

Adjust TCL sensor linkage. See Transmission Control Lever (TCL) Adjustment . (Group 9015-20.)

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 002661.16 still active?

Record of Actual Results:

312
 002661.16 —FNR Sensor Maximum Calibration Value Too High

Result:
YES:
Go to Component Check .
NO:
Repair complete.

3 Component Check
Action:

Remove the TCL sensor (B32) and verify the shaft is turning.

Is TCL sensor shaft turning?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Replace TCL sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-
20.)

4 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Is code 002661.16 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FAC-19-20080610

313
 002661.17 —FNR Sensor Minimum Calibration Value Too Low
002661.17 —
FNR Sensor Minimum Calibration Value Too Low

TCL Sensor Minimum Calibration Value Too Low

NOTE:

FNR is also referred to as the TCL.

TCL Sensor Minimum Calibration Value Too Low Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Record stored reverse calibration voltage from TCL sensor by accessing the Diagnostic / Calibrated Values /
Input Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service
Mode . (Group 9015-20.).

Record the neutral input voltage from TCL sensor by accessing the Diagnostic / Calibrated Values / Input
Voltages menu in the CMU menu structure.

Subtract 1.408 from the TCL sensor live neutral voltage.

Is subtracted value greater than stored calibration voltage?

Record of Actual Results:

Result:
YES:
Go to Sensor Adjustment .
NO:
Go to next check in this step.

2 Sensor Adjustment

Action:

Adjust TCL sensor linkage. See Transmission Control Lever (TCL) Adjustment . (Group 9015-20.)

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 002661.17 still active?

Record of Actual Results:

314
 002661.17 —FNR Sensor Minimum Calibration Value Too Low

Result:
YES:
Go to Component Check .
NO:
Repair complete.

3 Component Check
Action:

Remove the TCL sensor (B32) and verify the shaft is turning.

Is TCL sensor shaft turning?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Replace TCL sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-
20.)

4 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Is code 002661.17 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000F4A-19-20090527

315
 002661.18 —FNR Sensor Maximum Calibration Value Too Low
002661.18 —
FNR Sensor Maximum Calibration Value Too Low

TCL Sensor Maximum Calibration Value Too Low

NOTE:

FNR is also referred to as the TCL.

TCL Sensor Maximum Calibration Value Too Low Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Record stored forward calibration voltage from TCL sensor by accessing the Diagnostic / Calibrated Values /
Input Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service
Mode . (Group 9015-20.).

Record the neutral input voltage from TCL sensor by accessing the Diagnostic / Calibrated Values / Input
Voltages menu in the CMU menu structure.

Add 0.667 to the TCL sensor live neutral voltage.

Is Added value greater than stored calibration voltage?

Record of Actual Results:

Result:
YES:
Go to Sensor Adjustment .
NO:
Go to next check in this step.

2 Sensor Adjustment

Action:

Adjust TCL sensor linkage. See Transmission Control Lever (TCL) Adjustment . (Group 9015-20.)

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 002661.18 still active?

Record of Actual Results:

316
 002661.18 —FNR Sensor Maximum Calibration Value Too Low

Result:
YES:
Go to Component Check .
NO:
Repair complete.

3 Component Check
Action:

Remove the TCL sensor (B32) and verify the shaft is turning.

Is TCL sensor shaft turning?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Replace TCL sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-
20.)

4 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Is code 002661.18 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FAB-19-20090527

317
 522439.05 —Tank Bypass Solenoid Open Circuit
522439.05 —
Tank Bypass Solenoid Open Circuit

Hydrostatic Oil Reservoir Bypass Solenoid (Y17) Open Circuit

NOTE:

This DTC is only declared at machine start-up when the solenoid is energized.

Hydrostatic Oil Reservoir Bypass Solenoid Open Circuit Diagnostic Procedure

Alarm Level:

No Service Light

Launch Close Expand List Collapse List

1 Component Check
Action:

Turn key switch OFF.

Disconnect hydrostatic oil reservoir bypass solenoid (Y17). See Transmission Harness (W11) Component
Location . (Group 9015-10.)

Check resistance of solenoid. See Electrical Component Specifications . (Group 9015-20.)

Is solenoid within specifications?

Record of Actual Results:

Result:
YES:
Go to Open Circuit Check.
NO:
Replace solenoid.

2 Open Circuit Check

Action:

Turn key switch OFF.

Disconnect hydrostatic oil reservoir bypass solenoid (Y17). See Transmission Harness (W11) Wiring
Diagram . (Group 9015-10.)

Disconnect TCU connector (X2). See Operator's Station Harness (W7) Component Location . (Group 9015-
10.)

Check continuity between pin A (wire T27 BLU) on hydrostatic oil reservoir bypass solenoid (Y17) connector
and pin 5 on TCU connector (X2). See Transmission Harness (W11) Wiring Diagram and see Operator's
Station Harness (W7) Wiring Diagram . (Group 9015-10.)

318
 522439.05 —Tank Bypass Solenoid Open Circuit
Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check for an open circuit between pin A (wire T27 BLU) on hydrostatic oil reservoir bypass solenoid (Y17)
connector and pin 5 on TCU connector (X2). Repair or replace harness. See Transmission Harness (W11)
Wiring Diagram and see Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)
Action:

Key switch OFF.

Disconnect hydrostatic oil reservoir bypass solenoid (Y17).

Check continuity (wire G09 BLK) between pin B on hydrostatic oil reservoir bypass solenoid (Y17) connector
and frame ground. See Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Test.
NO:
Check for an open circuit between pin B (wire G09 BLK) on hydrostatic oil reservoir bypass solenoid (Y17)
connector and ground. Repair or replace harness. See Transmission Harness (W11) Wiring Diagram .
(Group 9015-10.)

3 Short Circuit Test

Action:

Disconnect hydrostatic oil reservoir bypass solenoid (Y17) connector and TCU connector (X2). See
Operator's Station Harness (W7) Component Location and see Transmission Harness (W11) Component
Location . (Group 9015-10.)

Check for short to ground at pin A (wire T27 BLU) of hydrostatic oil reservoir bypass solenoid (Y17)
connector. See Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)

Is there ground present?

Record of Actual Results:

Result:
YES:
319
 522439.05 —Tank Bypass Solenoid Open Circuit
Repair or replace harnesses, as necessary. See Operator's Station Harness (W7) Wiring Diagram or see
Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000F4C-19-20100702

320
 522440.05 —Blade Left Solenoid Open Circuit
522440.05 —
Blade Left Solenoid Open Circuit

Blade Angle Solenoid Left Open Circuit

Blade Angle Solenoid Left Open Circuit Diagnostic Procedure

Alarm Level:

No Service Light

Launch Close Expand List Collapse List

1 Component Check
Action:

Turn key switch OFF.

Disconnect blade angle solenoid left (Y7). See Transmission Harness (W11) Component Location . (Group
9015-10.)

Check resistance of solenoid across pins 1 and 2.

Is solenoid within specifications?

Item Measurement Specification

Blade Angle Solenoid Left (Top)—Y7 Resistance 24.2—27.3 ohms at -40°C (-40°F)
26.7—30.2 ohms at -20°C (-4°F)
29.2—33.0 ohms at 0°C (32°F)
31.8—35.8 ohms at 20°C (68°F)
34.2—38.6 ohms at 40°C (104°F)

Record of Actual Results:

Result:
YES:
Go to Open Circuit Check—Ground .
NO:
Replace blade angle solenoid left (Y7).

2 Open Circuit Check—Ground

Action:

Turn key switch OFF.

Disconnect blade angle solenoid left (Y7). See Transmission Harness (W11) Component Location . (Group
9015-10.)

Check continuity between pin 2 (wire G09 BLK) on blade angle solenoid left (Y7) and machine ground.

Is continuity indicated?

321
 522440.05 —Blade Left Solenoid Open Circuit

Record of Actual Results:

Result:
YES:
Go to Open Circuit Check—Signal .
NO:
Go to next step in this check.
Action:

Disconnect bulkhead connector (X19). See Engine Harness (W10) Component Location . (Group 9015-10.)

Check continuity between circuit G09 BLK (X19 pin 23) and machine ground on the engine harness side of
connector (X19).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Open circuit (G09 BLK) in transmission harness (W11). Repair or replace. See Transmission Harness (W11)
Wiring Diagram . (Group 9015-10.)
NO:
Open circuit (G09 BLK) in engine harness (W10). Repair or replace. See Engine Harness (W10) Wiring
Diagram . (Group 9015-10.)

3 Open Circuit Check—Signal

Action:

Turn key switch OFF.

Disconnect blade angle solenoid left (Y7), and TCU connector (X2). See Transmission Harness (W11)
Component Location and see Operator's Station Harness (W7) Component Location . (Group 9015-10.)

Check continuity of circuit H05 GRN (solenoid connector pin 1 and X2 pin 24).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Go to next step in this check.
Action:

Disconnect TCU connector (X2) and bulkhead connector

322 (X17). See Operator's Station Harness (W7)
 522440.05 —Blade Left Solenoid Open Circuit
Disconnect TCU connector (X2) and bulkhead connector (X17). See Operator's Station Harness (W7)
Component Location . (Group 9015-10.)

Check continuity of circuit H05 GRN (X17 pin 11 and X2 pin 24) on the operator's station side of connector
(X17).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Open circuit (H05 GRN) in transmission harness (W11). Repair or replace harness. See Transmission
Harness (W11) Wiring Diagram . (Group 9015-10.)
NO:
Open circuit (H05 GRN) in operator's station harness (W7). Repair or replace harness. See Operator's
Station Harness (W7) Wiring Diagram . (Group 9015-10.)

4 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 522440.05 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000F4D-19-20080610

323
 522440.06 —Blade Left Solenoid Short Circuit
522440.06 —
Blade Left Solenoid Short Circuit

Blade Angle Solenoid Left Short Circuit

Blade Angle Solenoid Left Short Circuit Diagnostic Procedure

Alarm Level:

No Service Light

Launch Close Expand List Collapse List

1 Blade Angle Solenoid Left Check

Action:

Turn key switch OFF.

Disconnect blade angle solenoid left (Y7). See Transmission Harness (W11) Component Location . (Group
9015-10.)

Check resistance of solenoid across pins 1 and 2.

Is solenoid within specifications?

Item Measurement Specification

Blade Angle Solenoid Left (Top)—Y7 Resistance 24.2—27.3 ohms at -40°C (-40°F)
26.7—30.2 ohms at -20°C (-4°F)
29.2—33.0 ohms at 0°C (32°F)
31.8—35.8 ohms at 20°C (68°F)
34.2—38.6 ohms at 40°C (104°F)

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
NO:
Replace blade angle solenoid left (Y7).

2 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect blade angle solenoid left (Y7) and TCU connector (X2). See Transmission Harness (W11)
Component Location and see Operator's Station Harness (W7) Component Location . (Group 9015-10.)

Check for continuity between solenoid connector pins 1 and 2.

Is continuity indicated?

324
 522440.06 —Blade Left Solenoid Short Circuit

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Go to Replace Controller .
Action:

Disconnect TCU connector (X2) and bulkhead connector (X17). See Operator's Station Harness (W7)
Component Location . (Group 9015-10.)

Check for continuity between circuit H05 GRN (X2 pin 24) and machine ground.

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Short to ground in operator's station harness (W11). Repair or replace harness. See Operator's Station
Harness (W7) Wiring Diagram . (Group 9015-10.)
NO:
Short to ground in transmission harness (W7). Repair or replace harness. See Transmission Harness (W11)
Wiring Diagram . (Group 9015-10.)

3 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 522440.06 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000F4E-19-20080610

325
 522441.05 —Blade Right Solenoid Open Circuit
522441.05 —
Blade Right Solenoid Open Circuit

Blade Angle Solenoid Right Open Circuit

Blade Angle Solenoid Right Open Circuit Diagnostic Procedure

Alarm Level:

No Service Light

Launch Close Expand List Collapse List

1 Component Check
Action:

Turn key switch OFF.

Disconnect blade angle solenoid right (Y8). See Transmission Harness (W11) Component Location . (Group
9015-10.)

Check resistance of solenoid across pins 1 and 2.

Is solenoid within specifications?

Item Measurement Specification

Blade Angle Solenoid Right (Bottom)—Y8 Resistance 24.2—27.3 ohms at -40°C (-40°F)
26.7—30.2 ohms at -20°C (-4°F)
29.2—33.0 ohms at 0°C (32°F)
31.8—35.8 ohms at 20°C (68°F)
34.2—38.6 ohms at 40°C (104°F)

Record of Actual Results:

Result:
YES:
Go to Open Circuit Check—Ground .
NO:
Replace blade angle solenoid right (Y8).

2 Open Circuit Check—Ground

Action:

Turn key switch OFF.

Disconnect blade angle solenoid right (Y8). See Transmission Harness (W11) Component Location . (Group
9015-10.)

Check continuity between circuit G09 BLK (solenoid connector pin 2) and machine ground.

Is continuity indicated?

326
 522441.05 —Blade Right Solenoid Open Circuit

Record of Actual Results:

Result:
YES:
Go to Open Circuit Check—Signal .
NO:
Go to next step in this check.
Action:

Disconnect bulkhead connector (X19). See Engine Harness (W10) Component Location . (Group 9015-10.)

Check continuity between circuit G09 BLK (X19 pin 23) and machine ground on the engine harness side of
connector (X19).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Open circuit (G09 BLK) in transmission harness (W11). Repair or replace. See Transmission Harness (W11)
Wiring Diagram . (Group 9015-10.)
NO:
Open circuit (G09 BLK) in engine harness (W10). Repair or replace. See Engine Harness (W10) Wiring
Diagram . (Group 9015-10.)

3 Open Circuit Check—Signal

Action:

Turn key switch OFF.

Disconnect blade angle solenoid right (Y8), and TCU connector (X2). See Transmission Harness (W11)
Component Location and see Operator's Station Harness (W7) Component Location . (Group 9015-10.)

Check continuity of circuit H04 GRN (solenoid connector pin 1 and X2 pin 20).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Go to next step in this check.
Action:

Disconnect TCU connector (X2) and bulkhead connector

327 (X17). See Operator's Station Harness (W7)
 522441.05 —Blade Right Solenoid Open Circuit
Disconnect TCU connector (X2) and bulkhead connector (X17). See Operator's Station Harness (W7)
Component Location . (Group 9015-10.)

Check continuity of circuit H04 GRN (X17 pin 10 and X2 pin 20) on the operator's station side of connector
(X17).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Open circuit (H04 GRN) in transmission harness (W11). Repair or replace harness. See Transmission
Harness (W11) Wiring Diagram . (Group 9015-10.)
NO:
Open circuit (H04 GRN) in operator's station harness (W7). Repair or replace harness. See Operator's
Station Harness (W7) Wiring Diagram . (Group 9015-10.)

4 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 522441.05 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000F4F-19-20080610

328
 522441.06 —Blade Right Solenoid Short Circuit
522441.06 —
Blade Right Solenoid Short Circuit

Blade Angle Solenoid Right Current Below Normal or Short to Ground

Blade Angle Solenoid Right Short Circuit Diagnostic Procedure

Alarm Level:

No Service Light

Launch Close Expand List Collapse List

1 Component Check
Action:

Turn key switch OFF.

Disconnect blade angle solenoid right (Y8). See Transmission Harness (W11) Component Location . (Group
9015-10.)

Check resistance of solenoid across pins 1 and 2.

Is solenoid within specifications?

Item Measurement Specification

Blade Angle Solenoid Right (Bottom)—Y8 Resistance 24.2—27.3 ohms at -40°C (-40°F)
26.7—30.2 ohms at -20°C (-4°F)
29.2—33.0 ohms at 0°C (32°F)
31.8—35.8 ohms at 20°C (68°F)
34.2—38.6 ohms at 40°C (104°F)

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
NO:
Replace blade angle solenoid right (Y8).

2 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect blade angle solenoid right (Y8) and TCU connector (X2). See Transmission Harness (W11)
Component Location and see Operator's Station Harness (W7) Component Location . (Group 9015-10.)

Check for continuity between solenoid connector pins 1 and 2.

Is continuity indicated?

329
 522441.06 —Blade Right Solenoid Short Circuit

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Go to Replace Controller .
Action:

Disconnect TCU connector (X2) and bulkhead connector (X17). See Operator's Station Harness (W7)
Component Location . (Group 9015-10.)

Check for continuity between circuit H04 GRN (X2 pin 20) and machine ground.

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Short to ground in operator's station harness (W11). Repair or replace harness. See Operator's Station
Harness (W7) Wiring Diagram . (Group 9015-10.)
NO:
Short to ground in transmission harness (W7). Repair or replace harness. See Transmission Harness (W11)
Wiring Diagram . (Group 9015-10.)

3 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Check for active codes.

Is code 522441.06 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000F50-19-20080610

330
 522442.00 —Blade Buttons Input Greater Than Maximum Calibration Value
522442.00 —
Blade Buttons Input Greater Than Maximum Calibration Value

Blade Buttons Input Greater Than Maximum Calibration Value

Blade Buttons Input Greater Than Maximum Calibration Value Diagnostic Procedure

Alarm Level:

No Service Light

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Start engine.

Observe the input voltage from blade angle switch (S4) by accessing the Diagnostic / Live Values / Input
Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode .
(Group 9015-20.)

Are approximately 0.50—3.50 V volts present when angling blade to the left and right?

Record of Actual Results:

Result:
YES:
Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)
NO:
Go to Code Check .

2 Code Check
Action:

Check for active codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 522442.03 or code 522442.04 present?

Record of Actual Results:

Result:
YES:
See code 522442.03— Blade Buttons Short to Power or 522442.04— Blade Buttons Open or Short . (Group
9001-30.)
NO:
Go to Replace Controller .

331
 522442.00 —Blade Buttons Input Greater Than Maximum Calibration Value

3 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Is code 522442.18 still active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FAA-19-20080610

332
 522442.01 —Blade Buttons Input Less Than Minimum Calibration Value
522442.01 —
Blade Buttons Input Less Than Minimum Calibration Value

Blade Buttons Input Less Than Minimum Calibration Value

Blade Buttons Input Less Than Minimum Calibration Value Diagnostic Procedure

Alarm Level:

No Service Light

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Start engine.

Observe the input voltage from blade angle switch (S4) by accessing the Diagnostic / Live Values / Input
Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode .
(Group 9015-20.)

Are approximately 0.50—3.50 V volts present when angling blade to the left and right?

Record of Actual Results:

Result:
YES:
Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)
NO:
Go to Code Check .

2 Code Check
Action:

Check for active codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 522442.03 or code 522442.04 present?

Record of Actual Results:

Result:
YES:
See code 522442.03— Blade Buttons Short to Power or 522442.04— Blade Buttons Open or Short . (Group
9001-30.)
NO:
Go to Replace Controller .

333
 522442.01 —Blade Buttons Input Less Than Minimum Calibration Value

3 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Is code 522442.01 still active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FA9-19-20080610

334
 522442.03 —Blade Buttons Short to Power
522442.03 —
Blade Buttons Short to Power

Blade Angle Switch Short to Power

Blade Buttons Short to Power Diagnostic Procedure

Alarm Level:

No Service Light

Launch Close Expand List Collapse List

1 Component Check
Action:

Turn key switch OFF.

Disconnect blade angle switch (S4). See Operator's Station Harness (W7) Component Location . (Group
9015-10.)

Start engine.

Is code 522442.03 active?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
NO:
Replace blade angle switch (S4).

2 Short Circuit Check

Action:

Turn key switch ON.

Disconnect blade angle switch (S4). See Operator's Station Harness (W7) Component Location . (Group
9015-10.)

Check voltage at pin B (wire H01 GRN) of blade angle switch (S4) connector.

Is voltage greater than 1 volt?

Record of Actual Results:

Result:
YES:
Circuit H01 GRN has a short to power in operator's station harness (W7). Repair or replace. See Operator's
335
 522442.03 —Blade Buttons Short to Power
Station Harness (W7) Wiring Diagram . (Group 9015-10.)
NO:
Go to Replace Controller .

3 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Is code 522442.03 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000F53-19-20080610

336
 522442.04 —Blade Buttons Open or Short
522442.04 —
Blade Buttons Open or Short

Blade Buttons Open or Short

Blade Buttons Open or Short Diagnostic Procedure

Alarm Level:

No Service Light

Launch Close Expand List Collapse List

1 Voltage Check
Action:

Disconnect blade angle switch (S4). See Operator's Station Harness (W7) Component Location . (Group
9015-10.)

Turn key switch ON.

Check voltage across pins A and C of blade angle switch (S4) connector.

Is voltage approximately 5 volts?

Record of Actual Results:

Result:
YES:
Go to Open Circuit Check—Signal .
NO:
Go to Code Check .

2 Code Check
Action:

Key switch ON.

Check codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 000620.04 active?

Record of Actual Results:

Result:
YES:
Resolve code 000620.04. See Diagnostic Trouble Code (DTC) Quick Reference List—Transmission Control
Unit (TCU) . Group 9001-30.)
NO:

337
 522442.04 —Blade Buttons Open or Short
Go to Open Circuit Check—Power and Ground .

3 Open Circuit Check—Power and Ground

Action:

Turn key switch OFF.

Disconnect bussed 5 volt sensor connector (X6) and bussed ground sensor connector (X7). See Operator's
Station Harness (W7) Component Location . (Group 9015-10.)

Check continuity between pins 1 and 8 on the jumper side of connector (X6).

Check continuity between pins 1 and 9 on the jumper side of connector (X7).

Is continuity indicated on both connectors?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Jumper side of connector (X6 or X7) has an open circuit. Repair or replace connector. See Operator's
Station Harness (W7) Wiring Diagram . (Group 9015-10.)
Action:

Disconnect blade angle switch (S4) connector, bussed 5 volt sensor connector (X6) and bussed GND sensor
connector (X7). See Operator's Station Harness (W7) Component Location . (Group 9015-10.)

Check continuity of the following circuits on the harness side of connectors (X6 and X7).

T14 BLU (switch connector pin A and X6 pin 5)

R09 BLK (switch connector pin C and X7 pin 5)

Is continuity of both circuits indicated?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .
NO:
Open circuit in operator's station harness. Repair or replace. See Operator's Station Harness (W7) Wiring
Diagram . (Group 9015-10.)

4 Open Circuit Check—Signal

Action:

Turn key switch OFF.

338
 522442.04 —Blade Buttons Open or Short
Disconnect blade angle switch (S4) and TCU connector (X1). See Operator's Station Harness (W7)
Component Location . (Group 9015-10.)

Check circuit H01 GRN for continuity between blade angle switch (S4) connector pin B and TCU connector
(X1) pin 19.

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
NO:
Open circuit (H01 GRN) in operator's station harness. Repair or replace. See Operator's Station Harness
(W7) Wiring Diagram . (Group 9015-10.)

5 Short Circuit Check

Action:

Key switch OFF.

Disconnect blade angle switch (S4) and TCU connector (X1). See Transmission Harness (W11) Component
Location and see Operator's Station Harness (W7) Component Location . (Group 9015-10.)

Check for continuity between circuit H01 GRN (X1 pin 19) and machine ground.

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Short circuit (H01 GRN) in operator's station harness (W7). Repair or replace. See Operator's Station
Harness (W7) Wiring Diagram . (Group 9015-10.)
NO:
Replace blade angle switch (S4). If code 522442.04 is still active after switch replacement, Go to Replace
Controller .

6 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Is code 522442.04 active?

Record of Actual Results:

339
 522442.04 —Blade Buttons Open or Short

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000F54-19-20080610

340
 522442.15 —Blade Buttons Minimum Calibration Value Too High
522442.15 —
Blade Buttons Minimum Calibration Value Too High

Blade Buttons Minimum Calibration Value Too High

Blade Buttons Minimum Calibration Value Too High Diagnostic Procedure

Alarm Level:

No Service Light

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Start engine.

Observe the input voltage from blade angle switch (S4) by accessing the Diagnostic / Live Values / Input
Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode .
(Group 9015-20.)

Are approximately 0.50—3.50 V volts present when angling blade to the left and right?

Record of Actual Results:

Result:
YES:
Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)
NO:
Go to Code Check .

2 Code Check
Action:

Check for active codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 522442.03 or code 522442.04 present?

Record of Actual Results:

Result:
YES:
See code 522442.03— Blade Buttons Short to Power or 522442.04— Blade Buttons Open or Short . (Group
9001-30.)
NO:
Go to Replace Controller .

341
 522442.15 —Blade Buttons Minimum Calibration Value Too High

3 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Is code 522442.18 still active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FA8-19-20080610

342
 522442.16 —Blade Buttons Maximum Calibration Value Too High
522442.16 —
Blade Buttons Maximum Calibration Value Too High

Blade Buttons Maximum Calibration Value Too High

Blade Buttons Maximum Calibration Value Too High Diagnostic Procedure

Alarm Level:

No Service Light

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Start engine.

Observe the input voltage from blade angle switch (S4) by accessing the Diagnostic / Live Values / Input
Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode .
(Group 9015-20.)

Are approximately 2.66—3.50 V volts present when angling blade to the left and right?

Record of Actual Results:

Result:
YES:
Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)
NO:
Go to Blade Button Resistance Check .

2 Blade Button Resistance Check

Action:

With key switch off, disconnect harness from blade angle switch (S4). Connect JT07239-3 3-pin test harness
between sensor and harness.

Connect JT07237-1 single-pin test harness to white and black wire connectors on 3-pin test harness and
multimeter.Record resistance with no buttons pressed and with each button pressed. See Electrical
Component Specifications . (Group 9015-20.)

Does resistance meet specifications?

Record of Actual Results:

Result:
YES:
Go to Wire Check .

343
 522442.16 —Blade Buttons Maximum Calibration Value Too High

NO:
Replace sensor as necessary.

3 Wire Check
Action:

Check H01 GRN wire for a short to power.

Check R09 BLK wire for an open circuit.

Do wires test ok?

Record of Actual Results:

Result:
YES:
Go to Code Check .
NO:
Repair wires.

4 Code Check

Action:

Check for active codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 522442.03 or code 522442.04 present?

Record of Actual Results:

Result:
YES:
See code 522442.03— Blade Buttons Short to Power or 522442.04— Blade Buttons Open or Short . (Group
9001-30.)
NO:
Go to Replace Controller .

5 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Is code 522442.16 still active?

Record of Actual Results:

344
 522442.16 —Blade Buttons Maximum Calibration Value Too High

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FA7-19-20110928

345
 522442.17 —Blade Buttons Minimum Calibration Value Too Low
522442.17 —
Blade Buttons Minimum Calibration Value Too Low

Blade Buttons Minimum Calibration Value Too Low

Blade Buttons Minimum Calibration Value Too Low Diagnostic Procedure

Alarm Level:

No Service Light

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Start engine.

Observe the input voltage from blade angle switch (S4) by accessing the Diagnostic / Live Values / Input
Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode .
(Group 9015-20.)

Are approximately 0.50—3.50 V volts present when angling blade to the left and right?

Record of Actual Results:

Result:
YES:
Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)
NO:
Go to Code Check .

2 Code Check
Action:

Check for active codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 522442.03 or DTC 522442.04 present?

Record of Actual Results:

Result:
YES:
See code 522442.03— Blade Buttons Short to Power or 522442.04— Blade Buttons Open or Short . (Group
9001-30.)
NO:
Go to Replace Controller .

346
 522442.17 —Blade Buttons Minimum Calibration Value Too Low

3 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Is code 522442.18 still active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000F57-19-20080610

347
 522442.18 —Blade Buttons Maximum Calibration Value Too Low
522442.18 —
Blade Buttons Maximum Calibration Value Too Low

Blade Buttons Maximum Calibration Value Too Low

Blade Buttons Maximum Calibration Value Too Low Diagnostic Procedure

Alarm Level:

No Service Light

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Start engine.

Observe the input voltage from blade angle switch (S4) by accessing the Diagnostic / Live Values / Input
Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode .
(Group 9015-20.)

Are approximately 0.50—3.50 V volts present when angling blade to the left and right?

Record of Actual Results:

Result:
YES:
Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)
NO:
Go to Code Check .

2 Code Check
Action:

Check for active codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 522442.03 or code 522442.04 present?

Record of Actual Results:

Result:
YES:
See code 522442.03— Blade Buttons Short to Power or 522442.04— Blade Buttons Open or Short . (Group
9001-30.)
NO:
Go to Replace Controller .

348
 522442.18 —Blade Buttons Maximum Calibration Value Too Low

3 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Is code 522442.18 still active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000F58-19-20080610

349
 522444.00 —Charge Pressure High
522444.00 —
Charge Pressure High

Charge Pressure High

Charge Pressure High Diagnostic Procedure

Alarm Level:

Transmission Charge Pressure Icon

Launch Close Expand List Collapse List

1 Charge Pressure Check

Action:

Check transmission charge pressure. See Low Charge Pressure Malfunctions . (Group 9026-15.)

Is code 522444.00 still active?

Record of Actual Results:

Result:
YES:
See code 522444.03— Charge Pressure Short to Power or 522444.04— Charge Pressure Open or Short .
(Group 9001-30.)
NO:
Repair complete.

Go to Section_9001:Group_30

WS68074,0000F59-19-20070307

350
 522444.01 —Charge Pressure Low
522444.01 —
Charge Pressure Low

Charge Pressure Low

Charge Pressure Low Diagnostic Procedure

Alarm Level:

Transmission Charge Pressure Icon

Launch Close Expand List Collapse List

1 Charge Pressure Check

Action:

Check transmission charge pressure. See Low Charge Pressure Malfunctions . (Group 9026-15.)

Is code 522444.01 still active?

Record of Actual Results:

Result:
YES:
See code 522444.03— Charge Pressure Short to Power or 522444.04— Charge Pressure Open or Short .
(Group 9001-30.)
NO:
Repair complete.

Go to Section_9001:Group_30

WS68074,0000F5A-19-20070307

351
 522444.03 —Charge Pressure Short to Power
522444.03 —
Charge Pressure Short to Power

Hydrostatic Charge Pressure Short to Power

Hydrostatic Charge Pressure Short to Power Diagnostic Procedure

Alarm Level:

No Service Warning

Launch Close Expand List Collapse List

1 Component Check
Action:

NOTE:

The hydrostatic charge pressure sensor is B4 for (S.N. —173641) and B41 for (S.N. 173642
— ).

Pressure sensor harness (W27) is used with B41 (S.N. 173642— ).

Turn key switch OFF.

Disconnect hydrostatic charge pressure sensor (B4 or B41). See Transmission Harness (W11) Component
Location . (Group 9015-10.)

Start engine.

Is code 522444.03 active?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check.
NO:
Replace hydrostatic charge pressure sensor (B4 or B41).

2 Short Circuit Check

Action:

Turn key switch ON.

Disconnect hydrostatic charge pressure sensor (B4 or B41). See Transmission Harness (W11) Component
Location . (Group 9015-10.)

Check voltage at pin C (wire T09 BLU) on hydrostatic charge pressure sensor (B4 or B41) connector.

Is voltage greater than 1 volt?

352
 522444.03 —Charge Pressure Short to Power

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Go to Replace Controller.
Action:

Disconnect bulkhead connector (X16). See Operator's Station Harness (W7) Component Location . (Group
9015-10.)

Check voltage at pin 2 of bulkhead connector (X16) (wire T09 BLU) on operator's station harness side of
connector.

Is voltage greater than 1 volt?

Record of Actual Results:

Result:
YES:
Check wire T09 BLU for short circuit in operator's station harness (W7). Repair or replace. See Operator's
Station Harness (W7) Wiring Diagram . (Group 9015-10.)
NO:
Check wire T09 BLU for short circuit in transmission harness (W11). Repair or replace. See Transmission
Harness (W11) Wiring Diagram . (Group 9015-10.)

3 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Is code 522444.03 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000F5B-19-20090924

353
 522444.04 —Charge Pressure Open or Short
522444.04 —
Charge Pressure Open or Short

Charge Pressure Open or Short

Charge Pressure Open or Short Diagnostic Procedure

Alarm Level:

No Service Warning

Launch Close Expand List Collapse List

1 Voltage Check
Action:

NOTE:

The hydrostatic charge pressure sensor is B4 for (S.N. —173641) and B41 for (S.N. 173642
— ).

Pressure sensor harness (W27) is used with B41 (S.N. 173642— ).

Disconnect hydrostatic charge pressure sensor (B4 or B41). See Transmission Harness (W11) Component
Location . (Group 9015-10.)

Turn key switch ON.

Check voltage between pins B and A of hydrostatic charge pressure sensor (B4 or B41) connector.

Is voltage approximately 5 volts?

Record of Actual Results:

Result:
YES:
Go to Open Circuit Check—Signal .
NO:
Go to Code Check.

2 Code Check
Action:

Key switch ON.

Check codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 000620.04 active?

Record of Actual Results:

354
 522444.04 —Charge Pressure Open or Short

Result:
YES:
Resolve code 000620.04. See Diagnostic Trouble Code (DTC) Quick Reference List—Transmission Control
Unit (TCU) . Group 9001-30.)
NO:
Go to Open Circuit Check—Power and Ground.

3 Open Circuit Check—Power and Ground

Action:

Turn key switch OFF.

Disconnect bussed 5 volt sensor connector (X6) and bussed ground sensor connector (X7). See Operator's
Station Harness (W7) Component Location . (Group 9015-10.)

Check continuity between pins 1 and 5 on the jumper side of connector (X6).

Check continuity between pins 1 and 5 on the jumper side of connector (X7).

Is continuity indicated on both connectors?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Jumper side of connector (X6 or X7) has an open circuit. Repair or replace connector. See Operator's
Station Harness (W7) Wiring Diagram . (Group 9015-10.)
Action:

Disconnect hydrostatic charge pressure sensor (B4 or B41) connector, bussed 5 volt sensor connector (X6)
and bussed GND sensor connector (X7). See Transmission Harness (W11) Component Location and see
Operator's Station Harness (W7) Component Location . (Group 9015-10.)

Check continuity of the following circuits on the harness side of connectors (X6 and X7).

T08 BLU (sensor connector pin B and X6 pin 5)

R05 BLK (sensor connector pin A and X7 pin 5)

Is continuity of both circuits indicated?

Record of Actual Results:

Result:
YES:
Go to Replace Controller .

355
 522444.04 —Charge Pressure Open or Short

NO:
Go to next step in this check.
Action:

Disconnect bulkhead connector (X16) and hydrostatic charge pressure sensor (B4 or B41) connector. See
Transmission Harness (W11) Component Location . (Group 9015-10.)

Check continuity of the following circuits on the transmission harness side of connector (X16).

T08 BLU (X16 pin 1 and sensor connector pin B)

R05 BLK (X16 pin 3 and sensor connector pin A)

Is continuity of both circuits indicated?

Record of Actual Results:

Result:
YES:
Open circuit in operator's station harness (W7). Repair or replace. See Operator's Station Harness (W7)
Wiring Diagram . (Group 9015-10.)
NO:
Open circuit in transmission harness (W11). Repair or replace. See Transmission Harness (W11) Wiring
Diagram . (Group 9015-10.)

4 Open Circuit Check—Signal

Action:

Turn key switch OFF.

Disconnect hydrostatic charge pressure sensor (B4 or B41) and TCU connector (X1). See Transmission
Harness (W11) Component Location and see Operator's Station Harness (W7) Component Location .
(Group 9015-10.)

Check circuit T09 BLU for continuity between hydrostatic charge pressure sensor (B4 or B41) connector pin
C and TCU connector (X1) pin 1.

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
NO:
Go to next step in this check.
Action:

Disconnect bulkhead connector (X16) and TCU connector (X1). See Operator's Station Harness (W7)
Component Location . (Group 9015-10.)

356
 522444.04 —Charge Pressure Open or Short
Check circuit T09 BLU for continuity between TCU connector (X1) pin 1 and bulkhead connector (X16) pin 2
on operator's station harness (W7).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Open circuit (T09 BLU) in operator's station harness (W7). Repair or replace. See Operator's Station
Harness (W7) Wiring Diagram . (Group 9015-10.)
NO:
Open circuit (T09 BLU) in transmission harness (W11). Repair or replace. See Transmission Harness (W11)
Wiring Diagram . (Group 9015-10.)

5 Short Circuit Check

Action:

Key switch OFF.

Disconnect hydrostatic charge pressure sensor (B4 or B41) and TCU connector (X1). See Transmission
Harness (W11) Component Location and see Operator's Station Harness (W7) Component Location .
(Group 9015-10.)

Check for continuity between circuit T09 BLU (X1 pin 1) and machine ground.

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Replace hydrostatic charge pressure sensor (B4 or B41). If code 522444.04 is still active after sensor
replacement, Go to Replace Controller .
Action:

Disconnect TCU connector (X1) and bulkhead connector (X16).

Check for continuity between circuit T09 BLU (X1 pin 1) and machine ground.

Is continuity indicated?

Record of Actual Results:

Result:
YES:
357
 522444.04 —Charge Pressure Open or Short
Short circuit in operator's station harness (W7). Repair or replace. See Operator's Station Harness (W7)
Wiring Diagram . (Group 9015-10.)
NO:
Short circuit in transmission harness (W11). Repair or replace. See Transmission Harness (W11) Wiring
Diagram . (Group 9015-10.)

6 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Is code 522444.04 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000F5C-19-20090924

358
 522445.00 —Right System Pressure High
522445.00 —
Right System Pressure High

Right System Pressure High

Right System Pressure High Diagnostic Procedure

Alarm Level:

No Service Warning

Launch Close Expand List Collapse List

1 Charge pressure Check

Action:

Check right system charge pressure. See Transmission Efficiency Test . (Group 9026-25.)

Is code 522445.00 still active?

Record of Actual Results:

Result:
YES:
See code 522445.04— Right System Press. Short to Power or 522445.05— Right System Press. Open or
Short . (Group 9001-30.)
NO:
Repair complete.

Go to Section_9001:Group_30

WS68074,0000F5D-19-20070307

359
 522445.01 —Right System Pressure Low
522445.01 —
Right System Pressure Low

Right System Pressure Low

Right System Pressure Low Diagnostic Procedure

Alarm Level:

No Service Warning

Launch Close Expand List Collapse List

1 Charge Pressure Check

Action:

Check right system charge pressure. See Transmission Efficiency Test . (Group 9026-25.)

Is code 522445.01 still active?

Record of Actual Results:

Result:
YES:
See code 522445.04— Right System Press. Short to Power or 522445.05— Right System Press. Open or
Short . (Group 9001-30.)
NO:
Repair complete.

Go to Section_9001:Group_30

WS68074,0000F5E-19-20070307

360
 522445.03 —Right System Press. Short to Power
522445.03 —
Right System Press. Short to Power

Right System Pressure Short to Power

Right System Pressure Short to Power Diagnostic Procedure

Alarm Level:

No Service Warning

Launch Close Expand List Collapse List

1 Component Check
Action:

Turn key switch OFF.

Disconnect hydrostatic pressure sensor right (B5). See Transmission Harness (W11) Component Location .
(Group 9015-10.)

Start Engine.

Is code 522445.03 active?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
NO:
Replace hydrostatic charge pressure sensor (B5).

2 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect hydrostatic pressure sensor right (B5). See Transmission Harness (W11) Component Location .
(Group 9015-10.)

Check voltage at pin C of (wire T11 BLU) on hydrostatic pressure sensor right (B5) connector.

Is voltage greater than 1 volt?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
361
 522445.03 —Right System Press. Short to Power

NO:
Go to Replace Controller .
Action:

Disconnect bulkhead connector (X16). See Operator's Station Harness (W7) Component Location . (Group
9015-10.)

Check voltage at pin 5 of bulkhead connector (X16) (wire T11 BLU) on operator's station harness (W7).

Is voltage greater than 1 volt?

Record of Actual Results:

Result:
YES:
Check wire T11 BLU for short circuit in operator's station harness (W7). Repair or replace. See Operator's
Station Harness (W7) Wiring Diagram . (Group 9015-10.)
NO:
Check wire T11 BLU for short circuit in transmission harness (W11). Repair or replace. See Transmission
Harness (W11) Wiring Diagram . (Group 9015-10.)

3 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Is code 522445.03 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000F5F-19-20080610

362
 522445.04 —Right System Press. Open or Short
522445.04 —
Right System Press. Open or Short

Right System Pressure Open or Short

Right System Pressure Open or Short Diagnostic Procedure

Alarm Level:

No Service Warning

Launch Close Expand List Collapse List

1 Code Check
Action:

NOTE:

The hydrostatic pressure sensor is B5 for (S.N. —173658) and B43 for (S.N. 173659— ).

Pressure sensor harness (W27) is used with B43 (S.N. 173659— ).

Check for active codes, see CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 000620.03 active?

Record of Actual Results:

Result:
YES:
See 000620.03— TCU 5V Supply Short to Power . (Group 9001-30.)
NO:
Go to Open Circuit Check.

2 Open Circuit Check

Action:

Turn key switch OFF.

Disconnect right hydrostatic charge pressure sensor (B5 or B43) connector. See Transmission Harness
(W11) Component Location . (Group 9015-10.)

Turn key switch ON.

Check voltage at pin B (wire T10 BLU) on right hydrostatic charge pressure sensor (B5 or B43) connector.
See Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)

Is voltage approximately 5 volts?

Record of Actual Results:

363
 522445.04 —Right System Press. Open or Short

Result:
YES:
Go to next step in this check.
NO:
Check for an open circuit between pin B (wire T10 BLU) on right hydrostatic charge pressure sensor (B5 or
B43) connector and pin 3 (wire T01 BLU) on TCU connector (X1). Repair or replace harness. See
Transmission Harness (W11) Wiring Diagram and see Operator's Station Harness (W7) Wiring Diagram .
(Group 9015-10.)
Action:

Key switch OFF.

Right hydrostatic charge pressure sensor (B5 or B43) disconnected.

Disconnect TCU connector (X1). See Operator's Station Harness (W7) Component Location . (Group 9015-
10.)

Check wire T11 BLU for continuity between pin C on right hydrostatic charge pressure sensor (B5 or B43)
connector and pin 15 on TCU connector (X1). See Transmission Harness (W11) Wiring Diagram and see
Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check T11 BLU for an open circuit between pin C on right hydrostatic charge pressure sensor (B5 or B43)
connector and pin 15 on TCU connector (X1). Repair or replace harness. See Transmission Harness (W11)
Wiring Diagram and see Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)
Action:

Key switch OFF.

Right hydrostatic charge pressure sensor (B5 or B43) and TCU connector (X1) disconnected.

Check for continuity between pin A (wire R06 BLK) on right hydrostatic charge pressure sensor (B5 or B43)
connector and pin 22 (R01 BLK) on TCU connector (X1). See Operator's Station Harness (W7) Wiring
Diagram . (Group 9015-10.)

Is continuity indicated?

Record of Actual Results:

Result:
YES:

364
 522445.04 —Right System Press. Open or Short
Go to Short Circuit Check.
NO:
Check for an open circuit between pin A (wire R06 BLK) on right hydrostatic charge pressure sensor (B5 or
B43) connector and pin 22 on TCU connector (X1). Repair or replace harness. See Operator's Station
Harness (W7) Wiring Diagram . (Group 9015-10.)

3 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect right hydrostatic charge pressure sensor (B5 or B43) connector and TCU connector (X1). See
Operator's Station Harness (W7) Component Location and see Transmission Harness (W11) Component
Location . (Group 9015-10.)

Check for ground at pin C (wire T11 BLU) on right hydrostatic charge pressure sensor (B5 or B43)
connector. See Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)

Is ground present?

Record of Actual Results:

Result:
YES:
Check for a short to ground (wire T11 BLU) between pin C on right hydrostatic charge pressure sensor (B5
or B43) connector and pin 2 on TCU connector (X1). See Transmission Harness (W11) Wiring Diagram and
see Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)
NO:
Go to Replace Controller.

4 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Is code 522445.04 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FD2-19-20091217

365
522445.04 —Right System Press. Open or Short

366
 522446.00 —Left System Pressure High
522446.00 —
Left System Pressure High

Left System Pressure High

Left System Pressure High Diagnostic Procedure

Alarm Level:

No Service Warning

Launch Close Expand List Collapse List

1 Charge pressure Check

Action:

Check left system charge pressure. See Transmission Efficiency Test . (Group 9026-25.)

Is code 522446.00 still active after checking charge pressure?

Record of Actual Results:

Result:
YES:
See code 522446.04— Left System Press. Short to Power or 522446.05— Left System Press. Open or Short
. (Group 9001-30.)
NO:
Repair complete.

Go to Section_9001:Group_30

WS68074,0000F61-19-20070307

367
 522446.01 —Left System Pressure Low
522446.01 —
Left System Pressure Low

Left System Pressure Low

Left System Pressure Low Diagnostic Procedure

Alarm Level:

No Service Warning

Launch Close Expand List Collapse List

1 Charge pressure Check

Action:

Check left system charge pressure. See Transmission Efficiency Test . (Group 9026-25.)

Is code 522446.01 still active?

Record of Actual Results:

Result:
YES:
See code 522446.04— Left System Press. Short to Power or 522446.05— Left System Press. Open or Short
. (Group 9001-30.)
NO:
Repair complete.

Go to Section_9001:Group_30

WS68074,0000F62-19-20070307

368
 522446.03 —Left System Press. Short to Power
522446.03 —
Left System Press. Short to Power

Left Hydrostatic Charge Pressure Short to Power

Left Hydrostatic Charge Pressure Short to Power Diagnostic Procedure

Alarm Level:

No Service Warning

Launch Close Expand List Collapse List

1 Component Check
Action:

NOTE:

The hydrostatic pressure sensor left is B6 for (S.N. —173658) and B44 for (S.N. 173659— ).

Pressure sensor harness (W27) is used with B44 (S.N. 173659— ).

Turn key switch OFF.

Disconnect hydrostatic pressure sensor left (B6 or B44). See Transmission Harness (W11) Component
Location . (Group 9015-10.)

Start Engine.

Is code 522446.03 still active?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check.
NO:
Replace hydrostatic pressure sensor left (B6 or B44).

2 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect hydrostatic pressure sensor left (B6 or B44) connector. See Transmission Harness (W11)
Component Location . (Group 9015-10.)

Check wire T10 BLU for voltage at pin B of hydrostatic pressure sensor left (B6 or B44).

Is there approximately 0 volts?

369
 522446.03 —Left System Press. Short to Power

Record of Actual Results:

Result:
YES:
Go to Replace Controller.
NO:
Go to next step in this check.
Action:

Disconnect operator's station harness-to-transmission harness connector (X16). See Transmission Harness
(W11) Component Location . (Group 9015-10.)

Check wire T36 BLU for voltage at pin C of hydrostatic pressure sensor left (B6 or B44) connector.

Is there 5 volts or more present?

Record of Actual Results:

Result:
YES:
Check transmission harness for a short to power on wire T36 BLU between pin 11 of connector (X16) and
pin C of hydrostatic pressure sensor left (B6 or B44). Repair or replace harness. See Transmission Harness
(W11) Wiring Diagram . (Group 9015-10.)
NO:
Check operator's station harness for a short to power between pin 11 of connector (X16) and pin 2 of TCU
connector (X1). Repair or replace harness. See Operator's Station Harness (W7) Wiring Diagram . (Group
9015-10.)

3 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Is code 522446.03 still active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000F63-19-20090924

370
 522446.04 —Left System Press. Open or Short
522446.04 —
Left System Press. Open or Short

Left System Pressure Open or Short

Left System Pressure Open or Short Diagnostic Procedure

Alarm Level:

No Service Warning

Launch Close Expand List Collapse List

1 Code Check
Action:

NOTE:

The hydrostatic pressure sensor left is B6 for (S.N. —173658) and B44 for (S.N. 173659— ).

Pressure sensor harness (W27) is used with B44 (S.N. 173659— ).

Check for active codes, see CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Is code 000620.04 active?

Record of Actual Results:

Result:
YES:
See 000620.04— TCU 5V Supply Open or Short . (Group 9001-30.)
NO:
Go to Open Circuit Check.

2 Open Circuit Check

Action:

Turn key switch OFF.

Disconnect left hydrostatic charge pressure sensor (B6 or B44) connector. See Transmission Harness (W11)
Component Location . (Group 9015-10.)

Turn key switch ON.

Check voltage at pin B (wire T10 BLU) on hydrostatic pressure sensor left (B6 or B44) connector. See
Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)

Is voltage approximately 5 volts?

Record of Actual Results:

371
 522446.04 —Left System Press. Open or Short

Result:
YES:
Go to next step in this check.
NO:
Check for an open circuit between pin B (wire T10 BLU) on hydrostatic pressure sensor left (B6 or B44)
connector and pin 3 (wire T01 BLU) on TCU connector (X1). Repair or replace harness. See Transmission
Harness (W11) Wiring Diagram and see Operator's Station Harness (W7) Wiring Diagram . (Group 9015-
10.)
Action:

Key switch OFF.

Hydrostatic pressure sensor left (B6 or B44) disconnected.

Disconnect TCU connector (X1). See Operator's Station Harness (W7) Component Location . (Group 9015-
10.)

Check wire T36 BLU for continuity between pin C on hydrostatic pressure sensor left (B6 or B44) connector
and pin 2 on TCU connector (X1). See Transmission Harness (W11) Wiring Diagram and see Operator's
Station Harness (W7) Wiring Diagram . (Group 9015-10.)

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check T36 BLU for an open circuit between pin C on hydrostatic pressure sensor left (B6 or B44) connector
and pin 2 on TCU connector (X1). Repair or replace harness. See Transmission Harness (W11) Wiring
Diagram and see Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)
Action:

Key switch OFF.

Hydrostatic pressure sensor left (B6 or B44) and TCU connector (X1) disconnected.

Check for continuity between pin A (wire R06 BLK) on hydrostatic pressure sensor left (B6 or B44) connector
and pin 22 (R01 BLK) on TCU connector (X1). See Operator's Station Harness (W7) Wiring Diagram .
(Group 9015-10.)

Is continuity indicated?

Record of Actual Results:

Result:
YES:

372
 522446.04 —Left System Press. Open or Short
Go to Short Circuit Check.
NO:
Check for an open circuit between pin A (wire R06 BLK) on hydrostatic pressure sensor left (B6 or B44)
connector and pin 22 on TCU connector (X1). Repair or replace harness. See Operator's Station Harness
(W7) Wiring Diagram . (Group 9015-10.)

3 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect hydrostatic pressure sensor left (B6 or B44) connector and TCU connector (X1). See Operator's
Station Harness (W7) Component Location and see Transmission Harness (W11) Component Location .
(Group 9015-10.)

Check for ground at pin C (wire T36 BLU) on left hydrostatic charge pressure sensor (B6 or b44) connector.
See Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)

Is ground present?

Record of Actual Results:

Result:
YES:
Check for a short to ground (wire T36 BLU) between pin C on hydrostatic pressure sensor left (B6 or B44)
connector and pin 22 (R01 BLK) on TCU connector (X1). See Transmission Harness (W11) Wiring Diagram
and see Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)
NO:
Go to Replace Controller.

4 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Is code 522446.04 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000FA5-19-20091217

373
522446.04 —Left System Press. Open or Short

374
 522447.05 —Right Forward Pump Coil Open
522447.05 —
Right Forward Pump Coil Open

Right Forward Pump Coil Open

Right Forward Pump Coil Open Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Connector Check
Action:

Check pump pressure control pilot (PCP) front (B8) connector, transmission control unit (TCU) connector
(X2), operator's station harness-to-transmission harness connector 1 (X16), and engine harness-to-
transmission harness connector (X19) for corrosion, loose fit, bent/pushed out terminals or crimp
malfunctions. See Engine Harness (W10) Component Location and see Operator's Station Harness (W7)
Component Location . (Group 9015-10.)

Are connectors in good condition?

Record of Actual Results:

Result:
YES:
Go to Component Check.
NO:
Repair or replace connector(s) or terminal(s) as needed.

2 Component Check
Action:

Disconnect pump pressure control pilot (PCP) front (B8).

Check resistance of PCP across pin 1 and 2.

Is resistance within specification? See Electrical Component Specifications . (Group 9015-20.)

Record of Actual Results:

Result:
YES:
Go to Open Circuit Check.
NO:
Replace PCP (B8). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

375
 522447.05 —Right Forward Pump Coil Open
3 Open Circuit Check

Action:

Turn key switch OFF.

Disconnect pump pressure control pilot (PCP) front (B8) connector and TCU connector (X2). See Engine
Harness (W10) Component Location and see Operator's Station Harness (W7) Component Location .
(Group 9015-10.)

Check wire T23 BLU for continuity between pin 2 on front pump pressure control pilot (PCP) (B8) connector
and pin 8 on TCU connector (X2).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Checks complete.
NO:
Go to next step in this check.
Action:

Key switch OFF.

Disconnect connector (X19) from transmission harness (W11).

Check wire T23 BLU for continuity between pin 1 on pump pressure control pilot (PCP) front (B8) connector
and pin 10 on connector (X19).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check wire T23 BLU for an open circuit between pin 1 on pump pressure control pilot (PCP) front (B8)
connector and pin 10 on connector (X19). Repair or replace harness if necessary. See Engine Harness
(W10) Wiring Diagram . (Group 9015-10.)
Action:

Key switch OFF.

Disconnect connector (X16) from operator's station harness (W7).

Check wire T23 BLU for continuity between pin 10 on connector (X19) and pin 18 on connector (X16).

Is continuity indicated?

376
 522447.05 —Right Forward Pump Coil Open

Record of Actual Results:

Result:
YES:
Check wire T23 BLU for an open circuit between pin 18 on connector (X16) and pin 8 on TCU connector
(X2). Repair or replace harness if necessary. See Operator's Station Harness (W7) Wiring Diagram . (Group
9015-10.)
NO:
Check wire T23 BLU for an open circuit between pin 10 on connector (X19) and pin 18 on connector (X16).
Repair or replace harness if necessary. See Transmission Harness (W11) Wiring Diagram . (Group 9015-
10.)

Go to Section_9001:Group_30

WS68074,0000F65-19-20091123

377
 522447.06 —Right Forward Pump Coil Short
522447.06 —
Right Forward Pump Coil Short

TCU Detects Forward Signal to Front Pump Pressure Control Pilot (PCP) Coil Circuit is Short to Ground

Right Forward Pump Coil Short Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Connector Check
Action:

Check pump pressure control pilot (PCP) front (B8) connector, transmission control unit (TCU) connector
(X2), operator's station harness-to-transmission harness connector 1 (X16), and engine harness-to-
transmission harness connector (X19) for corrosion, loose fit, bent/pushed out terminals or crimp
malfunctions. See Engine Harness (W10) Component Location and see Operator's Station Harness (W7)
Component Location . (Group 9015-10.)

Are connectors in good condition?

Record of Actual Results:

Result:
YES:
Go to Component Check.
NO:
Repair or replace connector(s) or terminal(s) as needed.

2 Component Check
Action:

Disconnect pump pressure control pilot (PCP) front (B8).

Check resistance of PCP across pin 1 and 2.

Is resistance within specification? See Electrical Component Specifications . (Group 9015-20.)

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check.
NO:
Replace PCP (B8). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

378
 522447.06 —Right Forward Pump Coil Short
3 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect pump pressure control pilot (PCP) front (B8) connector and TCU connector (X2). See Engine
Harness (W10) Component Location and see Operator's Station Harness (W7) Component Location .
(Group 9015-10.)

Check for ground at pin 1 (wire T23 BLU) on pump pressure control pilot (PCP) front (B8) connector.

Is ground present?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Checks complete.
Action:

Key switch OFF.

Disconnect connector (X19) from transmission harness (W11).

Check for ground at pin 10 (wire T23 BLU) on engine harness (W10) side of connector (X19).

Is ground present?

Record of Actual Results:

Result:
YES:
Check wire T23 BLU for short to ground between pin 1 on pump pressure control pilot (PCP) front (B8)
connector and pin 10 on connector (X19). Repair or replace harness if necessary. See Engine Harness
(W10) Wiring Diagram . (Group 9015-10.)
NO:
Go to next step in this check.
Action:

Key switch OFF.

Disconnect connector (X16) from operator's station harness (W7).

Check for ground at pin 18 (wire T23 BLU) on transmission harness (W11) side of connector (X16).

Is ground present?

Record of Actual Results:

379
 522447.06 —Right Forward Pump Coil Short

Result:
YES:
Check wire T23 BLU for short to ground between pin 10 on connector (X19) and pin 18 on connector (X16).
Repair or replace harness if necessary. See Transmission Harness (W11) Wiring Diagram . (Group 9015-
10.)
NO:
Check wire T23 BLU for short to ground between pin 18 on connector (X16) and pin 8 on TCU connector
(X2). Repair or replace harness if necessary. See Operator's Station Harness (W7) Wiring Diagram . (Group
9015-10.)

Go to Section_9001:Group_30

WS68074,0000F66-19-20091123

380
 522447.15 —Right Forward Pump Threshold Calibration Value Too High
522447.15 —
Right Forward Pump Threshold Calibration Value Too High

Right Forward Pump Threshold Calibration Value Too High

Right Forward Pump Threshold Calibration Value Too High Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Hydrostatic Motor RPM Check

Action:

Check hydrostatic motor rpm. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-
20.)

Is motor rpm OK?

Record of Actual Results:

Result:
YES:
Go to Calibrate Controller.
NO:
Go to Component Check.

2 Component Check

Action:

Turn Key Switch OFF.

Disconnect right motor speed sensor (B3). See Transmission Harness (W11) Component Location . (Group
9015-15.)

Turn Key Switch ON.

Check for voltage at the right motor speed sensor (B3) pin T06 Blu. See Electrical Component Specifications
. (Group 9015-20.)

Is voltage in specification?

Record of Actual Results:

Result:
YES:
Go to Calibrate Controller.

381
 522447.15 —Right Forward Pump Threshold Calibration Value Too High

NO:
Replace right motor speed sensor (B3). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration
. (Group 9015-20.)

3 Calibration Check
Action:

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 522447.15 still active?

Record of Actual Results:

Result:
YES:
See TCU Calibration Malfunctions . (Group 9026-15.)
NO:
Repair complete.

Go to Section_9001:Group_30

WS68074,0000F67-19-20180130

382
 522447.16 —Right Forward Pump Max Speed Calibration Value Too High
522447.16 —
Right Forward Pump Max Speed Calibration Value Too High

Pump Pressure Control Pilot (PCP) Front Right calibration Current Too Low At Maximum Speed in Forward
Direction

Right Forward Pump Max Speed Calibration Value Too High Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 522447.16 still active?

Record of Actual Results:

Result:
YES:
See TCU Calibration Malfunctions . (Group 9026-15.)
NO:
Repair complete.

Go to Section_9001:Group_30

WS68074,0000F68-19-20080611

383
 522447.17 —Right Forward Pump Threshold Calibration Value Too Low
522447.17 —
Right Forward Pump Threshold Calibration Value Too Low

Pump Pressure Control Pilot (PCP) Front Calibration Threshold Current Too Low in Forward Direction

Right Forward Pump Threshold Calibration Value Too Low Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Hydrostatic Motor RPM Check

Action:

Check hydrostatic motor rpm. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-
20.)

Is motor rpm OK?

Record of Actual Results:

Result:
YES:
Go to Calibrate Controller.
NO:
Go to Component Check.

2 Component Check

Action:

Turn Key Switch OFF.

Disconnect right motor speed sensor (B3). See Transmission Harness (W11) Component Location . (Group
9015-15.)

Turn Key Switch ON.

Check for voltage at the right motor speed sensor (B3) pin T06 Blu. See Electrical Component Specifications
. (Group 9015-20.)

Is voltage in specification?

Record of Actual Results:

Result:
YES:
Go to Calibrate Controller.

384
 522447.17 —Right Forward Pump Threshold Calibration Value Too Low

NO:
Replace right motor speed sensor (B3). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration
. (Group 9015-20.)

3 Calibration Check
Action:

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 522447.17 still active?

Record of Actual Results:

Result:
YES:
See TCU Calibration Malfunctions . (Group 9026-15.)
NO:
Repair complete.

Go to Section_9001:Group_30

WS68074,0000F69-19-20180130

385
 522447.18 —Right Forward Pump Max Speed Calibration Value Too Low
522447.18 —
Right Forward Pump Max Speed Calibration Value Too Low

Pump Pressure Control Pilot (PCP) Front Calibration Current Too Low At Maximum Speed in Forward Direction

Right Forward Pump Max Speed Calibration Value Too Low Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 522447.18 still active?

Record of Actual Results:

Result:
YES:
See TCU Calibration Malfunctions . (Group 9026-15.)
NO:
Repair complete.

Go to Section_9001:Group_30

WS68074,0000F6A-19-20090527

386
 522448.05 —Right Reverse Pump Coil Open
522448.05 —
Right Reverse Pump Coil Open

The Pump Pressure Control Pilot (PCP) Front Is Limited To Forward Direction And Current Draw Is Too Low In
Reverse Direction

Right Reverse Pump Coil Open Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Connector Check
Action:

Check pump pressure control pilot (PCP) front (B8) connector, transmission control unit (TCU) connector
(X2), operator's station harness-to-transmission harness connector 1 (X16), and engine harness-to-
transmission harness connector (X19) for corrosion, loose fit, bent/pushed out terminals or crimp
malfunctions. See Engine Harness (W10) Component Location and see Operator's Station Harness (W7)
Component Location . (Group 9015-10.)

Are connectors in good condition?

Record of Actual Results:

Result:
YES:
Go to Component Check.
NO:
Repair or replace connector(s) or terminal(s) as needed.

2 Component Check
Action:

Turn key switch OFF.

Disconnect pump pressure control pilot (PCP) front (B8).

Check resistance of PCP across pin 1 and 2 on pump pressure control pilot (PCP) front.

Is resistance within specification? See Electrical Component Specifications . (Group 9015-20.)

Record of Actual Results:

Result:
YES:
Go to Open Circuit Check.

387
 522448.05 —Right Reverse Pump Coil Open

NO:
Replace PCP (B8). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

3 Open Circuit Check

Action:

Turn key switch OFF.

Disconnect pump pressure control pilot (PCP) front (B8) connector and TCU connector (X2). See Engine
Harness (W10) Component Location and see Operator's Station Harness (W7) Component Location .
(Group 9015-10.)

Check wire T22 BLU for continuity between pin 1 on pump pressure control pilot (PCP) front (B8) connector
and pin 7 on TCU connector (X2).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Checks complete.
NO:
Go to next step in this check.
Action:

Key switch OFF.

Disconnect connector (X19) from transmission harness (W11).

Check wire T22 BLU for continuity between pin 1 on pump pressure control pilot (PCP) front (B8) connector
and pin 11 on connector (X19).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check wire T22 BLU for an open circuit between pin 1 on pump pressure control pilot (PCP) front (B8)
connector and pin 11 on connector (X19). Repair or replace harness if necessary. See Engine Harness
(W10) Wiring Diagram . (Group 9015-10.)
Action:

Key switch OFF.

Disconnect connector (X16) from operator's station harness (W7).

388
 522448.05 —Right Reverse Pump Coil Open
Check wire T22 BLU for continuity between pin 11 on connector (X19) and pin 17 on connector (X16).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Check wire T22 BLU for an open circuit between pin 17 on connector (X16) and pin 7 on TCU connector
(X2). Repair or replace harness if necessary. See Operator's Station Harness (W7) Wiring Diagram . (Group
9015-10.)
NO:
Check wire T22 BLU for an open circuit between pin 11 on connector (X19) and pin 17 on connector (X16).
Repair or replace harness if necessary. See Transmission Harness (W11) Wiring Diagram . (Group 9015-
10.)

Go to Section_9001:Group_30

CS33148,000229F-19-20091123

389
 522448.06 —Right Reverse Pump Coil Short
522448.06 —
Right Reverse Pump Coil Short

The Front Pump Pressure Control Pilot (PCP) Is Limited To Forward Direction and Current Draw Is Too High In
Reverse Direction

Right Reverse Pump Coil Short Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Connector Check
Action:

Check pump pressure control pilot (PCP) front (B8) connector, transmission control unit (TCU) connector
(X2), operator's station harness-to-transmission harness connector 1 (X16), and engine harness-to-
transmission harness connector (X19) for corrosion, loose fit, bent/pushed out terminals or crimp
malfunctions. See Engine Harness (W10) Component Location and see Operator's Station Harness (W7)
Component Location . (Group 9015-10.)

Are connectors in good condition?

Record of Actual Results:

Result:
YES:
Go to Component Check.
NO:
Repair or replace connector(s) or terminal(s) as needed.

2 Component Check
Action:

Turn key switch OFF.

Disconnect pump pressure control pilot (PCP) front (B8).

Check resistance of PCP across pin 1 and 2 on pump pressure control pilot (PCP) front.

Is resistance within specification? See Electrical Component Specifications . (Group 9015-20.)

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check.

390
 522448.06 —Right Reverse Pump Coil Short

NO:
Replace PCP (B8). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

3 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect pump pressure control pilot (PCP) front (B8) connector and TCU connector (X2). See Engine
Harness (W10) Component Location and see Operator's Station Harness (W7) Component Location .
(Group 9015-10.)

Check for ground at pin 1 (wire T22 BLU) on pump pressure control pilot (PCP) front (B8) connector.

Is ground present?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Checks complete.
Action:

Key switch OFF.

Disconnect connector (X19) from transmission harness (W11).

Check for ground at pin 11 (wire T22 BLU) on engine harness (W10) side of connector (X19).

Is ground present?

Record of Actual Results:

Result:
YES:
Check wire T22 BLU for short to ground between pin 1 on pump pressure control pilot (PCP) front (B8)
connector and pin 11 on connector (X19). Repair or replace harness if necessary. See Engine Harness
(W10) Wiring Diagram . (Group 9015-10.)
NO:
Go to next step in this check.
Action:

Key switch OFF.

Disconnect connector (X16) from operator's station harness (W7).

Check for ground at pin 17 (wire T22 BLU) on transmission harness (W11) side of connector (X16).

391
 522448.06 —Right Reverse Pump Coil Short
Is ground present?

Record of Actual Results:

Result:
YES:
Check wire T22 BLU for short to ground between pin 11 on connector (X19) and pin 17 on connector (X16).
Repair or replace harness if necessary. See Transmission Harness (W11) Wiring Diagram . (Group 9015-
10.)
NO:
Check wire T22 BLU for short to ground between pin 17 on connector (X16) and pin 7 on TCU connector
(X2). Repair or replace harness if necessary. See Operator's Station Harness (W7) Wiring Diagram . (Group
9015-10.)

Go to Section_9001:Group_30

CS33148,000229E-19-20091123

392
 522448.15 —Right Reverse Pump Threshold Calibration Value Too High
522448.15 —
Right Reverse Pump Threshold Calibration Value Too High

The Front Pump Pressure Control Pilot (PCP) (B8) Is Limited To The Reverse Direction and The Forward
Threshold (Point Of Track Movement) Is Too High

Right Reverse Pump Threshold Calibration Value Too High Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Hydrostatic Motor RPM Check

Action:

Check hydrostatic motor rpm. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-
20.)

Is motor rpm OK?

Record of Actual Results:

Result:
YES:
Go to Calibrate Controller.
NO:
Go to Component Check.

2 Component Check

Action:

Turn Key Switch OFF.

Disconnect right motor speed sensor (B3). See Transmission Harness (W11) Component Location . (Group
9015-15.)

Turn Key Switch ON.

Check for voltage at the right motor speed sensor (B3) pin T06 Blu. See Electrical Component Specifications
. (Group 9015-20.)

Is voltage in specification?

Record of Actual Results:

Result:
YES:
Go to Calibrate Controller.
393
 522448.15 —Right Reverse Pump Threshold Calibration Value Too High

NO:
Replace right motor speed sensor (B3). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration
. (Group 9015-20.)

3 Calibration Check
Action:

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 522448.15 still active?

Record of Actual Results:

Result:
YES:
See TCU Calibration Malfunctions . (Group 9026-15.)
NO:
Repair complete.

Go to Section_9001:Group_30

WS68074,0000F6D-19-20180130

394
 522448.16 —Right Reverse Pump Max Speed Calibration Value Too High
522448.16 —
Right Reverse Pump Max Speed Calibration Value Too High

The Front Pump Pressure Control Pilot (PCP) Maximum Calibration Speed Value Is Too High In Forward

Right Reverse Pump Max Speed Calibration Value Too High Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 522448.16 still active?

Record of Actual Results:

Result:
YES:
See TCU Calibration Malfunctions . (Group 9026-15.)
NO:
Repair complete.

Go to Section_9001:Group_30

WS68074,0000F6E-19-20090527

395
 522448.17 —Right Reverse Pump Thresh Calibration Value Too Low
522448.17 —
Right Reverse Pump Thresh Calibration Value Too Low

The Front Pump Pressure Control Pilot (PCP) Is Limited To The Forward Direction and The Reverse Threshold
(Point Of Track Movement) Is Too Low

Right Reverse Pump Threshold Calibration Value Too Low Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Hydrostatic Motor RPM Check

Action:

Check hydrostatic motor rpm. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-
20.)

Is motor rpm OK?

Record of Actual Results:

Result:
YES:
Go to Calibrate Controller.
NO:
Go to Component Check.

2 Component Check

Action:

Turn Key Switch OFF.

Disconnect right motor speed sensor (B3). See Transmission Harness (W11) Component Location . (Group
9015-15.)

Turn Key Switch ON.

Check for voltage at the right motor speed sensor (B3) pin T06 Blu. See Electrical Component Specifications
. (Group 9015-20.)

Is voltage in specification?

Record of Actual Results:

Result:
YES:
Go to Calibrate Controller.
396
 522448.17 —Right Reverse Pump Thresh Calibration Value Too Low

NO:
Replace right motor speed sensor (B3). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration
. (Group 9015-20.)

3 Calibration Check
Action:

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 522448.17 still active?

Record of Actual Results:

Result:
YES:
See TCU Calibration Malfunctions . (Group 9026-15.)
NO:
Repair complete.

Go to Section_9001:Group_30

WS68074,0000F6F-19-20180130

397
 522448.18 —Right Reverse Pump Max Speed Calibration Value Too Low
522448.18 —
Right Reverse Pump Max Speed Calibration Value Too Low

The Front Pump Pressure Control Pilot (PCP) Maximum Calibration Speed Value Is Too Low In Reverse

Right Reverse Pump Max Speed Calibration Value Too Low Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 522448.18 still active?

Record of Actual Results:

Result:
YES:
See TCU Calibration Malfunctions . (Group 9026-15.)
NO:
Repair complete.

Go to Section_9001:Group_30

WS68074,0000F70-19-20090527

398
 522449.05 —Left Reverse Pump Coil Open
522449.05 —
Left Reverse Pump Coil Open

The Rear Pump Pressure Control Pilot (PCP) Is Limited To Forward Direction And Current Draw Is Too Low In
Reverse Direction

Left Reverse Pump Coil Open Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Connector Check
Action:

Check pump pressure control pilot (PCP) rear (B7) connector, transmission control unit (TCU) connector
(X2), operator's station harness-to-transmission harness connector 1 (X16), and engine harness-to-
transmission harness connector (X19) for corrosion, loose fit, bent/pushed out terminals or crimp
malfunctions. See Engine Harness (W10) Component Location and see Operator's Station Harness (W7)
Component Location . (Group 9015-10.)

Are connectors in good condition?

Record of Actual Results:

Result:
YES:
Go to Component Check.
NO:
Repair or replace connector(s) or terminal(s) as needed.

2 Component Check
Action:

Turn key switch OFF.

Disconnect pump pressure control pilot (PCP) rear (B7).

Check resistance across pin 1 and 2 on rear pump pressure control pilot (PCP).

Is resistance within specification? See Electrical Component Specifications . (Group 9015-20.)

Record of Actual Results:

Result:
YES:
Go to Open Circuit Check.

399
 522449.05 —Left Reverse Pump Coil Open

NO:
Replace PCP (B7). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

3 Open Circuit Check

Action:

Key switch OFF.

Disconnect pump pressure control pilot (PCP) rear (B7) connector and TCU connector (X2). See Engine
Harness (W10) Component Location and see Operator's Station Harness (W7) Component Location .
(Group 9015-10.)

Check wire T20 BLU for continuity between pin 1 on rear pump pressure control pilot (PCP) (B7) connector
and pin 9 on TCU connector (X2).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Checks complete.
NO:
Go to next step in this check.
Action:

Key switch OFF.

Disconnect connector (X19) from transmission harness (W11).

Check wire T20 BLU for continuity between pin 1 on pump pressure control pilot (PCP) rear (B7) connector
and pin 9 on connector (X19).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check wire T20 BLU for an open circuit between pin 1 on pump pressure control pilot (PCP) rear (B7)
connector and pin 9 on connector (X19). Repair or replace harness if necessary. See Engine Harness (W10)
Wiring Diagram . (Group 9015-10.)
Action:

Key switch OFF.

Disconnect connector (X16) from operator's station harness (W7).

400
 522449.05 —Left Reverse Pump Coil Open
Check wire T20 BLU for continuity between pin 9 on connector (X19) and pin 19 on connector (X16).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Check wire T20 BLU for an open circuit between pin 19 on connector (X16) and pin 9 on TCU connector
(X2). Repair or replace harness if necessary. See Operator's Station Harness (W7) Wiring Diagram . (Group
9015-10.)
NO:
Check wire T20 BLU for an open circuit between pin 9 on connector (X19) and pin 19 on connector (X16).
Repair or replace harness if necessary. See Transmission Harness (W11) Wiring Diagram . (Group 9015-
10.)

Go to Section_9001:Group_30

WS68074,0000F71-19-20091123

401
 522449.06 —Left Reverse Pump Coil Short
522449.06 —
Left Reverse Pump Coil Short

The Rear Pump Pressure Control Pilot (PCP) Is Limited To Forward Direction And Current Draw Is Too High In
Reverse Direction

Left Reverse Pump Coil Open Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Connector Check
Action:

Check pump pressure control pilot (PCP) rear (B7) connector, transmission control unit (TCU) connector
(X2), operator's station harness-to-transmission harness connector 1 (X16), and engine harness-to-
transmission harness connector (X19) for corrosion, loose fit, bent/pushed out terminals or crimp
malfunctions. See Engine Harness (W10) Component Location and see Operator's Station Harness (W7)
Component Location . (Group 9015-10.)

Are connectors in good condition?

Record of Actual Results:

Result:
YES:
Go to Component Check.
NO:
Repair or replace connector(s) or terminal(s) as needed.

2 Component Check
Action:

Turn key switch OFF.

Disconnect pump pressure control pilot (PCP) rear (B7).

Check resistance across pin 1 and 2 on rear pump pressure control pilot (PCP).

Is resistance within specification? See Electrical Component Specifications . (Group 9015-20.)

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check.

402
 522449.06 —Left Reverse Pump Coil Short

NO:
Replace PCP (B7). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

3 Short Circuit Check

Action:

Key switch OFF.

Disconnect pressure control pilot (PCP) rear (B7) connector and TCU connector (X2). See Engine Harness
(W10) Component Location and see Operator's Station Harness (W7) Component Location . (Group 9015-
10.)

Check for ground at pin 1 (wire T20 BLU) on rear pump pressure control pilot (PCP) (B7) connector.

Is ground present?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Checks complete.
Action:

Key switch OFF.

Disconnect connector (X19) from transmission harness (W11).

Check for ground at pin 9 (wire T20 BLU) on engine harness (W10) side of connector (X19).

Is ground present?

Record of Actual Results:

Result:
YES:
Check wire T20 BLU for short to ground between pin 1 on pump pressure control pilot (PCP) rear (B7)
connector and pin 9 on connector (X19). Repair or replace harness if necessary. See Engine Harness (W10)
Wiring Diagram . (Group 9015-10.)
NO:
Go to next step in this check.
Action:

Key switch OFF.

Disconnect connector (X16) from operator's station harness (W7).

Check for ground at pin 19 (wire T20 BLU) on transmission harness (W11) side of connector (X16).

403
 522449.06 —Left Reverse Pump Coil Short
Is ground present?

Record of Actual Results:

Result:
YES:
Check wire T20 BLU for short to ground between pin 9 on connector (X19) and pin 19 on connector (X16).
Repair or replace harness if necessary. See Transmission Harness (W11) Wiring Diagram . (Group 9015-
10.)
NO:
Check wire T20 BLU for short to ground between pin 19 on connector (X16) and pin 9 on TCU connector
(X2). Repair or replace harness if necessary. See Operator's Station Harness (W7) Wiring Diagram . (Group
9015-10.)

Go to Section_9001:Group_30

WS68074,0000F72-19-20091123

404
 522449.15 —Left Reverse Pump Threshold Calibration Value Too High
522449.15 —
Left Reverse Pump Threshold Calibration Value Too High

The Rear Pump Pressure Control Pilot (PCP) Is Limited To The Forward Direction And The Reverse Threshold
(Point Of Track Movement) Is Too High

Left Reverse Pump Threshold Calibration Value Too High Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Hydrostatic Motor RPM Check

Action:

Check hydrostatic motor rpm. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-
20.)

Is motor rpm OK?

Record of Actual Results:

Result:
YES:
Go to Calibrate Controller.
NO:
Go to Component Check.

2 Component Check

Action:

Turn Key Switch OFF.

Disconnect left motor speed sensor (B2). See Transmission Harness (W11) Component Location . (Group
9015-15.)

Turn Key Switch ON.

Check for voltage at the left motor speed sensor (B2) pin T04 Blu. See Electrical Component Specifications .
(Group 9015-20.)

Is voltage in specification?

Record of Actual Results:

Result:
YES:
Go to Calibrate Controller.
405
 522449.15 —Left Reverse Pump Threshold Calibration Value Too High

NO:
Replace left motor speed sensor (B2). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration .
(Group 9015-20.)

3 Calibration Check
Action:

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 522449.15 still active?

Record of Actual Results:

Result:
YES:
See TCU Calibration Malfunctions . (Group 9026-15.)
NO:
Repair complete.

Go to Section_9001:Group_30

WS68074,0000F73-19-20180130

406
 522449.16 —Left Reverse Pump Max Speed Calibration Value Too High
522449.16 —
Left Reverse Pump Max Speed Calibration Value Too High

The Front Pump Pressure Control Pilot (PCP) Maximum Calibration Speed Value Is Too High In Reverse

Left Reverse Pump Max Speed Calibration Value Too High Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 522449.16 still active?

Record of Actual Results:

Result:
YES:
See TCU Calibration Malfunctions . (Group 9026-15.)
NO:
Repair complete.

Go to Section_9001:Group_30

WS68074,0000F74-19-20080611

407
 522449.17 —Left Reverse Pump Threshold Calibration Value Too Low
522449.17 —
Left Reverse Pump Threshold Calibration Value Too Low

The Rear Pump Pressure Control Pilot (PCP) Is Limited To The Forward Direction and The Reverse Threshold
(Point Of Track Movement) Is Too Low

Left Reverse Pump Threshold Calibration Value Too Low Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Hydrostatic Motor RPM Check

Action:

Check hydrostatic motor rpm. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-
20.)

Is motor rpm OK?

Record of Actual Results:

Result:
YES:
Go to Calibrate Controller.
NO:
Go to Component Check.

2 Component Check

Action:

Turn Key Switch OFF.

Disconnect left motor speed sensor (B2). See Transmission Harness (W11) Component Location . (Group
9015-15.)

Turn Key Switch ON.

Check for voltage at the left motor speed sensor (B2) pin T04 Blu. See Electrical Component Specifications .
(Group 9015-20.)

Is voltage in specification?

Record of Actual Results:

Result:
YES:
Go to Calibrate Controller.
408
 522449.17 —Left Reverse Pump Threshold Calibration Value Too Low

NO:
Replace left motor speed sensor (B2). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration .
(Group 9015-20.)

3 Calibration Check
Action:

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 522449.17 still active?

Record of Actual Results:

Result:
YES:
See TCU Calibration Malfunctions . (Group 9026-15.)
NO:
Repair complete.

Go to Section_9001:Group_30

WS68074,0000F75-19-20171106

409
 522449.18 —Left Reverse Pump Max Speed Calibration Value Too Low
522449.18 —
Left Reverse Pump Max Speed Calibration Value Too Low

The Rear Pump Pressure Control Pilot (PCP) Maximum Calibration Speed Value Is Too Low In Reverse

Left Reverse Pump Max Speed Calibration Value Too Low Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 522449.18 still active?

Record of Actual Results:

Result:
YES:
See TCU Calibration Malfunctions . (Group 9026-15.)
NO:
Repair complete.

Go to Section_9001:Group_30

WS68074,0000F76-19-20080611

410
 522450.05 —Left Forward Pump Coil Open
522450.05 —
Left Forward Pump Coil Open

The Rear Pump Pressure Control Pilot (PCP) Is Limited To Reverse Direction And Current Draw Is Too Low In
Forward Direction

Left Forward Pump Coil Open Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Connector Check
Action:

Check pump pressure control pilot (PCP) rear (B7) connector, transmission control unit (TCU) connector
(X2), operator's station harness-to-transmission harness connector 1 (X16), and engine harness-to-
transmission harness connector (X19) for corrosion, loose fit, bent/pushed out terminals or crimp
malfunctions. See Engine Harness (W10) Component Location and see Operator's Station Harness (W7)
Component Location . (Group 9015-10.)

Are connectors in good condition?

Record of Actual Results:

Result:
YES:
Go to Component Check.
NO:
Repair or replace connector(s) or terminal(s) as needed.

2 Component Check
Action:

Disconnect pump pressure control pilot (PCP) rear (B7).

Check resistance of PCP across pin 1 and 2 on pump pressure control pilot (PCP).

Is resistance within specification? See Electrical Component Specifications . (Group 9015-20.)

Record of Actual Results:

Result:
YES:
Go to Open Circuit Check.
NO:
Replace PCP (B7). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

411
 522450.05 —Left Forward Pump Coil Open

3 Open Circuit Check

Action:

Turn key switch OFF.

Disconnect pump pressure control pilot (PCP) rear (B7) connector and TCU connector (X2). See Engine
Harness (W10) Component Location and see Operator's Station Harness (W7) Component Location .
(Group 9015-10.)

Check wire T21 BLU for continuity between pin 2 on pump pressure control pilot (PCP) rear (B7) connector
and pin 17 on TCU connector (X2).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Checks complete.
NO:
Go to next step in this check.
Action:

Disconnect connector (X19) from transmission harness (W11).

Check wire T21 BLU for continuity between pin 2 on pump pressure control pilot (PCP) rear (B7) connector
and pin 8 on connector (X19).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check wire T21 BLU for an open circuit between pin 2 on pump pressure control pilot (PCP) rear (B7)
connector and pin 8 on connector (X19). Repair or replace harness if necessary. See Engine Harness (W10)
Wiring Diagram . (Group 9015-10.)
Action:

Disconnect connector (X16) from operator's station harness (W7).

Check wire T21 BLU for continuity between pin 8 on connector (X19) and pin 20 on connector (X16).

Is continuity indicated?

Record of Actual Results:

412
 522450.05 —Left Forward Pump Coil Open

Result:
YES:
Check wire T21 BLU for an open circuit between pin 20 on connector (X16) and pin 17 on TCU connector
(X2). Repair or replace harness if necessary. See Operator's Station Harness (W7) Wiring Diagram . (Group
9015-10.)
NO:
Check wire T21 BLU for an open circuit between pin 8 on connector (X19) and pin 20 on connector (X16).
Repair or replace harness if necessary. See Transmission Harness (W11) Wiring Diagram . (Group 9015-
10.)

Go to Section_9001:Group_30

WS68074,0000F77-19-20091123

413
 522450.06 —Left Forward Pump Coil Short
522450.06 —
Left Forward Pump Coil Short

The Rear Pump Pressure Control Pilot (PCP) Is Limited To Reverse Direction And Current Draw Is Too High In
Forward Direction

Left Forward Pump Coil Short Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Connector Check
Action:

Check pump pressure control pilot (PCP) rear (B7) connector, transmission control unit (TCU) connector
(X2), operator's station harness-to-transmission harness connector 1 (X16), and engine harness-to-
transmission harness connector (X19) for corrosion, loose fit, bent/pushed out terminals or crimp
malfunctions. See Engine Harness (W10) Component Location and see Operator's Station Harness (W7)
Component Location . (Group 9015-10.)

Are connectors in good condition?

Record of Actual Results:

Result:
YES:
Go to Component Check.
NO:
Repair or replace connector(s) or terminal(s) as needed.

2 Component Check
Action:

Disconnect pump pressure control pilot (PCP) rear (B7).

Check resistance across pin 1 and 2 on pump pressure control pilot (PCP).

Is resistance within specification? See Electrical Component Specifications . (Group 9015-20.)

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check.
NO:
Replace PCP (B7). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

414
 522450.06 —Left Forward Pump Coil Short

3 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect pump pressure control pilot (PCP) rear (B7) connector and TCU connector (X2). See Engine
Harness (W10) Component Location and see Operator's Station Harness (W7) Component Location .
(Group 9015-10.)

Check for ground at pin 2 (wire T21 BLU) on pump pressure control pilot (PCP) rear (B7) connector.

Is ground present?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Checks complete.
Action:

Key switch OFF.

Disconnect connector (X19) from transmission harness (W11).

Check for ground at pin 8 (wire T21 BLU) on engine harness (W10) side of connector (X19).

Is ground present?

Record of Actual Results:

Result:
YES:
Check wire T21 BLU for short to ground between pin 2 on pump pressure control pilot (PCP) rear (B7)
connector and pin 8 on connector (X19). Repair or replace harness if necessary. See Engine Harness (W10)
Wiring Diagram . (Group 9015-10.)
NO:
Go to next step in this check.
Action:

Key switch OFF.

Disconnect connector (X16) from operator's station harness (W7).

Check for ground at pin 20 (wire T21 BLU) on transmission harness (W11) side of connector (X16).

Is ground present?

Record of Actual Results:

415
 522450.06 —Left Forward Pump Coil Short

Result:
YES:
Check wire T21 BLU for short to ground between pin 8 on connector (X19) and pin 20 on connector (X16).
Repair or replace harness if necessary. See Transmission Harness (W11) Wiring Diagram . (Group 9015-
10.)
NO:
Check wire T21 BLU for short to ground between pin 20 on connector (X16) and pin 17 on TCU connector
(X2). Repair or replace harness if necessary. See Operator's Station Harness (W7) Wiring Diagram . (Group
9015-10.)

Go to Section_9001:Group_30

WS68074,0000F78-19-20091123

416
 522450.15 —Left Forward Pump Threshold Calibration Value Too High
522450.15 —
Left Forward Pump Threshold Calibration Value Too High

The Pump Pressure Control Pilot (PCP) Rear Is Limited To The Reverse Direction and The Forward Threshold
(Point Of Track Movement) Is Too High

Left Forward Pump Threshold Calibration Value Too High Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Hydrostatic Motor RPM Check

Action:

Check hydrostatic motor rpm. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-
20.)

Is motor rpm OK?

Record of Actual Results:

Result:
YES:
Go to Calibrate Controller.
NO:
Go to Component Check.

2 Component Check

Action:

Turn Key Switch OFF.

Disconnect left motor speed sensor (B2). See Transmission Harness (W11) Component Location . (Group
9015-15.)

Turn Key Switch ON.

Check for voltage at the left motor speed sensor (B2) pin T04 Blu. See Electrical Component Specifications .
(Group 9015-20.)

Is voltage in specification?

Record of Actual Results:

Result:
YES:
Go to Calibrate Controller.
417
 522450.15 —Left Forward Pump Threshold Calibration Value Too High

NO:
Replace left motor speed sensor (B2). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration .
(Group 9015-20.)

3 Calibration Check
Action:

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 522450.15 still active?

Record of Actual Results:

Result:
YES:
See TCU Calibration Malfunctions . (Group 9026-15.)
NO:
Repair complete.

Go to Section_9001:Group_30

WS68074,0000F79-19-20180130

418
 522450.16 —Left Forward Pump Max Speed Calibration Value Too High
522450.16 —
Left Forward Pump Max Speed Calibration Value Too High

The Rear Pump Pressure Control Pilot (PCP) Maximum Calibration Speed Value Is Too High In Forward

Left Forward Pump Max Speed Calibration Value Too High Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 522450.16 still active?

Record of Actual Results:

Result:
YES:
See TCU Calibration Malfunctions . (Group 9026-15.)
NO:
Repair complete.

Go to Section_9001:Group_30

WS68074,0000F7A-19-20080611

419
 522450.17 —Left Forward Pump Threshold Calibration Value Too Low
522450.17 —
Left Forward Pump Threshold Calibration Value Too Low

The Pump Pressure Control Pilot (PCP) Rear Is Limited To The Reverse Direction and The Forward Threshold
(Point Of Track Movement) Is Too Low

Left Forward Pump Threshold Calibration Value Too Low Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Hydrostatic Motor RPM Check

Action:

Check hydrostatic motor rpm. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-
20.)

Is motor rpm OK?

Record of Actual Results:

Result:
YES:
Go to Calibrate Controller.
NO:
Go to Component Check.

2 Component Check

Action:

Turn Key Switch OFF.

Disconnect left motor speed sensor (B2). See Transmission Harness (W11) Component Location . (Group
9015-15.)

Turn Key Switch ON.

Check for voltage at the left motor speed sensor (B2) pin T04 Blu. See Electrical Component Specifications .
(Group 9015-20.)

Is voltage in specification?

Record of Actual Results:

Result:
YES:
Go to Calibrate Controller.
420
 522450.17 —Left Forward Pump Threshold Calibration Value Too Low

NO:
Replace left motor speed sensor (B2). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration .
(Group 9015-20.)

3 Calibration Check
Action:

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 522450.17 still active?

Record of Actual Results:

Result:
YES:
See TCU Calibration Malfunctions . (Group 9026-15.)
NO:
Repair complete.

Go to Section_9001:Group_30

WS68074,0000F7B-19-20180130

421
 522450.18 —Left Forward Pump Max Speed Calibration Value Too Low
522450.18 —
Left Forward Pump Max Speed Calibration Value Too Low

The Rear Pump Pressure Control Pilot (PCP) Maximum Calibration Speed Value Is Too Low In Forward

Left Forward Pump Max Speed Calibration Value Too Low Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 522450.18 still active?

Record of Actual Results:

Result:
YES:
See TCU Calibration Malfunctions . (Group 9026-15.)
NO:
Repair complete.

Go to Section_9001:Group_30

WS68074,0000F7C-19-20080611

422
 522451.05 —Cooler Bypass Solenoid No Response
522451.05 —
Cooler Bypass Solenoid No Response

Hydrostatic Oil Cooler Bypass Solenoid (Y14) No Response

NOTE:

This DTC is only declared at machine start-up when the solenoid is energized.

Cooler Bypass Solenoid No Response Diagnostic Procedure

Alarm Level:

No Warning Lamp

Launch Close Expand List Collapse List

1 Component Check
Action:

NOTE:

This DTC is only declared when the solenoid is energized.

Turn key switch OFF.

Disconnect hydrostatic oil cooler bypass solenoid (Y14). See Transmission Harness (W11) Component
Location . (Group 9015-10.)

Check resistance of solenoid. See Electrical Component Specifications . (Group 9015-20.)

Is solenoid within specifications?

Record of Actual Results:

Result:
YES:
Go to Open Circuit Check.
NO:
Replace solenoid.

2 Open Circuit Check

Action:

Turn key switch OFF.

Disconnect TCU connector (X2) and hydrostatic oil cooler bypass solenoid (Y14) connector. See
Transmission Harness (W11) Component Location and See Operator's Station Harness (W7) Component
Location . (Group 9015-10.)

423
 522451.05 —Cooler Bypass Solenoid No Response
Check continuity between pin 16 (wire T35 BLU) of TCU connector (X2) and pin 1 of cooler bypass solenoid
connector (Y14).

Is there continuity indicated?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check for an open circuit between pin 1 (wire T35 BLU) of cooler bypass solenoid (Y14) connector and pin
16 of TCU connector (X2). Repair or replace harness. See Operator's Station Harness (W7) Wiring Diagram
and see Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)
Action:

Key switch OFF.

Disconnect hydrostatic oil cooler bypass solenoid (Y14) connector. See Transmission Harness (W11)
Component Location . (Group 9015-10.)

Check continuity (wire G09 BLK) between pin 2 of hydrostatic oil cooler bypass solenoid (Y14) connector
and ground.

Is there continuity indicated?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Test.
NO:
Check for an open circuit between pin 2 of hydrostatic oil cooler bypass solenoid (Y14) connector and
ground. see Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)

3 Short Circuit Test

Action:

Disconnect hydrostatic oil cooler bypass solenoid (Y14) connector and TCU connector (X2). See Operator's
Station Harness (W7) Component Location and see Transmission Harness (W11) Component Location .
(Group 9015-10.)

Check for short to ground at pin 1 (wire T35 BLU) of hydrostatic oil cooler bypass solenoid (Y14) connector.
See Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)

Is there ground present?

Record of Actual Results:

424
 522451.05 —Cooler Bypass Solenoid No Response

Result:
YES:
Repair or replace harnesses, as necessary. See Operator's Station Harness (W7) Wiring Diagram or see
Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000F7D-19-20100702

425
 523108.13 —TCU Not Calibrated High Speed Not Done
523108.13 —
TCU Not Calibrated High Speed Not Done

TCU Not Calibrated, High Speed Is Not Done

TCU Not Calibrated, High Speed Is Not Done Diagnostic Procedure

Launch Close Expand List Collapse List

1 Calibration Check

Action:

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 523108.13 still active?

Record of Actual Results:

Result:
YES:
See TCU Calibration Malfunctions . (Group 9026-15.)
NO:
Repair complete.

Go to Section_9001:Group_30

WS68074,0000F7E-19-20080611

426
 523108.14 —TCU Not Calibrated Sensor/Pump/Motor
523108.14 —
TCU Not Calibrated Sensor/Pump/Motor

TCU Not Calibrated Sensor/Pump/Motor

TCU Not Calibrated Sensor/Pump/Motor Diagnostic Procedure

Launch Close Expand List Collapse List

1 Calibration Check

Action:

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 523108.14 still active?

Record of Actual Results:

Result:
YES:
See TCU Calibration Malfunctions . (Group 9026-15.)
NO:
Repair complete.

Go to Section_9001:Group_30

WS68074,0000F7F-19-20080611

427
 523436.07 —TCU Watchdog Timer Exceeded
523436.07 —
TCU Watchdog Timer Exceeded

TCU Watchdog Timer Exceeded

TCU Watchdog Timer Exceeded Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Replace Controller
Action:

Replace the TCU.

Is code 523436.07 still active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Repair complete.

Go to Section_9001:Group_30

WS68074,0000F80-19-20080610

428
 523577.05 —Left Motor Solenoid Open Circuit
523577.05 —
Left Motor Solenoid Open Circuit

Left Motor Shift Solenoid Open Circuit

Left Motor Shift Solenoid Open Circuit Diagnostic Procedure

Alarm Level:

No Service Light

Launch Close Expand List Collapse List

1 Component Check
Action:

Turn key switch OFF.

Disconnect left motor shift solenoid (Y3). See Transmission Harness (W11) Component Location . (Group
9015-10.)

Check resistance of solenoid across pins 1 and 2.

Item Measurement Specification

Left Motor Shift Solenoid—Y3 Resistance 21.3 ohms at 20°C (68°F)

Is solenoid within specifications?

Record of Actual Results:

Result:
YES:
Go to Open Circuit Check .
NO:
Replace solenoid.

2 Open Circuit Check

Action:

Turn key switch OFF.

Disconnect left motor solenoid connector (Y3) and TCU connector (X2). See Operator's Station Harness
(W7) Component Location . (Group 9015-10.)

Check for continuity of wire T26 BLU at pin 1 of left motor solenoid connector (Y3) and pin 12 of TCU
connector (X2). See Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)

Is there continuity indicated?

Record of Actual Results:

429
 523577.05 —Left Motor Solenoid Open Circuit

Result:
YES:
Go to Replace Controller .
NO:
Go to next step in this check.
Action:

Disconnect operator's station harness-to-transmission harness connector (X16) and left motor solenoid
connector (Y3). See Transmission Harness (W11) Component Location . (Group 9015-10.)

Check for continuity of wire T26 BLU at pin 29 of connector (X16) and pin 1 of left motor solenoid connector
(Y3). See Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)

Is there continuity indicated?

Record of Actual Results:

Result:
YES:
Check the operator's station harness for an open on wire T26 BLU between pin 29 of connector (X16) and
the pin 12 of TCU connector (X2). Repair or replace harness. See Operator's Station Harness (W7) Wiring
Diagram . (Group 9015-10.)
NO:
Check the transmission harness for an open on wire T26 BLU between pin 29 of connector (X16) and pin 1
of the left motor solenoid connector (Y3). Repair or replace harness. See Transmission Harness (W11)
Wiring Diagram . (Group 9015-10.)

3 Replace Controller

Action:

Replace transmission control unit (TCU) (A1).

Is code 523577.05 still active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000F81-19-20091217

430
 523577.06 —Left Motor Solenoid Short Circuit
523577.06 —
Left Motor Solenoid Short Circuit

Left Motor Solenoid Short Circuit

Left Motor Solenoid Short Circuit Diagnostic Procedure

Alarm Level:

No warning Lamp

Launch Close Expand List Collapse List

1 Component Check
Action:

Turn key switch OFF.

Disconnect left motor shift solenoid (Y3). See Transmission Harness (W11) Component Location . (Group
9015-10.)

Check resistance of solenoid across pins 1 and 2.

Item Measurement Specification

Left Motor Shift Solenoid—Y3 Resistance 21.3 ohms at 20°C (68°F)

Is solenoid within specifications?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
NO:
Replace solenoid.

2 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect left motor shift solenoid (Y3). See Transmission Harness (W11) Component Location . (Group
9015-10.)

Check wire T26 BLU for ground at pin 1 of left motor shift solenoid connector (Y3). See Transmission
Harness (W11) Wiring Diagram . (Group 9015-10.)

Is there ground present?

Record of Actual Results:

431
 523577.06 —Left Motor Solenoid Short Circuit

Result:
YES:
Go to Replace Controller .
NO:
Go to next step in this check.
Action:

Disconnect operator's station harness-to-transmission harness connector (X16).

Check wire T26 BLU for ground at pin 1 of left motor shift solenoid connector (Y3). See Transmission
Harness (W11) Wiring Diagram . (Group 9015-10.)

Is there ground present?

Record of Actual Results:

Result:
YES:
Check transmission harness for a short to ground on wire T26 BLU between pin 29 of connector (X16) and
pin 1 of left motor shift solenoid connector (Y3). Repair or replace harness. See Transmission Harness
(W11) Wiring Diagram . (Group 9015-10.)
NO:
Check operator's station harness for a short to ground on wire T26 BLU between pin 29 of connector (X16)
and pin 12 of TCU connector (X2). Repair or replace harness. See Operator's Station Harness (W7) Wiring
Diagram . (Group 9015-10.)

3 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Is code 523577.06 still active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000F82-19-20080610

432
 523577.16 —Left Motor Maximum Calibration Value Too High
523577.16 —
Left Motor Maximum Calibration Value Too High

Left Motor Maximum Calibration Value Too High

Left Motor Maximum Calibration Value Too High Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 523577.16 active?

Record of Actual Results:

Result:
YES:
See TCU Calibration Malfunctions . (Group 9026-15.)
NO:
Repair complete.

Go to Section_9001:Group_30

WS68074,0000F83-19-20080611

433
 523577.18 —Left Motor Maximum Calibration Value Too Low
523577.18 —
Left Motor Maximum Calibration Value Too Low

Left Motor Maximum Calibration Value Too Low

Left Motor Maximum Calibration Value Too Low Diagnostic Procedure

Alarm Level:

No Warning Lamp

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 523577.18 active?

Record of Actual Results:

Result:
YES:
See TCU Calibration Malfunctions . (Group 9026-15.)
NO:
Repair complete.

Go to Section_9001:Group_30

WS68074,0000F84-19-20080611

434
 523578.05 —Right Motor Solenoid Open Circuit
523578.05 —
Right Motor Solenoid Open Circuit

Right Motor Solenoid Open Circuit

Right Motor Solenoid Open Circuit Diagnostic Procedure

Alarm Level:

No Service Light

Launch Close Expand List Collapse List

1 Component Check
Action:

Disconnect right motor shift solenoid (Y4). See Transmission Harness (W11) Component Location . (Group
9015-10.)

Check resistance of solenoid across pins 1 and 2.

Item Measurement Specification

Right Motor Shift Solenoid (Y4) Resistance 21.3 ohms at 20°C (68°F)

Is solenoid within specifications?

Record of Actual Results:

Result:
YES:
Go to Open Circuit Check .
NO:
Replace solenoid.

2 Open Circuit Check

Action:

Turn key switch OFF.

Disconnect right motor solenoid connector (Y4) and TCU connector (X2). See Operator's Station Harness
(W7) Component Location . (Group 9015-10.)

Check for continuity of wire T24 BLU at pin 1 of right motor solenoid connector (Y4) and pin 15 of TCU
connector (X2). See Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)

Is there continuity indicated?

Record of Actual Results:

435
 523578.05 —Right Motor Solenoid Open Circuit

Result:
YES:
Go to Replace Controller .
NO:
Go to next step in this check.
Action:

Disconnect operator's station harness-to-transmission harness connector (X16) and right motor solenoid
connector (Y4). See Transmission Harness (W11) Component Location . (Group 9015-10.)

Check for continuity of wire T24 BLU at pin 21 of connector (X16) and pin 1 of right motor solenoid connector
(Y4). See Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)

Is there continuity indicated?

Record of Actual Results:

Result:
YES:
Check the operator's station harness for an open on wire T24 BLU between pin 21 of connector (X16) and
the pin 15 of TCU connector (X2). Repair or replace harness. See Operator's Station Harness (W7) Wiring
Diagram . (Group 9015-10.)
NO:
Check the transmission harness for an open on wire T24 BLU between pin 21 of connector (X16) and pin 1
of the right motor solenoid connector (Y4). Repair or replace harness. See Transmission Harness (W11)
Wiring Diagram . (Group 9015-10.)

3 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Is code 523578.05 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000F85-19-20091217

436
 523578.06 —Right Motor Solenoid Short Circuit
523578.06 —
Right Motor Solenoid Short Circuit

Right Motor Solenoid Short Circuit

Right Motor Solenoid Short Circuit Diagnostic Procedure

Alarm Level:

No Service Light

Launch Close Expand List Collapse List

1 Component Check
Action:

Disconnect right motor shift solenoid (Y4). See Transmission Harness (W11) Component Location . (Group
9015-10.)

Check resistance of solenoid across pins 1 and 2.

Item Measurement Specification

Right Motor Shift Solenoid (Y4) Resistance 21.3 ohms at 20°C (68°F)

Is solenoid within specifications?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check .
NO:
Replace solenoid.

2 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect right motor shift solenoid (Y4). See Transmission Harness (W11) Component Location . (Group
9015-10.)

Check wire T24 BLU for ground at pin 1 of right motor shift solenoid connector (Y4). See Transmission
Harness (W11) Wiring Diagram . (Group 9015-10.)

Is there ground present?

Record of Actual Results:

437
 523578.06 —Right Motor Solenoid Short Circuit

Result:
YES:
Go to Replace Controller .
NO:
Go to next step in this check.
Action:

Disconnect operator's station harness-to-transmission harness connector (X16).

Check wire T24 BLU for ground at pin 1 of right motor shift solenoid connector (Y4). See Transmission
Harness (W11) Wiring Diagram . (Group 9015-10.)

Is there ground present?

Record of Actual Results:

Result:
YES:
Check transmission harness for a short to ground on wire T24 BLU between pin 21 of connector (X16) and
pin 1 of right motor shift solenoid connector (Y4). Repair or replace harness. See Transmission Harness
(W11) Wiring Diagram . (Group 9015-10.)
NO:
Check operator's station harness for a short to ground on wire T24 BLU between pin 21 of connector (X16)
and pin 15 of TCU connector (X2). Repair or replace harness. See Operator's Station Harness (W7) Wiring
Diagram . (Group 9015-10.)

3 Replace Controller
Action:

Replace transmission control unit (TCU) (A1).

Is code 523578.06 active?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_30

WS68074,0000F86-19-20080610

438
 523578.16 —Right Motor Maximum Calibration Value Too High
523578.16 —
Right Motor Maximum Calibration Value Too High

Right Motor Maximum Calibration Value Too High

Right Motor Maximum Calibration Value Too High Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 523578.16 active?

Record of Actual Results:

Result:
YES:
See TCU Calibration Malfunctions . (Group 9026-15.)
NO:
Repair complete.

Go to Section_9001:Group_30

WS68074,0000F87-19-20080611

439
 523578.18 —Right Motor Maximum Calibration Value Too Low
523578.18 —
Right Motor Maximum Calibration Value Too Low

Right Motor Maximum Calibration Value Too Low

Right Motor Maximum Calibration Value Too Low Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Calibration Check
Action:

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Is code 523578.18 active?

Record of Actual Results:

Result:
YES:
See TCU Calibration Malfunctions . (Group 9026-15.)
NO:
Repair complete.

Go to Section_9001:Group_30

WS68074,0000F88-19-20080611

440
 Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

The diagnostic trouble code number is indicated by a suspect parameter number (SPN) and a failure mode
indicator (FMI) number. In the example 000158.03 , 158 is the SPN and 03 is the FMI number.

To view diagnostic trouble codes, use one of the following methods:

Service ADVISOR™ system. See Reading Diagnostic Trouble Codes with Service ADVISOR™
Diagnostic Application . (Group 9015-20.)
CAN Monitor Unit (CMU): See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-
20.)

NOTE:

For in-depth diagnostics on all EHC diagnostic trouble codes, see specific code diagnostic
procedure. (Group 9001-40.)

Go to Section_9001:Group_40

AA95137,00007DF-19-20070405

441
 Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

The diagnostic trouble code number is indicated by a suspect parameter number (SPN) and a failure mode
indicator (FMI) number. In the example 000158.03 , 158 is the SPN and 03 is the FMI number.

To view diagnostic trouble codes, use one of the following methods:

Service ADVISOR™ system. See Reading Diagnostic Trouble Codes with Service ADVISOR™
Diagnostic Application . (Group 9015-20.)
CAN Monitor Unit (CMU): See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-
20.)

NOTE:

For in-depth diagnostics on all EHC diagnostic trouble codes, see specific code diagnostic
procedure. (Group 9001-40.)

Go to Section_9001:Group_40

AA95137,00007DF-19-20070405

442
 000158.03 —EHC System Volts Too High
000158.03 —
EHC System Volts Too High

The input voltage to the electrohydraulic controller (EHC) is more than 38 volts.

EHC System Volts Too High Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Component Check
Action:

Check alternator output. See Alternator Test . (Group 9015-20.)

Is alternator output within specifications?

Record of Actual Results:

Result:
YES:
Go to Reprogram Controller.
NO:
Alternator malfunction. Repair or replace alternator.

2 Reprogram Controller

Action:

Reprogram electrohydraulic controller.

Check for active codes.

Is EHC code 00158.03 present?

Record of Actual Results:

Result:
YES:
Controller malfunction. Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

AA95137,000079B-19-20070307

443
 000158.04 —EHC System Volts Too Low
000158.04 —
EHC System Volts Too Low

The input voltage to the electrohydraulic controller (EHC) is less than 9 volts.

EHC System Power Diagnostics

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Voltage Check
Action:

Check system voltage on monitor. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group
9015-20.)

Is system voltage (approximately 24 volts) present?

Record of Actual Results:

Result:
YES:
Go to Harness Check .
NO:
Check alternator. Perform Alternator Test . (Group 9015-20.)

Check batteries. See Handling, Checking and Servicing Batteries Carefully . (Operator's Manual.)

2 Harness Check
Action:

Turn key switch OFF.

Disconnect BCJ and EHC switched power relay (K102). See IGC Machine Harness (W21) and IGC Cab
Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Turn key switch ON.

Measure voltage at terminal 30 on relay connector.

Is system voltage (approximately 24 volts) present?

Record of Actual Results:

Result:
YES:

444
 000158.04 —EHC System Volts Too Low
Go to Code Check .
NO:
Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If
Equipped and see Operator's Station Harness (W7) Wiring Diagram . (Group 9015-10.)

3 Code Check

Action:

Turn key switch OFF.

Disconnect BCJ and EHC switched power relay (K102). See IGC Machine Harness (W21) and IGC Cab
Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Swap relay (K102) with relay (K101). See Fuse and Relay Specifications . (Group 9015-10.)

Check for active codes.

Is EHC code 000158.04 still present?

Record of Actual Results:

Result:
YES:
BCJ and EHC Switched Power Relay (K102) is OK. Go to Harness Voltage Check .
NO:
Relay malfunction. Replace relay. See Fuse and Relay Specifications . (Group 9015-10.)

4 Harness Voltage Check

Action:

Turn key switch OFF.

Disconnect EHC connector (X83). See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)

Turn key switch ON.

Check for voltage at pin 1 (wire P58 RED) on connector (X83).

Is system voltage (approximately 24 volts) present?

Record of Actual Results:

Result:
YES:
Go to Reprogram Controller .
NO:
Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If
Equipped . (Group 9015-10.)
445
 000158.04 —EHC System Volts Too Low

5 Reprogram Controller
Action:

Reprogram electrohydraulic controller (EHC).

Check for active codes.

Is EHC code 000158.04 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

JW40272,00000F0-19-20120816

446
 000620.03 —Sensor Short to Power
000620.03 —
Sensor Short to Power

The 5-volt supply to BCJ and pilot enable switch has a short to power.

Sensor Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Code Check
Action:

Turn key switch OFF.

Disconnect BCJ connector (X97). See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)

Check for active codes.

Is EHC code 000620.03 still present?

Record of Actual Results:

Result:
YES:
Go to Sensor Circuit Check—Short to Power .
NO:
BCJ malfunction. Replace BCJ.

2 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect BCJ connector (X97). See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)

Turn key switch ON.

Check for voltage at pin 1 (wire H22 BRN) on connector (X97).

Are more than 5.25 volts present?

Record of Actual Results:

Result:
447
 000620.03 —Sensor Short to Power

YES:
Go to next step in this check.
NO:
Go to Reprogram Controller.
Action:

Turn key switch OFF.

Disconnect connector (X95). See IGC Machine Harness (W21) and IGC Cab Harness (W22) Component
Location—If Equipped . (Group 9015-10.)

Turn key switch ON.

Check for voltage at pin 3 (wire H22 BRN) on connector (X95).

Are more than 5.25 volts present?

Record of Actual Results:

Result:
YES:
Short circuit in IGC machine harness (W21). Repair or replace harness. See Integrated Grade Control (IGC)
Machine Harness (W21) Wiring Diagram—If Equipped . (Group 9015-10.)
NO:
Short circuit in IGC cab harness (W22). Repair or replace harness. See Integrated Grade Control (IGC) Cab
Harness (W22) Wiring Diagram—If Equipped . (Group 9015-10.)

3 Reprogram Controller

Action:

Reprogram electrohydraulic controller (EHC).

Check for active codes.

Is EHC code 000620.03 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

AA95137,000079D-19-20070307

448
 000620.04 —Sensor Short to GND
000620.04 —
Sensor Short to GND

The 5-volt supply to BCJ and hydraulic enable switch is shorted to ground.

Sensor Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Code Check
Action:

Turn key switch OFF.

Disconnect BCJ connector (X97). See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)

Check for active codes.

Is EHC code 000620.04 still present?

Record of Actual Results:

Result:
YES:
BCJ malfunction. Replace BCJ.
NO:
Go to Short Circuit Check.

2 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect BCJ connector (X97) and EHC connector (X82). See IGC Machine Harness (W21) and IGC Cab
Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check for ground at pin 1 (wire H22 BRN) on connector (X97).

Is ground present?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
449
 000620.04 —Sensor Short to GND

NO:
Go to Reprogram Controller.
Action:

Disconnect connector (X95). See IGC Machine Harness (W21) and IGC Cab Harness (W22) Component
Location—If Equipped . (Group 9015-10.)

Check for ground at pin 1 (wire H22 BRN) on connector (X97).

Is ground present?

Record of Actual Results:

Result:
YES:
Short circuit to ground on IGC cab harness (W22). Repair or replace harness. See Integrated Grade Control
(IGC) Cab Harness (W22) Wiring Diagram—If Equipped . (Group 9015-10.)
NO:
Short circuit to ground on IGC machine harness (W21). Repair or replace harness. See Integrated Grade
Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped . (Group 9015-10.)

3 Reprogram Controller
Action:

Reprogram electrohydraulic controller (EHC).

Check for active codes.

Is EHC code 00620.04 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

LW86157,000015F-19-20070501

450
 001903.00 —Aux 1 PVE Open Circuit
001903.00 —
Aux 1 PVE Open Circuit

The auxiliary 1 electrohydraulic actuator signal wire has an open circuit.

Auxiliary 1 Electrohydraulic Actuator Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Component Check
Action:

Look at LEDs on auxiliary 1 electrohydraulic actuator (if equipped).

Is LED constantly lit red?

Record of Actual Results:

Result:
YES:
Replace auxiliary 1 electrohydraulic actuator. See IGC Machine Harness (W21) and IGC Cab Harness
(W22) Component Location—If Equipped . (Group 9015-10.)
NO:
Go to Open Circuit Check.

2 Open Circuit Check

Action:

Disconnect EHC connector (X83) and auxiliary 1 actuator. See IGC Machine Harness (W21) and IGC Cab
Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check wire H30 GRN for continuity between connector pin 14 on connector (X83) and pin 1 on connector
(X90).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to Reprogram Controller.
NO:
Open circuit in harness. Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped . (Group 9015-10.)

451
 001903.00 —Aux 1 PVE Open Circuit
3 Reprogram Controller

Action:

Reprogram electrohydraulic controller (EHC).

Check for active codes.

Is EHC code 001903.00 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

AA95137,000079F-19-20090527

452
 001903.01 —Aux 1 PVE Low or Open Circuit
001903.01 —
Aux 1 PVE Low or Open Circuit

The auxiliary 1 electrohydraulic actuator signal wire has an open or short.

Auxiliary 1 Electrohydraulic Actuator Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Component Check
Action:

Look at LEDs on auxiliary 1 electrohydraulic actuator (if equipped).

Is LED constantly lit red?

Record of Actual Results:

Result:
YES:
Replace auxiliary 1 electrohydraulic actuator. See IGC Machine Harness (W21) and IGC Cab Harness
(W22) Component Location—If Equipped . (Group 9015-10.)
NO:
Go to Open Circuit Check.

2 Open Circuit Check

Action:

Turn key switch OFF.

Disconnect EHC connector (X83) and auxiliary 1 actuator. See IGC Machine Harness (W21) and IGC Cab
Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check wire H30 GRN for continuity between connector pin 14 on connector (X83) and pin 1 on connector
(X90). See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped and see
Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped . (Group 9015-10.)

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check.
NO:

453
 001903.01 —Aux 1 PVE Low or Open Circuit
Open circuit in harness. Repair or replace harness.

3 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect auxiliary 1 actuator and EHC connector (X83). See IGC Machine Harness (W21) and IGC Cab
Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check for continuity between pin 1 (wire H30 GRN) and pin 4 (wire P61 RED) on connector (X90). See
Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped . (Group 9015-10.)

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Short circuit between wires H30 and P61. Repair or replace harness.
NO:
Go to Reprogram Controller.

4 Reprogram Controller
Action:

Reprogram electrohydraulic controller (EHC).

Check for active codes.

Is EHC code 001903.01 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

AA95137,00007A0-19-20120731

454
 001903.03 —Aux 1 PVE Short to Power
001903.03 —
Aux 1 PVE Short to Power

The auxiliary 1 electrohydraulic actuator circuit is shorted to power.

Auxiliary 1 Electrohydraulic Actuator Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Component Check
Action:

Look at LEDs on auxiliary 1 electrohydraulic actuator (if equipped).

Is LED constantly lit red?

Record of Actual Results:

Result:
YES:
Replace auxiliary 1 electrohydraulic actuator. See IGC Machine Harness (W21) and IGC Cab Harness
(W22) Component Location—If Equipped . (Group 9015-10.)
NO:
Go to Short Circuit Check.

2 Short Circuit Check

Action:

Check wire H30 GRN for short to power.

Is wire H30 GRN shorted to power?

Record of Actual Results:

Result:
YES:
Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If
Equipped (Group 9015-10.)
NO:
Go to Reprogram Controller.

3 Reprogram Controller
Action:

Reprogram electrohydraulic controller (EHC).

455
 001903.03 —Aux 1 PVE Short to Power
Reprogram electrohydraulic controller (EHC).

Check for active codes.

Is EHC code 001903.03 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

AA95137,00007A1-19-20070307

456
 001903.04 —Aux 1 PVE Short to GND
001903.04 —
Aux 1 PVE Short to GND

The auxiliary 1 electrohydraulic actuator circuit is shorted to ground.

Auxiliary 1 Electrohydraulic Actuator Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Code Check
Action:

Turn key switch OFF.

Disconnect auxiliary 1 electrohydraulic actuator. See IGC Machine Harness (W21) and IGC Cab Harness
(W22) Component Location—If Equipped . (Group 9015-10.)

Check for active codes.

Is EHC code 001903.04 still present?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check.
NO:
Replace auxiliary 1 electrohydraulic actuator. See IGC Machine Harness (W21) and IGC Cab Harness
(W22) Component Location—If Equipped . (Group 9015-10.)

2 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect EHC connector (X83) and disconnect auxiliary 1 electrohydraulic actuator. See IGC Machine
Harness (W21) and IGC Cab Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check for ground at pin 1 (wire H30 GRN) on connector (X90).

Is ground present?

Record of Actual Results:

Result:
YES:
457
 001903.04 —Aux 1 PVE Short to GND
Short circuit to ground in harness. Repair or replace harness. See Integrated Grade Control (IGC) Machine
Harness (W21) Wiring Diagram—If Equipped . (Group 9015-10.)
NO:
Go to Reprogram Controller.

3 Reprogram Controller

Action:

Reprogram electrohydraulic controller (EHC).

Check for active codes.

Is EHC code 001903.04 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

AA95137,00007A2-19-20120731

458
 001903.31 —Aux 1 PVE Spool Pos Error
001903.31 —
Aux 1 PVE Spool Pos Error

The auxiliary 1 electrohydraulic actuator indicates a spool position fault.

Auxiliary 1 Electrohydraulic Actuator Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Component Check
Action:

Look at LEDs on auxiliary 1 electrohydraulic actuator (if equipped).

Is LED constantly lit red?

Record of Actual Results:

Result:
YES:
Replace auxiliary 1 electrohydraulic actuator. See IGC Machine Harness (W21) and IGC Cab Harness
(W22) Component Location—If Equipped . (Group 9015-10.)
NO:
Go to Short Circuit Check.

2 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect auxiliary 1 electrohydraulic actuator (X90) and EHC connector (X83). See Integrated Grade
Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped and See IGC Machine Harness (W21)
and IGC Cab Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check continuity between pin 1 (wire H30 GRN) and pin 4 (wire P61 RED) on connector (X90).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Short circuit in harness. Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped (Group 9015-10.)
NO:

459
 001903.31 —Aux 1 PVE Spool Pos Error
Go to Reprogram Controller.

3 Reprogram Controller

Action:

Reprogram electrohydraulic controller (EHC).

Check for active codes.

Is EHC code 001903.31 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

AA95137,00007A3-19-20070405

460
 001915.00 —Aux 2 PVE Open Circuit
001915.00 —
Aux 2 PVE Open Circuit

Not Applicable

Go to Section_9001:Group_40

AA95137,00007A4-19-20070208

461
 001915.01 —Aux 2 PVE Low or Open Circuit
001915.01 —
Aux 2 PVE Low or Open Circuit

Not Applicable

Go to Section_9001:Group_40

AA95137,00007A5-19-20070208

462
 001915.03 —Aux 2 PVE Short to Power
001915.03 —
Aux 2 PVE Short to Power

Not Applicable

Go to Section_9001:Group_40

AA95137,00007A6-19-20070208

463
 001915.04 —Aux 2 PVE Short to GND
001915.04 —
Aux 2 PVE Short to GND

Not Applicable

Go to Section_9001:Group_40

AA95137,00007A7-19-20070208

464
 001915.31 —Aux 2 PVE Spool Pos Error
001915.31 —
Aux 2 PVE Spool Pos Error

Not Applicable

Go to Section_9001:Group_40

AA95137,00007A8-19-20070208

465
 002697.09 —CAN Joystick Pos Missing From BCJ
002697.09 —
CAN Joystick Pos Missing From BCJ

The CAN joystick position signal is missing from blade control joystick.

CAN Circuit Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 CAN Circuit Check

Action:

Perform CAN Circuit Test . (Group 9015-20.)

Is CAN circuit OK?

Record of Actual Results:

Result:
YES:
Go to Component Check .
NO:
Repair CAN circuit wires. See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If
Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped .
(Group 9015-10.)

2 Component Check

Action:

Observe the joystick's 4-way axis movement as a percentage by accessing the Diagnostic / Live Values /
Performance menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service
Mode . (Group 9015-20.)

Slowly move the joystick handle through complete range in all four axes.

Do the joystick values in the CMU menu correspond with the joystick movements?

Record of Actual Results:

Result:
YES:
Go to Reprogram Controller .
NO:
Replace BCJ. See IGC Machine Harness (W21) and IGC Cab Harness (W22) Component Location—If
Equipped . (Group 9015-10.)

466
 002697.09 —CAN Joystick Pos Missing From BCJ

3 Reprogram Controller

Action:

Reprogram electrohydraulic controller (EHC).

Check for active codes.

Is EHC code 002697.09 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

JW40272,00000F4-19-20120816

467
 002712.00 —Hyd Enable Sw Inputs Both On
002712.00 —
Hyd Enable Sw Inputs Both On

The EHC detects both inputs from hydraulic enable switch at the same time.

Hydraulic Enable Switch Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Component Check
Action:

Turn key switch OFF.

Disconnect hydraulic enable switch (S8). See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)

With switch in ENABLED position, check for continuity between pins 1 and 2.

With switch in DISABLED position, check for continuity between pins 2 and 3.

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Internal short in switch. Replace hydraulic enable switch. See IGC Machine Harness (W21) and IGC Cab
Harness (W22) Component Location—If Equipped . (Group 9015-10.)
NO:
Go to Short Circuit Check.

2 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect hydraulic enable switch (S8) and disconnect EHC connector (X82). See IGC Machine Harness
(W21) and IGC Cab Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check for continuity between pin 1 (wire H36 GRN) and pin 3 (wire H23 GRN) on switch connector.

Is continuity indicated?

Record of Actual Results:

468
 002712.00 —Hyd Enable Sw Inputs Both On

Result:
YES:
Go to next step in this check.
NO:
Go to Short Circuit Check—Short to Power.
Action:

Disconnect connector (X95). See IGC Machine Harness (W21) and IGC Cab Harness (W22) Component
Location—If Equipped . (Group 9015-10.)

Check for continuity between pin 1 (wire H36 GRN) and pin 3 (wire H23 GRN) on switch connector.

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Short in IGC cab harness. Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness
(W22) Wiring Diagram—If Equipped . (Group 9015-10.)
NO:
Short in IGC machine harness. Repair or replace harness. See Integrated Grade Control (IGC) Machine
Harness (W21) Wiring Diagram—If Equipped . (Group 9015-10.)

3 Short Circuit Check—Short to Power

Action:

Turn key switch OFF.

Disconnect hydraulic enable switch (S8). See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)

Turn key switch ON.

Check for voltage at pin 1 (wire H36 GRN) on switch connector.

Check for voltage at pin 3 (wire H23 GRN) on switch connector.

Is voltage present?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Go to Reprogram Controller.
Action:

Turn key switch OFF. 469

 002712.00 —Hyd Enable Sw Inputs Both On
Turn key switch OFF.

Disconnect connector (X95). See IGC Machine Harness (W21) and IGC Cab Harness (W22) Component
Location—If Equipped . (Group 9015-10.)

Turn key switch ON.

Check for voltage at pin 15 (wire H23 GRN) on connector (X95).

Check for voltage at pin 18 (wire H36 GRN) on connector (X95).

Is voltage present?

Record of Actual Results:

Result:
YES:
Short to power in IGC machine harness (W21). Repair or replace. See Integrated Grade Control (IGC)
Machine Harness (W21) Wiring Diagram—If Equipped . (Group 9015-10.)
NO:
Short to power in IGC cab harness (W22). Repair or replace. See Integrated Grade Control (IGC) Cab
Harness (W22) Wiring Diagram—If Equipped . (Group 9015-10.)

4 Reprogram Controller

Action:

Reprogram electrohydraulic controller (EHC).

Check for active codes.

Is EHC code 002712.00 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

AA95137,00007AA-19-20070307

470
 002712.01 —Hyd Enable Sw Inputs Both Off
002712.01 —
Hyd Enable Sw Inputs Both Off

The EHC detects no input from the hydraulic enable switch.

Hydraulic Enable Switch Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Component Check
Action:

Disconnect hydraulic enable switch (S8). See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)

With switch in ENABLED position, check for continuity between pins 2 and 3.

With switch in DISABLED position, check for continuity between pins 1 and 2.

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to Open Circuit Check.
NO:
Switch malfunction. Replace hydraulic enable switch (S8). See IGC Machine Harness (W21) and IGC Cab
Harness (W22) Component Location—If Equipped . (Group 9015-10.)

2 Open Circuit Check

Action:

Turn key switch OFF.

Disconnect hydraulic enable switch (S8) and disconnect EHC connector (X82). See IGC Machine Harness
(W21) and IGC Cab Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check wire H22 GRN for continuity between pin 2 on switch connector and pin 3 on EHC connector (X82).

Check wire H23 GRN for continuity between pin 3 on switch connector and pin 18 on EHC connector (X82).

Check wire H36 GRN for continuity between pin 1 on switch connector and pin 17 on EHC connector (X82).

Is continuity indicated?

Record of Actual Results:

471
 002712.01 —Hyd Enable Sw Inputs Both Off

Result:
YES:
Go to Reprogram Controller.
NO:
Go to next step in this check.
Action:

Disconnect connector (X95). See IGC Machine Harness (W21) and IGC Cab Harness (W22) Component
Location—If Equipped . (Group 9015-10.)

Check wire H22 GRN for continuity between pin 2 on switch connector and pin 13 on EHC connector (X95).

Check wire H23 GRN for continuity between pin 3 on switch connector and pin 15 on EHC connector (X95).

Check wire H36 GRN for continuity between pin 1 on switch connector and pin 18 on EHC connector (X95).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Open circuit in IGC machine harness. Repair or replace harness. See Integrated Grade Control (IGC)
Machine Harness (W21) Wiring Diagram—If Equipped . (Group 9015-10.)
NO:
Open circuit in IGC cab harness. Repair or replace harness. See Integrated Grade Control (IGC) Cab
Harness (W22) Wiring Diagram—If Equipped . (Group 9015-10.)

3 Reprogram Controller

Action:

Reprogram electrohydraulic controller (EHC).

Check for active codes.

Is EHC code 002712.01 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

472
002712.01 —Hyd Enable Sw Inputs Both Off

Go to Section_9001:Group_40

AA95137,00007AB-19-20070307

473
 003157.03 —Incr / Decr Buttons Short to Power
003157.03 —
Incr / Decr Buttons Short to Power

The blade height increment / decrement buttons circuit is shorted to power.

Blade Height Increment / Decrement Buttons Diagnostic Procedure

Alarm Level:

No Warning Light

Launch Close Expand List Collapse List

1 Code Check
Action:

Turn key switch OFF.

Disconnect BCJ connector (X97). See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)

Check for active codes.

Is EHC code 003157.03 still present?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check.
NO:
BCJ malfunction. Replace BCJ.

2 Short Circuit Check

Action:

Turn key switch OFF.

Disconnect BCJ connector (X97). See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)

Turn key switch ON.

Check for voltage at pin 3 (wire H20 BLU) on BCJ connector (X97).

Is voltage present?

Record of Actual Results:

Result:
474
 003157.03 —Incr / Decr Buttons Short to Power

YES:
Go to next step in this check.
NO:
Go to Reprogram Controller.
Action:

Disconnect connector (X95). See IGC Machine Harness (W21) and IGC Cab Harness (W22) Component
Location—If Equipped . (Group 9015-10.)

Check for voltage at pin 1 (wire H20 BLU) on connector (X95).

Is voltage present?

Record of Actual Results:

Result:
YES:
Short in IGC machine harness (W21). Repair or replace harness. See Integrated Grade Control (IGC)
Machine Harness (W21) Wiring Diagram—If Equipped . (Group 9015-10.)
NO:
Short in IGC cab harness (W22). Repair or replace harness. See Integrated Grade Control (IGC) Cab
Harness (W22) Wiring Diagram—If Equipped . (Group 9015-10.)

3 Reprogram Controller
Action:

Reprogram electrohydraulic controller (EHC).

Check for active codes.

Is EHC code 003157.03 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

AA95137,00007AC-19-20070307

475
 003157.04 —Incr / Decr Buttons Open or Short
003157.04 —
Incr / Decr Buttons Open or Short

The blade height increment/decrement buttons circuit is open or short to ground.

Blade Height Increment / Decrement Buttons Diagnostic Procedure

Alarm Level:

No Warning Light

Launch Close Expand List Collapse List

1 Code Check
Action:

Disconnect BCJ connector (X97). See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)

Check for active codes.

Is EHC code 003157.04 still present?

Record of Actual Results:

Result:
YES:
Go to Open Circuit Check.
NO:
BCJ malfunction. Replace BCJ.

2 Open Circuit Check

Action:

Disconnect EHC connector (X82) and BCJ connector (X97). See IGC Machine Harness (W21) and IGC Cab
Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check the following circuits for continuity:

H20 BLU (X82 pin 21 and X97 pin 3)

H22 BRN (X82 pin 3 and X97 pin 1)
R41 PNK (X82 pin 22 and X97 pin 6)

Does each circuit have continuity?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check.
476
 003157.04 —Incr / Decr Buttons Open or Short

NO:
Go to next step in this check.
Action:

Disconnect bulkhead connector (X95) and BCJ connector (X97). See IGC Machine Harness (W21) and IGC
Cab Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check the following circuits for continuity:

H20 BLU (X95 pin 1 and X97 pin 3)

H22 BRN (X95 pin 3 and X97 pin 1)
R41 PNK (X95 pin 2 and X97 pin 6)

Does each circuit have continuity?

Record of Actual Results:

Result:
YES:
Open circuit in IGC machine harness. Repair or replace harness. See Integrated Grade Control (IGC)
Machine Harness (W21) Wiring Diagram—If Equipped . (Group 9015-10.)
NO:
Open circuit in IGC cab harness. Repair or replace harness. See Integrated Grade Control (IGC) Cab
Harness (W22) Wiring Diagram—If Equipped . (Group 9015-10.)

3 Short Circuit Check

Action:

Disconnect EHC connector (X82) and BCJ connector (X97). See IGC Machine Harness (W21) and IGC Cab
Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check the following circuits for continuity to machine ground:

H20 BLU ( X97 pin 3)

H22 BRN (X97 pin 1)

Do either of the circuits have continuity with machine ground?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Go to Reprogram Controller.
Action:

Disconnect EHC connector (X82) and bulkhead connector (X95). See IGC Machine Harness (W21) and IGC
Cab Harness (W22) Component Location—If Equipped . (Group 9015-10.)

477
 003157.04 —Incr / Decr Buttons Open or Short
Check the following circuits for continuity to machine ground.

H20 BLU (X95 pin 1)

H22 BRN (X95 pin 3)

Do either of the circuits have continuity with machine ground?

Record of Actual Results:

Result:
YES:
Short to ground in IGC machine harness. Repair or replace harness. See Integrated Grade Control (IGC)
Machine Harness (W21) Wiring Diagram—If Equipped . (Group 9015-10.)
NO:
Short to ground in IGC cab harness. Repair or replace harness. See Integrated Grade Control (IGC) Cab
Harness (W22) Wiring Diagram—If Equipped . (Group 9015-10.)

4 Reprogram Controller
Action:

Reprogram electrohydraulic controller (EHC).

Check for active codes.

Is EHC code 003157.04 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

AA95137,00008AE-19-20070313

478
 003751.31 —Incr / Decr Buttons Invalid Output
003751.31 —
Incr / Decr Buttons Invalid Output

There is an abnormal value from the blade increment/decrement buttons.

Blade Height Increment / Decrement Buttons Diagnostic Procedure

Alarm Level:

No Warning Light

Launch Close Expand List Collapse List

1 Code Check
Action:

Disconnect BCJ connector (X97). See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)

Check for active codes.

Is EHC code 003157.03 present?

Record of Actual Results:

Result:
YES:
Go to Harness Check.
NO:
BCJ malfunction. Replace BCJ.

2 Harness Check
Action:

Check circuit H20 for bad connections or wiring.

Are connectors and wiring OK?

Record of Actual Results:

Result:
YES:
BCJ internal malfunction. Replace BCJ.
NO:
Repair or replace faulty connectors or wiring. See Integrated Grade Control (IGC) Machine Harness (W21)
Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—
If Equipped . (Group 9015-10.)

479
003751.31 —Incr / Decr Buttons Invalid Output

Go to Section_9001:Group_40

AA95137,00007AE-19-20070307

480
 522442.31 —Blade Buttons Invalid Output
522442.31 —
Blade Buttons Invalid Output

There is an abnormal value from the blade angle buttons.

Blade Angle Buttons Circuit Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Code Check
Action:

Disconnect connector X97 on the BCJ.

Check for active codes.

Is EHC code 522442.31 present?

Record of Actual Results:

Result:
YES:
Go to Harness Check.
NO:
BCJ malfunction. Replace BCJ.

2 Harness Check

Action:

Check circuit H25 WHT for bad connections or wiring.

Are connectors and wiring ok?

Record of Actual Results:

Result:
YES:
Go to Reprogram Controller.
NO:
Repair or replace faulty connectors or wiring. See Integrated Grade Control (IGC) Machine Harness (W21)
Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—
If Equipped . (Group 9015-10.)

3 Reprogram Controller

481
 522442.31 —Blade Buttons Invalid Output

Action:

Reprogram electrohydraulic controller (EHC).

Check for active codes.

Is EHC code 522442.31 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

AA95137,00008AF-19-20070313

482
 523779.00 —Blade Rotate Current Above Max
523779.00 —
Blade Rotate Current Above Max

The blade angle electrohydraulic actuator current is more than the maximum requirement.

Blade Angle Electrohydraulic Actuator Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Code Check
Action:

Connect blade angle electrohydraulic actuator (Y30) connector to new blade angle elecrohydraulic actuator.

Check for active codes.

Is EHC code 523779.00 still present?

Record of Actual Results:

Result:
YES:
Reconnect original actuator and go to Short Circuit Check.
NO:
Blade angle elecrohydraulic actuator malfunction. Replace actuator.

2 Short Circuit Check

Action:

Disconnect connector X83 from EHC and disconnect actuator connector.

Check continuity between circuit H31 RED (X83 pin 12) and ground.

Check continuity between circuit H34 BLK (X83 pin 5) and ground.

Is there continuity between circuit H31 RED or H34 RED and ground?

Record of Actual Results:

Result:
YES:
Short to ground in harness. Repair or replace harness. See Integrated Grade Control (IGC) Machine
Harness (W21) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22)
Wiring Diagram—If Equipped . (Group 9015-10.)
NO:

483
 523779.00 —Blade Rotate Current Above Max
Go to Reprogram Controller.

3 Reprogram Controller

Action:

Reprogram electrohydraulic controller (EHC).

Check for active codes.

Is EHC code 523779.00 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

AA95137,00008B0-19-20091217

484
 523779.01 —Blade Rotate Current Below Min
523779.01 —
Blade Rotate Current Below Min

The blade rotate current is below the minimum requirement.

Blade Angle Electrohydraulic Actuator Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Code Check
Action:

Connect blade angle electrohydraulic actuator (Y30) connector to new blade angle elecrohydraulic actuator.

Check for active codes.

Is EHC code 523779.01 still present?

Record of Actual Results:

Result:
YES:
Reconnect original actuator and go to Open Circuit Check.
NO:
Blade angle elecrohydraulic actuator malfunction. Replace actuator.

2 Open Circuit Check

Action:

Disconnect connector X83 from EHC and disconnect actuator connector.

Check circuit H31 RED (X83 pin 12 and actuator connector pin 1) for continuity.

Check circuit H34 BLK (X83 pin 5 and actuator connector pin 4) for continuity.

Do both circuits have continuity?

Record of Actual Results:

Result:
YES:
Go to Reprogram Controller.
NO:
Open circuit in harness. Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Wiring

485
 523779.01 —Blade Rotate Current Below Min
Diagram—If Equipped . (Group 9015-10.)

3 Reprogram Controller
Action:

Reprogram electrohydraulic controller (EHC).

Check for active codes.

Is EHC code 523779.01 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

AA95137,00008B1-19-20070313

486
 523780.00 —Tilt PVE Open Circuit
523780.00 —
Tilt PVE Open Circuit

There is an open circuit present on the blade tilt actuator circuit.

Blade Tilt Actuator Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Component Check
Action:

Look at LEDs on blade tilt actuator (Y31). See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)

Is LED constantly lit red?

Record of Actual Results:

Result:
YES:
Blade tilt actuator (Y31) malfunction. Replace actuator.
NO:
Go to Voltage Check.

2 Voltage Check

Action:

Disconnect actuator (Y31) connector.

Measure voltage of circuit P62 RED (pins 4 and 3).

Is voltage approximately 24 volts?

Record of Actual Results:

Result:
YES:
Go to Open Circuit Check.
NO:
Open circuit in harness. Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped . (Group 9015-10.)

3 Open Circuit Check

487
 523780.00 —Tilt PVE Open Circuit

Action:

Disconnect EHC connector (X83) and actuator connector.

Check circuit H32 GRN (X83 pin 20 and actuator connector pin 1) for continuity.

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to Reprogram Controller.
NO:
Open circuit in harness. Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped . (Group 9015-10.)

4 Reprogram Controller
Action:

Reprogram electrohydraulic controller (EHC).

Check for active codes.

Is EHC code 523780.00 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

AA95137,00007B2-19-20070307

488
 523780.01 —Tilt PVE Low or Open Circuit
523780.01 —
Tilt PVE Low or Open Circuit

There is an open or short present on the blade tilt electrohydraulic actuator circuit.

Blade Tilt Actuator Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Component Check
Action:

Look at LEDs on blade tilt actuator (Y31). See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)

Is LED constantly lit red?

Record of Actual Results:

Result:
YES:
Blade tilt actuator (Y31) malfunction. Replace actuator.
NO:
Go to Short Circuit Check.

2 Short Circuit Check

Action:

Remove EHC connector (X83) and actuator connector. See IGC Machine Harness (W21) and IGC Cab
Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check for continuity between circuits P62 RED (actuator connector pin 4) and H35 GRN (actuator connector
pin 1).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Short circuit in harness. Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped . (Group 9015-10.)
NO:
Go to Open Circuit Check.

489
 523780.01 —Tilt PVE Low or Open Circuit
3 Open Circuit Check

Action:

Remove EHC connector (X83) and actuator connector. See IGC Machine Harness (W21) and IGC Cab
Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check circuit H32 GRN (X83 pin 20 and actuator connector pin 1) for continuity.

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to Reprogram Controller.
NO:
Open circuit in harness. Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Wiring
Diagram—If Equipped . (Group 9015-10.)

4 Reprogram Controller

Action:

Reprogram electrohydraulic controller (EHC).

Check for active codes.

Is EHC code 523780.01 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

AA95137,00007B3-19-20070307

490
 523780.03 —Tilt PVE Short to Power
523780.03 —
Tilt PVE Short to Power

There is a short to power present on the blade tilt electrohydraulic actuator circuit.

Blade Tilt Actuator Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Component Check
Action:

Look at LEDs on blade tilt actuator (Y31). See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)

Is LED constantly lit red?

Record of Actual Results:

Result:
YES:
Blade tilt actuator (Y31) malfunction. Replace actuator.
NO:
Go to Short Circuit Check.

2 Short Circuit Check

Action:

Check wire H32 GRN for short to power.

Is wire H32 GRN shorted to power?

Record of Actual Results:

Result:
YES:
Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If
Equipped . (Group 9015-10.)
NO:
Go to Reprogram Controller.

3 Reprogram Controller
Action:

Reprogram EHC.
491
 523780.03 —Tilt PVE Short to Power
Reprogram EHC.

Check for active codes.

Is EHC code 523780.03 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

AA95137,00007B4-19-20070405

492
 523780.04 —Tilt PVE Short to GND
523780.04 —
Tilt PVE Short to GND

There is a short to ground present on the blade tilt electrohydraulic actuator circuit.

Blade Tilt Actuator Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Component Check
Action:

Look at LEDs on blade tilt actuator (Y31). See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)

Is LED constantly lit red?

Record of Actual Results:

Result:
YES:
Blade tilt actuator (Y31) malfunction. Replace actuator.
NO:
Go to Code Check .

2 Code Check

Action:

Check and record DTCs. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Are either of the following codes present?

523780.00
523780.01

Record of Actual Results:

Result:
YES:
Resolve other codes first. See Diagnostic Trouble Code (DTC) Quick Reference List—Electrohydraulic
Controller (EHC) . (Group 9001-40.)
NO:
Go to Short Circuit Check .

3 Short Circuit Check

493
 523780.04 —Tilt PVE Short to GND

Action:

Remove connector (X83) from EHC and actuator connector.

Check the following circuits for continuity with machine ground.

H32 GRN (X83 pin 20)

P62 RED (X83 pin 19)

Is there continuity with ground in either of the circuits?

Record of Actual Results:

Result:
YES:
Short to ground in harness. Repair or replace harness. See Integrated Grade Control (IGC) Machine
Harness (W21) Wiring Diagram—If Equipped . (Group 9015-10.)
NO:
Go to Reprogram Controller .

4 Reprogram Controller

Action:

Reprogram electrohydraulic controller.

Check for active codes.

Is EHC code 523780.04 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

JW40272,00000F5-19-20120816

494
 523780.31 —Tilt PVE Spool Pos Error
523780.31 —
Tilt PVE Spool Pos Error

There is a spool position fault present on the blade tilt electrohydraulic actuator.

Blade Tilt Actuator Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Component Check
Action:

Look at LEDs on blade tilt actuator (Y31). See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)

Is LED constantly lit red?

Record of Actual Results:

Result:
YES:
Blade tilt actuator (Y31) malfunction. Replace actuator.
NO:
Go to Short Circuit Check.

2 Short Circuit Check

Action:

Remove EHC connector (X83) and actuator connector. See IGC Machine Harness (W21) and IGC Cab
Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check continuity between circuit H32 GRN (actuator connector pin 1) and circuit P62 RED (actuator
connector pin 4).

Is there continuity indicated?

Record of Actual Results:

Result:
YES:
Short circuit in harness. Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped . (Group 9015-10.)
NO:
Go to Reprogram Contoller.

495
 523780.31 —Tilt PVE Spool Pos Error
3 Reprogram Controller

Action:

Reprogram electrohydraulic controller (EHC).

Check for active codes.

Is EHC code 523780.31 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

AA95137,00007C7-19-20070307

496
 523781.00 —Height PVE Open Circuit
523781.00 —
Height PVE Open Circuit

There is an open circuit present on the blade lift hydraulic actuator circuit.

Blade Lift Hydraulic Actuator Diagnostics

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Component Check
Action:

Look at LEDs on blade lift actuator (Y32). See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)

Is LED constantly lit red?

Record of Actual Results:

Result:
YES:
Blade lift actuator (Y32) malfunction. Replace actuator.
NO:
Go to Open Circuit Check.

2 Open Circuit Check

Action:

Disconnect EHC connector (X83) and actuator connector. See Integrated Grade Control (IGC) Machine
Harness (W21) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22)
Wiring Diagram—If Equipped . (Group 9015-10.)

Check circuit H35 GRN (X83 pin 24 and actuator connector pin 1) for continuity.

Is there continuity?

Record of Actual Results:

Result:
YES:
Go to Reprogram Controller.
NO:
Open circuit in harness. Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped . (Group 9015-10.)

497
 523781.00 —Height PVE Open Circuit
3 Reprogram Controller

Action:

Reprogram electrohydraulic controller (EHC).

Check for active codes.

Is EHC code 523781.00 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

AA95137,00007C8-19-20070405

498
 523781.01 —Height PVE Low or Open Circuit
523781.01 —
Height PVE Low or Open Circuit

There is low voltage or an open circuit present on the blade lift hydraulic actuator circuit.

Blade Lift Hydraulic Actuator Diagnostics

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Component Check
Action:

Look at LEDs on blade lift actuator (Y32). See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)

Is LED constantly lit red?

Record of Actual Results:

Result:
YES:
Blade lift actuator (Y32) malfunction. Replace actuator.
NO:
Go to Short Circuit Check.

2 Short Circuit Check

Action:

Disconnect EHC connector (X83), blade lift actuator (Y32) connector. See IGC Machine Harness (W21) and
IGC Cab Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check circuits P62 RED (actuator connector pin 4) and H35 RED (actuator connector pin 1) for continuity.

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Short circuit in harness. Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped . (Group 9015-10.)
NO:
Go to Open Circuit Check.

499
 523781.01 —Height PVE Low or Open Circuit

3 Open Circuit Check

Action:

Disconnect EHC connector (X83) and actuator connector.

Check circuit H35 GRN (X83 pin 24 and actuator connector pin 1) for continuity.

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to Reprogram Controller.
NO:
Open circuit in harness. Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped . (Group 9015-10.)

4 Reprogram Controller
Action:

Reprogram electrohydraulic controller.

Check for active codes.

Is EHC code 523781.01 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

AA95137,00007C9-19-20070307

500
 523781.03 —Height PVE Short to Power
523781.03 —
Height PVE Short to Power

There is a short to power present on the blade lift hydraulic actuator circuit.

Blade Lift Hydraulic Actuator Diagnostics

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Component Check
Action:

Look at LEDs on blade lift actuator (Y32). See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)

Is LED constantly lit red?

Record of Actual Results:

Result:
YES:
Blade lift actuator (Y32) malfunction. Replace actuator.
NO:
Go to Short Circuit Check.

2 Short Circuit Check

Action:

Check wire H35 GRN for short to power.

Is wire H35 GRN shorted to power.

Record of Actual Results:

Result:
YES:
Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If
Equipped . (Group 9015-10.)
NO:
Go to Reprogram Controller.

3 Reprogram Controller
Action:

Reprogram electrohydraulic controller (EHC).

501
 523781.03 —Height PVE Short to Power
Reprogram electrohydraulic controller (EHC).

Check for active codes.

Is EHC code 523781.03 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

AA95137,00007CA-19-20120731

502
 523781.04 —Height PVE Short to GND
523781.04 —
Height PVE Short to GND

There is a short to ground present on the blade lift hydraulic actuator circuit.

Blade Lift Hydraulic Actuator Diagnostics

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Component Check
Action:

Look at LEDs on blade lift actuator (Y32). See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)

Is LED constantly lit red?

Record of Actual Results:

Result:
YES:
Blade lift actuator (Y32) malfunction. Replace actuator.
NO:
Go to Code Check .

2 Code Check

Action:

Check and record DTCs. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Are either of the following codes present?

523781.00
523781.01

Record of Actual Results:

Result:
YES:
Resolve other codes first. See Diagnostic Trouble Code (DTC) Quick Reference List—Electrohydraulic
Controller (EHC) . (Group 9001-40.)
NO:
Go to Blade Lift Actuator Harness Check—Short to Ground

3 Short Circuit Check

503
 523781.04 —Height PVE Short to GND

Action:

Disconnect EHC connector (X83) and actuator connector.

Check continuity between circuit H35 GRN (actuator connector pin 1) and machine ground.

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Short to ground in harness. Repair or replace harness. See Integrated Grade Control (IGC) Machine
Harness (W21) Wiring Diagram—If Equipped . (Group 9015-10.)
NO:
Go to Reprogram Controller .

4 Reprogram Controller

Action:

Reprogram electrohydraulic controller (EHC).

Check for active codes.

Is EHC code 523781.04 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

JW40272,00000F6-19-20120816

504
 523781.31 —Height PVE Spool Pos Error
523781.31 —
Height PVE Spool Pos Error

There is a spool position fault on the blade lift electrohydraulic actuator circuit.

Blade Lift Hydraulic Actuator Diagnostics

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Component Check
Action:

Look at LEDs on blade lift actuator (Y32). See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)

Is LED constantly lit red?

Record of Actual Results:

Result:
YES:
Blade lift actuator (Y32) malfunction. Replace actuator.
NO:
Go to Short Circuit Check.

2 Short Circuit Check

Action:

Remove EHC connector (X83) and actuator connector. See IGC Machine Harness (W21) and IGC Cab
Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check circuits P62 RED (actuator connector pin 4) and H35 GREEN (actuator connector pin 1) for continuity.
See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped . (Group 9015-
10.)

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Short circuit in harness. Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped . (Group 9015-10.)
NO:
Go to Reprogram Controller.

505
 523781.31 —Height PVE Spool Pos Error

3 Reprogram Controller

Action:

Reprogram electrohydraulic controller (EHC).

Check for active codes.

Is EHC code 523781.31 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

AA95137,00007CC-19-20090330

506
 524059.00 —Aux 2 Jstk Sensor 2 Volts High
524059.00 —
Aux 2 Jstk Sensor 2 Volts High

Not Applicable

Go to Section_9001:Group_40

NM00125,000086C-19-20110524

507
 524059.01 —Aux 2 Jstk Sensor 2 Volts Low
524059.01 —
Aux 2 Jstk Sensor 2 Volts Low

Not Applicable

Go to Section_9001:Group_40

NM00125,000086D-19-20110524

508
 524059.03 —Aux 2 Jstk Sensor 2 Short to Power
524059.03 —
Aux 2 Jstk Sensor 2 Short to Power

Not Applicable

Go to Section_9001:Group_40

AA95137,00007CD-19-20070209

509
 524059.04 —Aux 2 Jstk Sensor 2 Short to GND
524059.04 —
Aux 2 Jstk Sensor 2 Short to GND

Not Applicable

Go to Section_9001:Group_40

AA95137,00007CE-19-20070209

510
 524059.31 —Aux 2 Jstk Sensor 2 Invalid Output
524059.31 —
Aux 2 Jstk Sensor 2 Invalid Output

Not Applicable

Go to Section_9001:Group_40

AA95137,00007CF-19-20070209

511
 524062.00 —Aux 1 Jstk Sensor 2 Volts High
524062.00 —
Aux 1 Jstk Sensor 2 Volts High

Auxiliary 1 joystick sensor 2 (circuit H37 GRN) voltage is above normal operating range.

Sensor 2 of Auxiliary Joystick 1 Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Code Check
Action:

Disconnect connector X85 from auxiliary joystick. See IGC Machine Harness (W21) and IGC Cab Harness
(W22) Component Location—If Equipped . (Group 9015-10.)

Check for electrohydraulic controller control unit (EHC) code 524062.04.

Is EHC code 524062.04 active?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check.
NO:
Auxiliary 1 joystick malfunction. Replace auxiliary 1 joystick.

2 Short Circuit Check

Action:

Ignition OFF.

Disconnect auxiliary joystick connector (X85) and electrohydraulic controller (EHC) connector (X82). See
IGC Machine Harness (W21) and IGC Cab Harness (W22) Component Location—If Equipped . (Group
9015-10.)

Ignition ON.

Check circuit H37 GRN for voltage at pin 4 of auxiliary joystick connector (X85).

Is voltage present?

Record of Actual Results:

Result:
YES:
512
 524062.00 —Aux 1 Jstk Sensor 2 Volts High
Circuit H37 GRN is short to power. Repair or replace harness.

See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped . (Group 9015-
10.)

See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped . (Group 9015-10.)

NO:
Go to Harness Check.

3 Harness Check
Action:

Turn battery disconnect switch to the OFF position.

Disconnect electrohydraulic control unit (EHC) connectors (X82 and X83), auxiliary joystick connector (X85),
and eloctrohydraulic control unit interface connector (X96). See IGC Machine Harness (W21) and IGC Cab
Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check for continuity between pin 4 (circuit H37 GRN) of auxiliary joystick connector (X85) and remaining pins
of EHC connectors (X82, X83, and X96).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Circuit H37 GRN is short to circuit that indicated continuity. Repair or replace harness.

See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped . (Group 9015-
10.)

See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped . (Group 9015-10.)

NO:
Auxiliary 1 joystick malfunction. Replace auxiliary 1 joystick.

Go to Section_9001:Group_40

NM00125,000086E-19-20120731

513
 524062.01 —Aux 1 Jstk Sensor 2 Volts Low
524062.01 —
Aux 1 Jstk Sensor 2 Volts Low

Auxiliary 1 joystick sensor 2 (circuit H37 GRN) voltage is below normal operating range.

Sensor 2 of Auxiliary Joystick 1 Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Code Check
Action:

Disconnect connector X85 from auxiliary joystick. See IGC Machine Harness (W21) and IGC Cab Harness
(W22) Component Location—If Equipped . (Group 9015-10.)

Check for electrohydraulic controller control unit (EHC) code 524062.04.

Is EHC code 524062.04 active?

Record of Actual Results:

Result:
YES:
Auxiliary 1 joystick malfunction. Replace auxiliary 1 joystick.
NO:
Go to Open Circuit Check.

2 Open Circuit Check

Action:

Ignition OFF.

Disconnect auxiliary joystick connector (X85) and electrohydraulic controller (EHC) connector (X82). See
IGC Machine Harness (W21) and IGC Cab Harness (W22) Component Location—If Equipped . (Group
9015-10.)

Check circuit H37 GRN for continuity between pin 4 of auxiliary joystick conncector (X85) and pin 16 EHC
connector (X82).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check.
514
 524062.01 —Aux 1 Jstk Sensor 2 Volts Low

NO:
Circuit H37 GRN is open. Repair or replace harness.

See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped . (Group 9015-
10.)

See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped . (Group 9015-10.)

3 Short Circuit Check

Action:

Ignition OFF.

Disconnect auxiliary joystick connector (X85) and electrohydraulic controller (EHC) connector (X82). See
IGC Machine Harness (W21) and IGC Cab Harness (W22) Component Location—If Equipped . (Group
9015-10.)

Check circuit H37 GRN for ground at pin 4 of auxiliary joystick connector (X85).

Is ground indicated?

Record of Actual Results:

Result:
YES:
Circuit H37 GRN is short to ground. Repair or replace harness.

See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped . (Group 9015-
10.)

See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped . (Group 9015-10.)

NO:
Go to Harness Check.

4 Harness Check
Action:

Turn battery disconnect switch to the OFF position.

Disconnect electrohydraulic control unit (EHC) connectors (X82 and X83), auxiliary joystick connector (X85),
and eloctrohydraulic control unit interface connector (X96). See IGC Machine Harness (W21) and IGC Cab
Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check for continuity between pin 4 (circuit H37 GRN) of auxiliary joystick connector (X85) and remaining pins
of EHC connectors (X82, X83, and X96).

Is continuity indicated?

Record of Actual Results:

515
 524062.01 —Aux 1 Jstk Sensor 2 Volts Low

Result:
YES:
Circuit H37 GRN is short to circuit that indicated continuity. Repair or replace harness.

See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped . (Group 9015-
10.)

See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped . (Group 9015-10.)

NO:
Auxiliary 1 joystick malfunction. Replace auxiliary 1 joystick.

Go to Section_9001:Group_40

NM00125,0000874-19-20110622

516
 524062.03 —Aux 1 Jstk Sensor 2 Short to Power
524062.03 —
Aux 1 Jstk Sensor 2 Short to Power

There is a short to power present on the sensor 2 circuit of auxiliary joystick 1.

Sensor 2 of Auxiliary Joystick 1 Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Code Check
Action:

Disconnect connector X85 from auxiliary joystick (if equipped). See IGC Machine Harness (W21) and IGC
Cab Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check for active codes.

Is EHC code 524062.03 present?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check.
NO:
Auxiliary 1 joystick malfunction. Replace auxiliary 1 joystick.

2 Short Circuit Check

Action:

Disconnect auxiliary joystick (if equipped) connector (X85).

Check voltage of circuit H37 GRN (X85 pin 4).

Is voltage present?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Go to Reprogram Controller.
Action:

Disconnect bulkhead connector (X95). See IGC Machine Harness (W21) and IGC Cab Harness (W22)
517
 524062.03 —Aux 1 Jstk Sensor 2 Short to Power
Disconnect bulkhead connector (X95). See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)

Check voltage of circuit H37 GRN (X95 pin 31) on IGC machine harness (W21).

Is voltage present?

Record of Actual Results:

Result:
YES:
Short to power in IGC machine harness (W22). Repair or replace harness. See Integrated Grade Control
(IGC) Machine Harness (W21) Wiring Diagram—If Equipped . (Group 9015-20.)
NO:
Short to power in IGC cab harness (W21). Repair or replace harness. See Integrated Grade Control (IGC)
Cab Harness (W22) Wiring Diagram—If Equipped . (Group 9015-10.)

3 Reprogram Controller

Action:

Reprogram electrohydraulic controller.

Check for active codes.

Is EHC code 524062.03 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

AA95137,00007DC-19-20120731

518
 524062.04 —Aux 1 Jstk Sensor 2 Short to GND
524062.04 —
Aux 1 Jstk Sensor 2 Short to GND

There is a short to ground present on the sensor 2 circuit of auxiliary joystick 1.

Sensor 2 of Auxiliary Joystick 1 Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Code Check
Action:

Disconnect connector (X85) from auxiliary joystick (if equipped). See IGC Machine Harness (W21) and IGC
Cab Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check for active codes.

Is EHC code 524062.04 present?

Record of Actual Results:

Result:
YES:
Go to Sensor 2 of Auxiliary Joystick 1 Harness Check—Short to Ground .
NO:
Auxiliary 1 joystick malfunction. Replace auxiliary 1 joystick.

2 Open Circuit Check

Action:

Disconnect EHC connector (X82) and connector (X85) from auxiliary joystick (if equipped). See IGC Machine
Harness (W21) and IGC Cab Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check continuity of the following circuits:

H37 GRN (X85 pin 4 and X82 pin 23)

H22 GRN (X85 pin 2 and X82 pin 3)
R41 BLK (X85 pin 1 and X82 pin 22)

Do all the circuits have continuity?

Record of Actual Results:

Result:
YES:
Go to Reprogram Controller.
519
 524062.04 —Aux 1 Jstk Sensor 2 Short to GND

NO:
Go to next step in this check.
Action:

Disconnect connector (X85) from auxiliary joystick (if equipped) and bulkhead connector (X95). See IGC
Machine Harness (W21) and IGC Cab Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check continuity of the following circuits:

H37 GRN (X85 pin 4 and X95 pin 31)

H22 GRN (X85 pin 2 and X95 pin 13)
R41 BLK (X85 pin 1 and X95 pin 16)

Do all the circuits have continuity?

Record of Actual Results:

Result:
YES:
Open circuit in IGC machine harness (W21). Repair or replace harness. See Integrated Grade Control (IGC)
Machine Harness (W21) Wiring Diagram—If Equipped . (Group 9015-10.)
NO:
Open circuit in IGC cab harness (W22). Repair or replace harness. See Integrated Grade Control (IGC) Cab
Harness (W22) Wiring Diagram—If Equipped . (Group 9015-10.)

3 Short Circuit Check

Action:

Disconnect connector (X85) from auxiliary joystick (if equipped). See IGC Machine Harness (W21) and IGC
Cab Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check continuity of the following circuits to machine ground:

H37 GRN (X85 pin 4)

H22 GRN (X85 pin 2)

Do either of the circuits have continuity to machine ground?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Go to Reprogram Controller.
Action:

Disconnect connector X95. See IGC Machine Harness (W21) and IGC Cab Harness (W22) Component
Location—If Equipped . (Group 9015-10.)

520
 524062.04 —Aux 1 Jstk Sensor 2 Short to GND
Check continuity between the following circuits at (X95) on the IGC machine harness (W21) and machine
ground:

H37 GRN (X95 pin 31)

H22 GRN (X95 pin 15)

Does either circuit have continuity to machine ground?

Record of Actual Results:

Result:
YES:
Short circuit in IGC machine harness (W21). Repair or replace harness. See Integrated Grade Control (IGC)
Machine Harness (W21) Wiring Diagram—If Equipped . (Group 9015-10.)
NO:
Short circuit in IGC cab harness (W22). Repair or replace harness. see Integrated Grade Control (IGC) Cab
Harness (W22) Wiring Diagram—If Equipped . (Group 9015-10.)

4 Reprogram Controller

Action:

Reprogram electrohydraulic controller (EHC).

Check for active codes.

Is EHC code 524062.04 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

AA95137,00007DD-19-20070307

521
 524062.31 —Aux 1 Jstk Sensor 2 Invalid Output
524062.31 —
Aux 1 Jstk Sensor 2 Invalid Output

The EHC detects abnormal value from sensor 2 circuit of auxiliary 1 joystick.

Sensor 2 of Auxiliary Joystick 1 Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Code Check
Action:

Disconnect connector (X85) from auxiliary joystick (if equipped).

Check for active codes.

Is EHC code 524062.03 present?

Record of Actual Results:

Result:
YES:
Go to Voltage Check.
NO:
Auxiliary 1 joystick malfunction. Replace auxiliary 1 joystick.

2 Voltage Check

Action:

Disconnect connector X85 from auxiliary 1 joystick (if equipped).

Check voltage across circuits H22 GRN (X85 pin 1) and R41 BLK (X85 pin 4).

Is voltage 4.75—5.25 volts?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check.
NO:
Open circuit in harness. Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Wiring
Diagram—If Equipped . (Group 9015-10.)

522
 524062.31 —Aux 1 Jstk Sensor 2 Invalid Output
3 Short Circuit Check

Action:

Disconnect EHC connector (X83) and auxiliary 1 joystick (if equipped) connector (X85).

Check continuity between circuits H37 GRN (X85 pin 3) and H26 GRN (X85 pin 2).

Check continuity between circuit H37 GRN (X85 pin 3) machine ground.

Is there continuity between circuits H37 GRN and H26 GRN or ground?

Record of Actual Results:

Result:
YES:
Short circuit in harness. Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Wiring
Diagram—If Equipped . (Group 9015-10.)
NO:
Go to Reprogram Controller.

4 Reprogram Controller

Action:

Reprogram electrohydraulic controller (EHC).

Check for active codes.

Is EHC code 524062.31 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

AA95137,00007DE-19-20070307

523
 524085.00 —Aux 2 Jstk Sensor 2 Volts High
524085.00 —
Aux 2 Jstk Sensor 2 Volts High

Not Applicable

Go to Section_9001:Group_40

NM00125,0000875-19-20110526

524
 524085.01 —Aux 2 Jstk Sensor 2 Volts Low
524085.01 —
Aux 2 Jstk Sensor 2 Volts Low

Not Applicable

Go to Section_9001:Group_40

NM00125,0000876-19-20110526

525
 524085.03 —Aux 2 Jstk Sensor 1 Short to Power
524085.03 —
Aux 2 Jstk Sensor 1 Short to Power

Not Applicable

Go to Section_9001:Group_40

AA95137,00007D3-19-20070209

526
 524085.04 —Aux 2 Jstk Sensor 1 Short to GND
524085.04 —
Aux 2 Jstk Sensor 1 Short to GND

Not Applicable

Go to Section_9001:Group_40

AA95137,00007D4-19-20070209

527
 524085.14 —Aux 2 Jstk Sensor Mismatch
524085.14 —
Aux 2 Jstk Sensor Mismatch

Not Applicable

Go to Section_9001:Group_40

AA95137,00007D5-19-20070209

528
 524085.31 —Aux 2 Jstk Sensor 1 Invalid Output
524085.31 —
Aux 2 Jstk Sensor 1 Invalid Output

Not Applicable

Go to Section_9001:Group_40

AA95137,00007D6-19-20070209

529
 524086.00 —Aux 1 Jstk Sensor 1 Volts High
524086.00 —
Aux 1 Jstk Sensor 1 Volts High

Auxiliary 1 joystick sensor 2 (circuit H26 GRN) voltage is above normal operating range.

Sensor 1 of Auxiliary Joystick 1 Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Code Check
Action:

Disconnect connector X85 from auxiliary joystick (if equipped). See IGC Machine Harness (W21) and IGC
Cab Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check for electrohydraulic controller control unit (EHC) code 524086.04.

Is EHC code 524086.04 active?

Record of Actual Results:

Result:
YES:
Auxiliary 1 joystick malfunction. Replace auxiliary 1 joystick.
NO:
Go to Open Circuit Check.

2 Short Circuit Check

Action:

Ignition OFF.

Disconnect auxiliary joystick connector (X85) and electrohydraulic controller (EHC) connector (X82). See
IGC Machine Harness (W21) and IGC Cab Harness (W22) Component Location—If Equipped . (Group
9015-10.)

Ignition ON.

Check circuit H26 GRN for voltage at pin 3 of auxiliary joystick connector (X85).

Is voltage present?

Record of Actual Results:

Result:
YES:
530
 524086.00 —Aux 1 Jstk Sensor 1 Volts High
Circuit H26 GRN is short to power. Repair or replace harness.

See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped . (Group 9015-
10.)

See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped . (Group 9015-10.)

NO:

3 Harness Check
Action:

Turn battery disconnect switch to the OFF position.

Disconnect electrohydraulic control unit (EHC) connectors (X82 and X83), auxiliary joystick connector (X85),
and eloctrohydraulic control unit interface connector (X96). See IGC Machine Harness (W21) and IGC Cab
Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check for continuity between pin 3 (circuit H26 GRN) of auxiliary joystick connector (X85) and remaining pins
of EHC connectors (X82, X83, and X96).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Circuit H37 GRN is short to circuit that indicated continuity. Repair or replace harness.

See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped . (Group 9015-
10.)

See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped . (Group 9015-10.)

NO:
Auxiliary 1 joystick malfunction. Replace auxiliary 1 joystick.

Go to Section_9001:Group_40

NM00125,0000879-19-20110621

531
 524086.01 —Aux 1 Jstk Sensor 1 Volts Low
524086.01 —
Aux 1 Jstk Sensor 1 Volts Low

Auxiliary 1 joystick sensor 2 (circuit H26 GRN) voltage is below normal operating range.

Sensor 1 of Auxiliary Joystick 1 Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Code Check
Action:

Disconnect connector X85 from auxiliary joystick (if equipped). See IGC Machine Harness (W21) and IGC
Cab Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check for electrohydraulic controller control unit (EHC) code 524086.04.

Is EHC code 524086.04 active?

Record of Actual Results:

Result:
YES:
Auxiliary 1 joystick malfunction. Replace auxiliary 1 joystick.
NO:
Go to Open Circuit Check.

2 Open Circuit Check

Action:

Ignition OFF.

Disconnect auxiliary joystick connector (X85) and electrohydraulic controller (EHC) connector (X82). See
IGC Machine Harness (W21) and IGC Cab Harness (W22) Component Location—If Equipped . (Group
9015-10.)

Check circuit H26 GRN for continuity between pin 3 of auxiliary joystick connector (X85) and pin 23 of EHC
connector (X82).

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check.
532
 524086.01 —Aux 1 Jstk Sensor 1 Volts Low

NO:
Circuit H26 GRN is open. Repair or replace harness.

See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped . (Group 9015-
10.)

See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped . (Group 9015-10.)

3 Short Circuit Check

Action:

Ignition OFF.

Disconnect auxiliary joystick connector (X85) and electrohydraulic controller (EHC) connector (X82). See
IGC Machine Harness (W21) and IGC Cab Harness (W22) Component Location—If Equipped . (Group
9015-10.)

Check circuit H26 GRN for ground at pin 3 of auxiliary joystick connector (X85).

Is ground present?

Record of Actual Results:

Result:
YES:
Circuit H26 GRN is short to ground. Repair or replace harness.

See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped . (Group 9015-
10.)

See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped . (Group 9015-10.)

NO:
Go to Harness Check.

4 Harness Check
Action:

Turn battery disconnect switch to the OFF position.

Disconnect electrohydraulic control unit (EHC) connectors (X82 and X83), auxiliary joystick connector (X85),
and eloctrohydraulic control unit interface connector (X96). See IGC Machine Harness (W21) and IGC Cab
Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check for continuity between pin 3 (circuit H26 GRN) of auxiliary joystick connector (X85) and remaining pins
of EHC connectors (X82, X83, and X96).

Is continuity indicated?

Record of Actual Results:

533
 524086.01 —Aux 1 Jstk Sensor 1 Volts Low

Result:
YES:
Circuit H37 GRN is short to circuit that indicated continuity. Repair or replace harness.

See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped . (Group 9015-
10.)

See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped . (Group 9015-10.)

NO:
Auxiliary 1 joystick malfunction. Replace auxiliary 1 joystick.

Go to Section_9001:Group_40

NM00125,0000878-19-20110621

534
 524086.03 —Aux 1 Jstk Sensor 1 Short to Power
524086.03 —
Aux 1 Jstk Sensor 1 Short to Power

There is a short to power present on the sensor 1 circuit of auxiliary joystick 1.

Sensor 1 of Auxiliary Joystick 1 Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Code Check
Action:

Disconnect connector (X85) from auxiliary joystick (if equipped). See IGC Machine Harness (W21) and IGC
Cab Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check for active codes.

Is EHC code 524086.03 present?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check.
NO:
Auxiliary 1 joystick malfunction. Replace auxiliary 1 joystick.

2 Short Circuit Check

Action:

Disconnect connector (X85) from auxiliary joystick (if equipped). See IGC Machine Harness (W21) and IGC
Cab Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check voltage of circuit H26 GRN (X85 pin 2).

Is voltage present?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Go to Reprogram Controller.
Action:

535
 524086.03 —Aux 1 Jstk Sensor 1 Short to Power

Disconnect connector X95. See IGC Machine Harness (W21) and IGC Cab Harness (W22) Component
Location—If Equipped . (Group 9015-10.)

Check voltage of circuit H26 GRN (X95 pin 17) on IGC machine harness (W21).

Is voltage present?

Record of Actual Results:

Result:
YES:
Short to power in IGC machine harness (W22). Repair or replace harness. See Integrated Grade Control
(IGC) Machine Harness (W21) Wiring Diagram—If Equipped . (Group 9015-20.)
NO:
Short to power in IGC cab harness (W21). Repair or replace harness. See Integrated Grade Control (IGC)
Cab Harness (W22) Wiring Diagram—If Equipped . (Group 9015-10.)

3 Reprogram Controller

Action:

Reprogram electrohydraulic controller (EHC).

Check for active codes.

Is EHC code 524086.03 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

AA95137,00007D7-19-20120823

536
 524086.04 —Aux 1 Jstk Sensor 1 Short to GND
524086.04 —
Aux 1 Jstk Sensor 1 Short to GND

There is a short to ground present on the sensor 1 circuit of auxiliary joystick 1.

Sensor 1 of Auxiliary Joystick 1 Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Code Check
Action:

Disconnect connector (X85) from auxiliary joystick (if equipped). See IGC Machine Harness (W21) and IGC
Cab Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check for active codes.

Is EHC code 524086.04 present?

Record of Actual Results:

Result:
YES:
Go to Open Circuit Check.
NO:
Auxiliary 1 joystick malfunction. Replace auxiliary 1 joystick.

2 Open Circuit Check

Action:

Disconnect EHC connector (X82) and connector (X85) from auxiliary joystick (if equipped). See IGC Machine
Harness (W21) and IGC Cab Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check continuity of the following circuits.

H26 GRN (X85 pin 3 and X82 pin 23)

H22 GRN (X85 pin 2 and X82 pin 3)
R41 BLK (X85 pin 1 and X82 pin 22)

Do all the circuits have continuity?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check.
537
 524086.04 —Aux 1 Jstk Sensor 1 Short to GND

NO:
Go to next step in this check.
Action:

Disconnect connector (X85) from auxiliary joystick (if equipped) and bulkhead connector (X95). See IGC
Machine Harness (W21) and IGC Cab Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check continuity of the following circuits.

H26 GRN (X85 pin 3 and X95 pin 17)

H22 GRN (X85 pin 2 and X95 pin 13)
R41 BLK (X85 pin 1 and X95 pin 16)

Do all the circuits have continuity?

Record of Actual Results:

Result:
YES:
Open circuit in IGC machine harness (W21). Repair or replace harness. See Integrated Grade Control (IGC)
Machine Harness (W21) Wiring Diagram—If Equipped . (Group 9015-10.)
NO:
Open circuit in IGC cab harness (W22). Repair or replace harness. see Integrated Grade Control (IGC) Cab
Harness (W22) Wiring Diagram—If Equipped . (Group 9015-10.)

3 Short Circuit Check

Action:

Disconnect connector X85 from auxiliary joystick (if equipped). See IGC Machine Harness (W21) and IGC
Cab Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check continuity of the following circuits to machine ground:

H26 GRN (X85 pin 3)

H22 GRN (X85 pin 2)

Do either of the circuits have continuity to machine ground?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Go to Reprogram Controller.
Action:

Disconnect bulkhead connector (X95). See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)

538
 524086.04 —Aux 1 Jstk Sensor 1 Short to GND
Check continuity between the following circuits at connector (X95) on the IGC machine harness (W21) and
machine ground:

H26 GRN (X95 pin 17)

H22 GRN (X95 pin 15)

Does either circuit have continuity to machine ground?

Record of Actual Results:

Result:
YES:
Short circuit in IGC machine harness (W21). Repair or replace harness. See Integrated Grade Control (IGC)
Machine Harness (W21) Wiring Diagram—If Equipped . (Group 9015-10.)
NO:
Short circuit in IGC cab harness (W22). Repair or replace harness. See Integrated Grade Control (IGC) Cab
Harness (W22) Wiring Diagram—If Equipped . (Group 9015-10.)

4 Reprogram Controller

Action:

Reprogram electrohydraulic controller.

Check for active codes.

Is EHC code 524086.04 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

AA95137,00007D8-19-20070307

539
 524086.14 —Aux 1 Jstk Sensor Mismatch
524086.14 —
Aux 1 Jstk Sensor Mismatch

The EHC detects mismatched signals from sensors 1 and 2 of auxiliary 1 joystick.

Auxiliary Joystick 1 Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Code Check
Action:

Disconnect connector (X85) from auxiliary joystick (if equipped).

Check for active codes.

Is EHC code 524086.14 present?

Record of Actual Results:

Result:
YES:
Go to Voltage Check.
NO:
Auxiliary 1 joystick malfunction. Replace auxiliary 1 joystick.

2 Voltage Check

Action:

Disconnect connector (X85) from auxiliary 1 joystick (if equipped). See IGC Machine Harness (W21) and
IGC Cab Harness (W22) Component Location—If Equipped . (Group 9015-10.)

Check voltage across circuits H22 GRN (X85 pin 2) and R41 BLK (X85 pin 1).

Is voltage 4.75—5.25 volts?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check—Sensor 1.
NO:
Harness malfunction. Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Wiring
Diagram—If Equipped . (Group 9015-10.)

540
 524086.14 —Aux 1 Jstk Sensor Mismatch

3 Short Circuit Check—Sensor 1

Action:

Disconnect connectors X83 from EHC and X85 from auxiliary 1 joystick (if equipped).

Check continuity between circuits H37 GRN (X85 pin 4) and H26 GRN (X85 pin 3).

Check continuity between circuit H26 GRN (X85 pin 3) and system power and machine ground.

Is there continuity between circuits H26 GRN and H37 GRN or power and ground?

Record of Actual Results:

Result:
YES:
Short circuit in harness. Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Wiring
Diagram—If Equipped . (Group 9015-10.)
NO:
Go to Short Circuit Check—Sensor 2.

4 Short Circuit Check—Sensor 2

Action:

Disconnect EHC connector (X83) and connector (X85) from auxiliary 1 joystick (if equipped).

Check continuity between circuits H37 GRN (X85 pin 4) and H26 GRN (X85 pin 3).

Check continuity between circuit H37 GRN (X85 pin 4) and system power and machine ground.

Is there continuity between circuits H37 GRN and H26 GRN or power and ground?

Record of Actual Results:

Result:
YES:
Short circuit in harness. Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Wiring
Diagram—If Equipped . (Group 9015-10.)
NO:
Go to Reprogram Controller.

5 Reprogram Controller
Action:

Reprogram EHC.

541
 524086.14 —Aux 1 Jstk Sensor Mismatch
Check for active codes.

Is EHC code 524086.14 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

AA95137,00007D9-19-20070307

542
 524086.31 —Aux 1 Jstk Sensor 1 Invalid Output
524086.31 —
Aux 1 Jstk Sensor 1 Invalid Output

The EHC detects abnormal value from sensor 1 circuit of auxiliary 1 joystick.

Sensor 1 of Auxiliary Joystick 1 Diagnostic Procedure

Alarm Level:

Check Service Code

Launch Close Expand List Collapse List

1 Code Check
Action:

Disconnect connector (X85) from auxiliary joystick (if equipped).

Check for active codes.

Is EHC code 524086.31 present?

Record of Actual Results:

Result:
YES:
Go to Voltage Check.
NO:
Auxiliary 1 joystick malfunction. Replace auxiliary 1 joystick.

2 Voltage Check

Action:

Disconnect connector (X85) from auxiliary 1 joystick (if equipped).

Check voltage across circuits H22 GRN (X85 pin 2) and R41 BLK (X85 pin 1).

Is voltage 4.75—5.25 volts?

Record of Actual Results:

Result:
YES:
Go to Short Circuit Check.
NO:
Open circuit in harness. Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Wiring
Diagram—If Equipped . (Group 9015-10.)

543
 524086.31 —Aux 1 Jstk Sensor 1 Invalid Output
3 Short Circuit Check

Action:

Disconnect EHC connector (X83 and X85) from auxiliary 1 joystick (if equipped).

Check continuity between circuits H37 GRN (X85) pin 4 and H26 GRN (X85 pin 3).

Check continuity between circuit H26 GRN (X85) pin 3 and system power and machine ground.

Is there continuity between circuits H26 GRN and H37 GRN or power and ground?

Record of Actual Results:

Result:
YES:
Short circuit in harness. Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Wiring
Diagram—If Equipped . (Group 9015-10.)
NO:
Go to Reprogram EHC.

4 Reprogram EHC

Action:

Reprogram electrohydraulic controller (EHC).

Check for active codes.

Is EHC code 524086.31 present?

Record of Actual Results:

Result:
YES:
Replace controller.
NO:
Checks complete.

Go to Section_9001:Group_40

AA95137,00007DA-19-20070307

544
 Blade Control Joystick (BCJ) Diagnostic Trouble Codes

Blade Control Joystick (BCJ) Diagnostic Trouble Codes

The diagnostic trouble code number is indicated by a Suspect Parameter Number (SPN) and a Failure Mode
Indicator (FMI) number. In the example 002697.03 , 2697 is the SPN and 03 is the FMI number.

To view diagnostic trouble codes, use one of the following methods:

Service ADVISOR™ system. See Reading Diagnostic Trouble Codes with Service ADVISOR™
Diagnostic Application . (Group 9015-20.)
CAN Monitor Unit (CMU). See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-
20.)

NOTE:

For in-depth diagnostics on all BCJ diagnostic trouble codes, see specific code diagnostic
procedure. (Group 9001-50.)

Go to Section_9001:Group_50

AA95137,0000790-19-20070405

545
 Blade Control Joystick (BCJ) Diagnostic Trouble Codes

Blade Control Joystick (BCJ) Diagnostic Trouble Codes

The diagnostic trouble code number is indicated by a Suspect Parameter Number (SPN) and a Failure Mode
Indicator (FMI) number. In the example 002697.03 , 2697 is the SPN and 03 is the FMI number.

To view diagnostic trouble codes, use one of the following methods:

Service ADVISOR™ system. See Reading Diagnostic Trouble Codes with Service ADVISOR™
Diagnostic Application . (Group 9015-20.)
CAN Monitor Unit (CMU). See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-
20.)

NOTE:

For in-depth diagnostics on all BCJ diagnostic trouble codes, see specific code diagnostic
procedure. (Group 9001-50.)

Go to Section_9001:Group_50

AA95137,0000790-19-20070405

546
 002697.03 —X-Axis Sensor Out of Range High
002697.03 —
X-Axis Sensor Out of Range High

The x-axis effect sensor is out of range high.

Alarm Level:

Check Service Code

Joystick Diagnostic Procedure

Launch Close Expand List Collapse List

1 Code Check
Action:

Check for active codes.

Is BCJ code 002697.03 still present?

Record of Actual Results:

Result:
YES:
Joystick malfunction. Replace joystick. See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)
NO:
Check complete.

Go to Section_9001:Group_50

AA95137,000078F-19-20070405

547
 002697.04 —X-Axis Sensor Out of Range Low
002697.04 —
X-Axis Sensor Out of Range Low

The x-axis effect sensor is out of range low.

Alarm Level:

Check Service Code

Joystick Diagnostic Procedure

Launch Close Expand List Collapse List

1 Code Check
Action:

Check for active codes.

Is BCJ code 002697.04 still present?

Record of Actual Results:

Result:
YES:
Joystick malfunction. Replace joystick. See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)
NO:
Check complete.

Go to Section_9001:Group_50

AA95137,0000791-19-20070405

548
 002697.12 —X-Axis Joystick Internal Failure
002697.12 —
X-Axis Joystick Internal Failure

There is an internal malfunction in the x-axis joystick.

Alarm Level:

Check Service Code

Joystick Diagnostic Procedure

Launch Close Expand List Collapse List

1 Code Check
Action:

Check for active codes.

Is BCJ code 002697.12 still present?

Record of Actual Results:

Result:
YES:
Joystick malfunction. Replace joystick. See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)
NO:
Check complete.

Go to Section_9001:Group_50

AA95137,0000792-19-20070405

549
 002697.13 —X-Axis Joystick Setup Failure
002697.13 —
X-Axis Joystick Setup Failure

There is an x-axis setup malfunction in the joystick.

Alarm Level:

Check Service Code

Joystick Diagnostic Procedure

Launch Close Expand List Collapse List

1 Code Check
Action:

Check for active codes.

Is BCJ code 002697.13 still present?

Record of Actual Results:

Result:
YES:
Joystick malfunction. Replace joystick. See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)
NO:
Check complete.

Go to Section_9001:Group_50

AA95137,0000793-19-20070405

550
 002697.14 —X-Axis Joystick Sensor Failure
002697.14 —
X-Axis Joystick Sensor Failure

There is an x-axis sensor malfunction in the joystick.

Alarm Level:

Check Service Code

Joystick Diagnostic Procedure

Launch Close Expand List Collapse List

1 Code Check
Action:

Check for active codes.

Is BCJ code 002697.14 still present?

Record of Actual Results:

Result:
YES:
Joystick malfunction. Replace joystick. See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)
NO:
Check complete.

Go to Section_9001:Group_50

AA95137,0000794-19-20070405

551
 002698.03 —Y-Axis Sensor Out of Range High
002698.03 —
Y-Axis Sensor Out of Range High

The y-axis effect sensor is out of range high.

Alarm Level:

Check Service Code

Joystick Diagnostic Procedure

Launch Close Expand List Collapse List

1 Code Check
Action:

Check for active codes.

Is BCJ code 002698.03 still present?

Record of Actual Results:

Result:
YES:
Joystick malfunction. Replace joystick. See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)
NO:
Check complete.

Go to Section_9001:Group_50

AA95137,0000795-19-20070405

552
 002698.04 —Y-Axis Sensor Out of Range Low
002698.04 —
Y-Axis Sensor Out of Range Low

The y-axis effect sensor is out of range low.

Alarm Level:

Check Service Code

Joystick Diagnostic Procedure

Launch Close Expand List Collapse List

1 Code Check
Action:

Check for active codes.

Is BCJ code 002698.04 still present?

Record of Actual Results:

Result:
YES:
Joystick malfunction. Replace joystick. See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)
NO:
Check complete.

Go to Section_9001:Group_50

AA95137,0000796-19-20070405

553
 002698.12 —Y-Axis Joystick Internal Failure
002698.12 —
Y-Axis Joystick Internal Failure

There is an internal malfunction in the y-axis joystick.

Alarm Level:

Check Service Code

Joystick Diagnostic Procedure

Launch Close Expand List Collapse List

1 Code Check
Action:

Check for active codes.

Is BCJ code 002698.12 still present?

Record of Actual Results:

Result:
YES:
Joystick malfunction. Replace joystick. See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)
NO:
Check complete.

Go to Section_9001:Group_50

AA95137,0000797-19-20070405

554
 002698.13 —Y-Axis Joystick Setup Failure
002698.13 —
Y-Axis Joystick Setup Failure

There is a setup malfunction in the y-axis joystick.

Alarm Level:

Check Service Code

Joystick Diagnostic Procedure

Launch Close Expand List Collapse List

1 Code Check
Action:

Check for active codes.

Is BCJ code 002698.13 still present?

Record of Actual Results:

Result:
YES:
Joystick malfunction. Replace joystick. See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)
NO:
Check complete.

Go to Section_9001:Group_50

AA95137,0000798-19-20070405

555
 002698.14 —Y-Axis Joystick Sensor Failure
002698.14 —
Y-Axis Joystick Sensor Failure

The y-axis joystick has a sensor malfunction.

Alarm Level:

Check Service Code

Joystick Diagnostic Procedure

Launch Close Expand List Collapse List

1 Code Check
Action:

Check for active codes.

Is BCJ code 002698.13 still present?

Record of Actual Results:

Result:
YES:
Joystick malfunction. Replace joystick. See IGC Machine Harness (W21) and IGC Cab Harness (W22)
Component Location—If Equipped . (Group 9015-10.)
NO:
Check complete.

Go to Section_9001:Group_50

AA95137,0000799-19-20070405

556
 Table of Contents

Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout

557
 Operational Checkout

Operational Checkout

Use this procedure to make a quick check of machine operation by doing a walk around inspection and
performing specific checks from operator's seat.

Complete visual checks (oil levels, oil condition, external leaks, loose hardware, linkage, wiring, etc.) before
performing checkout.

Most checks will require machine systems to be at normal operating temperatures and a level area with adequate
space to operate machine. Some checks may require varied surfaces.

No special tools are necessary to perform the checkout.

If no problem is found, go to next check. If problem is indicated, an additional check or repair procedure will be
suggested.

1 Diagnostic Trouble Code (DTC) Check

Launch Close Expand List Collapse List

1A Display and Clear Trouble Codes

Action:

Always check for diagnostic trouble codes and correct them before performing the operational
checkout.

Check for active and stored diagnostic trouble codes (DTCs).

Diagnostic trouble codes can be displayed by using one of the following methods.

CAN Monitor Unit (CMU)

To access and clear DTCs using the CMU, see CAN Monitor Unit (CMU) Menu Structure
—Service Mode . (Group 9015-20.)
Service ADVISOR™ Diagnostic Application
To access and clear DTCs using Service ADVISOR™ diagnostic application, see Reading
Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-
20.)

LOOK: Are diagnostic trouble codes present that cannot be cleared?

Record of Actual Results:

Result:
YES:
Correct all diagnostic trouble codes before proceeding. See Diagnostic Trouble Codes (DTC) Quick
Reference List . (Group 9015-20.)
NO:
Continue with operational checkout.

2 Operational Checks—Key Switch OFF, Engine OFF

Launch Close Expand List Collapse List
558
 Operational Checkout

2A Battery Check

Action:

Push and hold SELECT button on CMU until battery volts are displayed.

LOOK: Do battery volts read a minimum of 24 volts?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Check for loose connection on battery power connector X49. If battery power connector is okay, check and
recharge batteries. See Check Battery Electrolyte Level and Terminals . (Operator's Manual.) Check voltage
on each battery before recharging.

NOTE: If one battery will not hold a charge, replace both batteries.

2B Horn Check
Action:

Push horn button.

LISTEN: Does horn activate?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Check horn 5 A fuse (F19). See Fuse and Relay Specifications . (Group 9015-10.)

If fuse okay, check horn circuit. See System Functional Schematic and Section Legend . (Group 9015-10.)

2C Seat Control Checks

Action:

NOTE:

For seat adjustment procedures, see Adjusting Seat . (Operator's Manual.)

If machine is equipped with air seat, key switch must be ON to raise seat.

Does seat raise and lower easily?

559
 Operational Checkout
Does seat angle change easily?

Does lever move easily to unlock seat support?

Does seat move forward and rearward easily?

Does lever lock seat support in position when released?

Does seat back tilt forward and rearward easily?

Does lever unlock and lock easily to hold seat back in position?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Inspect linkage and repair.

3 Operational Checks—Key Switch ON, Engine OFF

Launch Close Expand List Collapse List

3A Battery Disconnect Switch Check

Action:

T118722B-UN: Battery Disconnect Switch

NOTE:

Battery disconnect switch is located inside of the right rear service door.

Turn battery disconnect switch OFF.

Turn key switch on.

LOOK: Do monitor indicator lights come on?

Record of Actual Results:

Result:
YES:

560
 Operational Checkout
Switch is malfunctioning. Check battery disconnect switch.
NO:
Continue check.
Action:

Turn battery disconnect switch ON.

Turn key switch ON. Do not start engine.

LOOK: Do monitor indicator lights come on?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Check battery disconnect switch.

3B Monitor Check
Action:

Turn key switch ON.

Observe monitor and note changes for first 3 seconds (bulbs, indicators and gauges).

LOOK/LISTEN: Do all lights come on and is the audible alarm activated?

Does the LCD display show “John Deere” and the model number?

Do all the gauge indicators point to approximately 12 o’clock position?

Does the backlighting for the gauges come on?

After four seconds observe changes in monitor.

LOOK: Do gauge indicators change from 12 o’clock to normal readings?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Check CMU ignition power 5 A fuse (F4). See Fuse and Relay Specifications . (Group 9015-10.)

If fuse okay, check monitor circuit. See System Functional Schematic and Section Legend . (Group 9015-10.)

3C Backup Alarm Check

561
 Operational Checkout

Action:

Key switch ON.

Put park lock lever down position.

Move park lock lever to the UNLOCK (down) position.

Move transmission control lever to reverse position.

LISTEN: Does backup alarm activate?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Check for voltage at backup alarm. See Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)

If no voltage is present, calibrate TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

3D Front/Rear Wiper and Washer Motor Check—If Equipped

Action:

T199302A-UN: Wiper Switches (S.N. —210213)

TX1114380A-UN: Wiper Switches (S.N. 210214— )

LEGEND:

562
 Operational Checkout
1 - Left/Right Door Wiper Switch
2 - Front/Rear Wiper Switch

Key switch ON.

Push front/rear wiper switch (2) to first detent (middle) position (S.N. —210213) or turn front/rear wiper
switch (2) to the number three (end) position (S.N. 210214— ).

LOOK: Do front and rear wipers operate?

Push wiper switch fully to momentary position and hold.

LOOK: Does the front/rear washer pump operate?

LOOK: Do front and rear wipers continue to operate?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Washer fluid reservoir may be empty. Check washer fluid.

Check front/rear wiper motor 10 A fuse (F21). See Fuse and Relay Specifications . (Group 9015-10.)

If fuse okay, check wiper circuit. See System Functional Schematic and Section Legend . (Group 9015-10.)

3E Left/Right Door Wiper and Washer Motor Check—If Equipped

Action:

T199302A-UN: Wiper Switches (S.N. —210213)

563
 Operational Checkout

TX1114380A-UN: Wiper Switches (S.N. 210214— )

LEGEND:
1 - Left/Right Door Wiper Switch
2 - Front/Rear Wiper Switch

Key switch ON.

Push left/right wiper switch (1) to first detent (middle) position (S.N. —210213) or turn left/right door wiper
switch (1) to the number three (end) position (S.N. 210214— ).

LOOK: Do left and right wipers operate?

Push wiper switch fully to momentary position and hold.

LOOK: Does left/right washer pump operate?

LOOK: Do left and right wipers continue to operate?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Washer fluid reservoir may be empty. Check washer fluid.

Check left/right wiper motor 10 A fuse (F22). See Fuse and Relay Specifications . (Group 9015-10.)

If fuse okay, check wiper circuit. See System Functional Schematic and Section Legend . (Group 9015-10.)

3F Heater Blower Motor Check—If Equipped

Action:

564
 Operational Checkout

TX1114381A-UN: Air Conditioning Controls

LEGEND:
1 - Air Conditioning Switch
2 - Blower Switch
3 - Temperature Control
4 - Air Duct (8 used)

Key switch ON.

Turn blower switch (2) to 1st, 2nd, 3rd, and 4th positions.

FEEL: Does air exit all ducts from roof?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Check heater blower 15 A fuse (F12). See Fuse and Relay Specifications . (Group 9015-10.)

If fuse okay, check heater blower circuit. See System Functional Schematic and Section Legend . (Group
9015-10.)

4 Operational Checks—Key Switch ON, Engine ON

Launch Close Expand List Collapse List

4A Alternator Check
Action:

Start engine and operate at slow idle.

Start engine.

LOOK: Is ENGINE ALT VOLTS indicator light on?

Record of Actual Results:

565
 Operational Checkout

Result:
YES:
Check and recharge batteries. See Check Battery Electrolyte Level and Terminals . (Operator's Manual.)
Check voltage on each battery before recharging.

NOTE: If one battery will not hold a charge, replace both batteries.

Test alternator. See Alternator Test . (Group 9015-20.)

NO:
Check complete.

4B Air Filter Restriction Indicator Check

Action:

T206395-UN: Air Filter Restriction Indicator Light

Operated engine at slow idle and fast idle.

LOOK: Does air filter restriction indicator light come on?

Record of Actual Results:

Result:
YES:
Clean or replace air cleaner elements. See Replace Air Filter Elements . (Operator's Manual.)

If air cleaner elements are okay, check air filter restriction switch circuit. See System Functional Schematic
and Section Legend . (Group 9015-10.)

NO:
Check complete.
566
 Operational Checkout

4C Slow and Fast Idle Check

Action:

Run engine at slow and fast idle while noting rpm readings on monitor.

LOOK: Are slow and fast idle displayed on monitor?

Item Measurement Specification

Engine Slow Idle Speed 880—910 rpm
Engine Fast Idle Speed 2255—2285 rpm

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Check crankshaft position sensor circuit connections. See Engine Control Unit (ECU) Circuit Theory of
Operation . (Group 9015-15.)

Check monitor connections. See CAN Monitor Unit (CMU) Circuit Theory of Operation . (Group 9015-15.)

4D Park Brake Valve Leakage Check

Action:

Hydrostatic oil must be at operating temperature 66°C (150°F). Oil temperature can be viewed on monitor.

Adjust engine speed control to slow idle with park lock lever in the LOCK (up) position.

Observe charge pressure reading on monitor display. The charge pressure can be accessed as a live value
in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-
20.)

LOOK: Does pressure drop as park lock lever is moved down, then return to original value?

Fully depress decel/brake pedal, then release.

LOOK: Does pressure drop as decel/brake pedal is released, then return to original value?

LOOK: Do tracks creep or move?

Record of Actual Results:

Result:
YES:
Isolate park brakes, brake valve to locate leakage.
YES:
Tracks move in neutral. Inspect park brake valve. See Park Brake Valve Operation . (Group 9026-05.)

567
 Operational Checkout
Perform Park Brake Test . (Group 9026-25.)
NO:
Check complete.

4E Decelerator/Brake Pedal and Park Brake Check

Action:

CAUTION:
Prevent possible injury from machine movement. Perform this check in an open area
away from other people and machinery.

Operate engine at slow idle.

CAUTION:
Prevent possible injury from sudden machine stops. Wear seat belt while operating
machine.

Fasten seat belt.

Move park lock lever to the UNLOCK (down) position.

Operate machine slowly in forward. Fully depress decel/brake pedal and then release.

LOOK: Does machine stop when pedal is depressed and move when pedal is released?

Depress decel/brake pedal until spring resistance is felt.

Adjust engine speed to fast idle and transmission speed to 3.0.

Move transmission control lever to forward position.

Release decel/brake pedal.

LOOK: Does machine accelerate smoothly to maximum speed?

NOTE:

Decel/brake response time can be set to operator preference. See CAN Monitor Unit (CMU)
Menu Structure—Service Mode . (Group 9015-20.)

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Inspect park brake valve. See Park Brake Valve Operation . (Group 9026-05.) Perform Transmission Control
568
 Operational Checkout
Unit (TCU) Calibration . (Group 9015-20.)

4F Transmission Control Lever (TCL) Check

Action:

CAUTION:
Prevent possible injury from machine movement. Make sure there is adequate room
and be aware of bystanders.

Operate engine at 1500 rpm.

Put transmission speed to 2.0.

Make several shifts from neutral to forward, neutral to reverse, and then forward to reverse.

Item Measurement Specification

Engine Speed 1500 rpm

LOOK: Does machine shift smoothly?

LOOK: Does machine operate in forward and reverse?

NOTE:

Transmission control lever shift rate can be set to operator preference. Low has a slower
reaction time and high has a quicker reaction time. See CAN Monitor Unit (CMU) Menu
Structure—Service Mode . (Group 9015-20.)

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Test transmission control lever sensor.

4G Transmission Speed Check

Action:

Operate engine at slow idle.

Check transmission speed. Transmission speed should be defaulted to 1.6.

LOOK: Does transmission speed default to 1.6?

Increase transmission speed to 3.0.

LOOK: Does transmission speed increase to 3.0?

569
 Operational Checkout

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Calibrate TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

4H Tracking and Maximum Speed Check

Action:

NOTE:

Track sag must be at specification and machine must be driven on a level surface for all
tracking checks.

Push decelerator mode switch to ENGINE MODE position.

Operate engine at fast idle.

Put transmission speed to 3.0.

Move park lock lever to the UNLOCK (down) position.

Push decelerator pedal fully to stop.

Move TCL to FORWARD position.

Slowly increase engine speed from slow to fast idle by slowly raising the decelerator pedal.

LOOK: Does machine speed increase as engine rpm increases? Is tracking straight at all speeds?

Repeat check for reverse travel.

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Calibrate machine. Perform Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

See Mistrack/Index Malfunctions and See Machine Full Speed Malfunctions . (Group 9026-15.)

4I Reverse Fan Check (If Equipped)

Action:

570
 Operational Checkout

T194319-UN: Reverse Fan Switch

Push the reverse fan switch to enable manual mode (reverse engine fan indicator light on).

NOTE:

Reverse fan function cannot be operated twice within 1 minute. Wait 1 minute before
attempting to reverse fan direction again.

LISTEN/LOOK: Does fan reverse direction and operate at full speed for 15 seconds?

Fan will change directions and operate at normal speed.

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Verify that function is enabled in the CMU machine configuration menu. See CAN Monitor Unit (CMU) Menu
Structure—Service Mode . (Group 9015-20.)

If function is enabled, see Hydraulic Fan Drive Operation . (Group 9026-05.)

4J Blade Control Lever Check

Action:

T8404AC-UN: Control Valve Linkage and Float Detent

LEGEND:
A - Blade Tilt Right
B - Blade Lift
571
 Operational Checkout
C - Blade Tilt Left
D - Blade Down
E - Blade Float

Push hydraulic enable switch to the LOCKED position to disable the pilot controls.

Move control lever to positions (A—D) and release.

LOOK/FEEL: Does blade control lever move to all positions easily and return to neutral when released?

NOTE:

Blade control lever will not return to neutral when moved to blade float position (E). Lever
must be manually pulled from float position.

Record of Actual Results:

Result:
YES:
Check complete.
NO:
If functions hesitate or do not operate smoothly, see Hydraulic System Diagnose Malfunctions . (Group 9025-
15.) See Hydraulic System Diagnose Malfunctions—IGC . (Group 9025-15.)

4K Hydraulic Enable Circuit Check

Action:

T194312-UN: Hydraulic Enable Switch

Operate engine at slow idle.

Hydraulic enable switch in the LOCKED position. Pilot controls disabled.

Move blade control lever to all positions.

LOOK: Do any blade functions operate?

Record of Actual Results:

572
 Operational Checkout

Result:
YES:
Check hydraulic enable switch and circuit. See System Functional Schematic and Section Legend . (Group
9015-10.)
NO:
Continue check.
Action:

Push hydraulic enable switch to the UNLOCKED position to enable the pilot controls.

Move blade control lever to all positions.

LOOK: Do all blade functions operate?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Check hydraulic enable switch and circuit. See System Functional Schematic and Section Legend . (Group
9015-10.)

4L Hydraulic Controls Check

Action:

Operate engine at slow idle.

NOTE:

For machines equipped with IGC, put blade control in manual mode by pushing the IGC
on/off button located on the joystick handle. The blade control is in manual mode when the
auto blade light on the CMU is off.

Slowly move blade control lever to all positions except blade float detent.

For machines equipped with PAT and IGC, push blade angle buttons on joystick handle to rotate blade in
both directions.

LOOK/FEEL: Do all blade functions operate smoothly, without hesitation?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
See Hydraulic System Diagnose Malfunctions and/or See Hydraulic System Diagnose Malfunctions—IGC .

573
 Operational Checkout
(Group 9025-15.)

4M Quick-Drop Valve Check (Outside Dozers Only)

Action:

Operate engine at fast idle.

Raise blade to maximum height.

NOTE:

Quick-Drop is activated when control lever is in float position or when lever is at the end of
power down position.

Move control lever to float position and record time it takes to lower blade to ground from maximum height.

LOOK: Does it take 1 second or less for blade to lower to ground with Quick-Drop activated?

Raise blade after blade has been lowered with quick drop valve.

LOOK: Does blade raise immediately?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
See Quick-Drop Valve Operation . (Group 9025-05.)

4N Blade Float Check

Action:

Operate engine at slow idle.

Raise front of machine off ground by fully lowering and tilting blade.

Push hydraulic control lever into float detent position.

LOOK: Does front of crawler lower to ground?

FEEL: Does hydraulic control lever stay in float detent position?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
574
 Operational Checkout
Check blade float detent coil and hydraulic enable circuit. See System Functional Schematic and Section
Legend . (Group 9015-10.)

4O Cycle Time Check

Action:

Use the CAN Monitor Unit (CMU) or Service ADVISOR™ Diagnostic Application to read engine rpm and
hydraulic oil temperature.

Item Measurement Specification

Hydraulic Oil Temperature 57—66°C
135—150°F
Engine Speed Fast Idle
Blade Raise—OSD Cycle Time 2.8 seconds
Blade Raise—PAT Cycle Time 2.9 seconds
Blade Power Down—OSD Cycle Time 2.2 seconds
Blade Power Down—PAT Cycle Time 1.8 seconds
Blade Tilt Left—OSD Cycle Time 1.0 seconds
Blade Tilt Left—PAT Cycle Time 1.4 seconds
Blade Tilt Right—750J OSD Cycle Time 1.0 seconds
Blade Tilt Right—PAT Cycle Time 1.4 seconds
Blade Angle Left—PAT and IGC Cycle Time 4.0 seconds
Blade Angle Right—PAT and IGC Cycle Time 4.1 seconds

Do cycle times meet or exceed specification?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Check hydraulic pump. See Hydraulic Pump Flow Test . (Group 9025-25.)

4P Air Conditioner Check—If Equipped

Action:

575
 Operational Checkout
TX1114381A-UN: Air Conditioning Controls
LEGEND:
1 - Air Conditioning Switch
2 - Blower Switch
3 - Temperature Control
4 - Air Duct (8 used)

Operate engine at fast idle.

Turn air conditioner switch (1) to on position. On position is up (snow flake). Position down is not used for
this test.

Turn blower switch (2) to 4th position.

Wait for any warm air in duct system to dissipate.

FEEL: Is air from ducts cool?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
See Air Conditioning System Diagnose Malfunctions . (Group 9031-15.)

Go to Section_9005:Group_10

LW86157,0000161-19-20120525

576
 Operational Checkout

Operational Checkout

Use this procedure to make a quick check of machine operation by doing a walk around inspection and
performing specific checks from operator's seat.

Complete visual checks (oil levels, oil condition, external leaks, loose hardware, linkage, wiring, etc.) before
performing checkout.

Most checks will require machine systems to be at normal operating temperatures and a level area with adequate
space to operate machine. Some checks may require varied surfaces.

No special tools are necessary to perform the checkout.

If no problem is found, go to next check. If problem is indicated, an additional check or repair procedure will be
suggested.

1 Diagnostic Trouble Code (DTC) Check

Launch Close Expand List Collapse List

1A Display and Clear Trouble Codes

Action:

Always check for diagnostic trouble codes and correct them before performing the operational
checkout.

Check for active and stored diagnostic trouble codes (DTCs).

Diagnostic trouble codes can be displayed by using one of the following methods.

CAN Monitor Unit (CMU)

To access and clear DTCs using the CMU, see CAN Monitor Unit (CMU) Menu Structure
—Service Mode . (Group 9015-20.)
Service ADVISOR™ Diagnostic Application
To access and clear DTCs using Service ADVISOR™ diagnostic application, see Reading
Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-
20.)

LOOK: Are diagnostic trouble codes present that cannot be cleared?

Record of Actual Results:

Result:
YES:
Correct all diagnostic trouble codes before proceeding. See Diagnostic Trouble Codes (DTC) Quick
Reference List . (Group 9015-20.)
NO:
Continue with operational checkout.

2 Operational Checks—Key Switch OFF, Engine OFF

Launch Close Expand List Collapse List
577
 Operational Checkout

2A Battery Check

Action:

Push and hold SELECT button on CMU until battery volts are displayed.

LOOK: Do battery volts read a minimum of 24 volts?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Check for loose connection on battery power connector X49. If battery power connector is okay, check and
recharge batteries. See Check Battery Electrolyte Level and Terminals . (Operator's Manual.) Check voltage
on each battery before recharging.

NOTE: If one battery will not hold a charge, replace both batteries.

2B Horn Check
Action:

Push horn button.

LISTEN: Does horn activate?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Check horn 5 A fuse (F19). See Fuse and Relay Specifications . (Group 9015-10.)

If fuse okay, check horn circuit. See System Functional Schematic and Section Legend . (Group 9015-10.)

2C Seat Control Checks

Action:

NOTE:

For seat adjustment procedures, see Adjusting Seat . (Operator's Manual.)

If machine is equipped with air seat, key switch must be ON to raise seat.

Does seat raise and lower easily?

578
 Operational Checkout
Does seat angle change easily?

Does lever move easily to unlock seat support?

Does seat move forward and rearward easily?

Does lever lock seat support in position when released?

Does seat back tilt forward and rearward easily?

Does lever unlock and lock easily to hold seat back in position?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Inspect linkage and repair.

3 Operational Checks—Key Switch ON, Engine OFF

Launch Close Expand List Collapse List

3A Battery Disconnect Switch Check

Action:

T118722B-UN: Battery Disconnect Switch

NOTE:

Battery disconnect switch is located inside of the right rear service door.

Turn battery disconnect switch OFF.

Turn key switch on.

LOOK: Do monitor indicator lights come on?

Record of Actual Results:

Result:
YES:

579
 Operational Checkout
Switch is malfunctioning. Check battery disconnect switch.
NO:
Continue check.
Action:

Turn battery disconnect switch ON.

Turn key switch ON. Do not start engine.

LOOK: Do monitor indicator lights come on?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Check battery disconnect switch.

3B Monitor Check
Action:

Turn key switch ON.

Observe monitor and note changes for first 3 seconds (bulbs, indicators and gauges).

LOOK/LISTEN: Do all lights come on and is the audible alarm activated?

Does the LCD display show “John Deere” and the model number?

Do all the gauge indicators point to approximately 12 o’clock position?

Does the backlighting for the gauges come on?

After four seconds observe changes in monitor.

LOOK: Do gauge indicators change from 12 o’clock to normal readings?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Check CMU ignition power 5 A fuse (F4). See Fuse and Relay Specifications . (Group 9015-10.)

If fuse okay, check monitor circuit. See System Functional Schematic and Section Legend . (Group 9015-10.)

3C Backup Alarm Check

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 Operational Checkout

Action:

Key switch ON.

Put park lock lever down position.

Move park lock lever to the UNLOCK (down) position.

Move transmission control lever to reverse position.

LISTEN: Does backup alarm activate?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Check for voltage at backup alarm. See Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)

If no voltage is present, calibrate TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

3D Front/Rear Wiper and Washer Motor Check—If Equipped

Action:

T199302A-UN: Wiper Switches (S.N. —210213)

TX1114380A-UN: Wiper Switches (S.N. 210214— )

LEGEND:

581
 Operational Checkout
1 - Left/Right Door Wiper Switch
2 - Front/Rear Wiper Switch

Key switch ON.

Push front/rear wiper switch (2) to first detent (middle) position (S.N. —210213) or turn front/rear wiper
switch (2) to the number three (end) position (S.N. 210214— ).

LOOK: Do front and rear wipers operate?

Push wiper switch fully to momentary position and hold.

LOOK: Does the front/rear washer pump operate?

LOOK: Do front and rear wipers continue to operate?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Washer fluid reservoir may be empty. Check washer fluid.

Check front/rear wiper motor 10 A fuse (F21). See Fuse and Relay Specifications . (Group 9015-10.)

If fuse okay, check wiper circuit. See System Functional Schematic and Section Legend . (Group 9015-10.)

3E Left/Right Door Wiper and Washer Motor Check—If Equipped

Action:

T199302A-UN: Wiper Switches (S.N. —210213)

582
 Operational Checkout

TX1114380A-UN: Wiper Switches (S.N. 210214— )

LEGEND:
1 - Left/Right Door Wiper Switch
2 - Front/Rear Wiper Switch

Key switch ON.

Push left/right wiper switch (1) to first detent (middle) position (S.N. —210213) or turn left/right door wiper
switch (1) to the number three (end) position (S.N. 210214— ).

LOOK: Do left and right wipers operate?

Push wiper switch fully to momentary position and hold.

LOOK: Does left/right washer pump operate?

LOOK: Do left and right wipers continue to operate?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Washer fluid reservoir may be empty. Check washer fluid.

Check left/right wiper motor 10 A fuse (F22). See Fuse and Relay Specifications . (Group 9015-10.)

If fuse okay, check wiper circuit. See System Functional Schematic and Section Legend . (Group 9015-10.)

3F Heater Blower Motor Check—If Equipped

Action:

583
 Operational Checkout

TX1114381A-UN: Air Conditioning Controls

LEGEND:
1 - Air Conditioning Switch
2 - Blower Switch
3 - Temperature Control
4 - Air Duct (8 used)

Key switch ON.

Turn blower switch (2) to 1st, 2nd, 3rd, and 4th positions.

FEEL: Does air exit all ducts from roof?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Check heater blower 15 A fuse (F12). See Fuse and Relay Specifications . (Group 9015-10.)

If fuse okay, check heater blower circuit. See System Functional Schematic and Section Legend . (Group
9015-10.)

4 Operational Checks—Key Switch ON, Engine ON

Launch Close Expand List Collapse List

4A Alternator Check
Action:

Start engine and operate at slow idle.

Start engine.

LOOK: Is ENGINE ALT VOLTS indicator light on?

Record of Actual Results:

584
 Operational Checkout

Result:
YES:
Check and recharge batteries. See Check Battery Electrolyte Level and Terminals . (Operator's Manual.)
Check voltage on each battery before recharging.

NOTE: If one battery will not hold a charge, replace both batteries.

Test alternator. See Alternator Test . (Group 9015-20.)

NO:
Check complete.

4B Air Filter Restriction Indicator Check

Action:

T206395-UN: Air Filter Restriction Indicator Light

Operated engine at slow idle and fast idle.

LOOK: Does air filter restriction indicator light come on?

Record of Actual Results:

Result:
YES:
Clean or replace air cleaner elements. See Replace Air Filter Elements . (Operator's Manual.)

If air cleaner elements are okay, check air filter restriction switch circuit. See System Functional Schematic
and Section Legend . (Group 9015-10.)

NO:
Check complete.
585
 Operational Checkout

4C Slow and Fast Idle Check

Action:

Run engine at slow and fast idle while noting rpm readings on monitor.

LOOK: Are slow and fast idle displayed on monitor?

Item Measurement Specification

Engine Slow Idle Speed 880—910 rpm
Engine Fast Idle Speed 2255—2285 rpm

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Check crankshaft position sensor circuit connections. See Engine Control Unit (ECU) Circuit Theory of
Operation . (Group 9015-15.)

Check monitor connections. See CAN Monitor Unit (CMU) Circuit Theory of Operation . (Group 9015-15.)

4D Park Brake Valve Leakage Check

Action:

Hydrostatic oil must be at operating temperature 66°C (150°F). Oil temperature can be viewed on monitor.

Adjust engine speed control to slow idle with park lock lever in the LOCK (up) position.

Observe charge pressure reading on monitor display. The charge pressure can be accessed as a live value
in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-
20.)

LOOK: Does pressure drop as park lock lever is moved down, then return to original value?

Fully depress decel/brake pedal, then release.

LOOK: Does pressure drop as decel/brake pedal is released, then return to original value?

LOOK: Do tracks creep or move?

Record of Actual Results:

Result:
YES:
Isolate park brakes, brake valve to locate leakage.
YES:
Tracks move in neutral. Inspect park brake valve. See Park Brake Valve Operation . (Group 9026-05.)

586
 Operational Checkout
Perform Park Brake Test . (Group 9026-25.)
NO:
Check complete.

4E Decelerator/Brake Pedal and Park Brake Check

Action:

CAUTION:
Prevent possible injury from machine movement. Perform this check in an open area
away from other people and machinery.

Operate engine at slow idle.

CAUTION:
Prevent possible injury from sudden machine stops. Wear seat belt while operating
machine.

Fasten seat belt.

Move park lock lever to the UNLOCK (down) position.

Operate machine slowly in forward. Fully depress decel/brake pedal and then release.

LOOK: Does machine stop when pedal is depressed and move when pedal is released?

Depress decel/brake pedal until spring resistance is felt.

Adjust engine speed to fast idle and transmission speed to 3.0.

Move transmission control lever to forward position.

Release decel/brake pedal.

LOOK: Does machine accelerate smoothly to maximum speed?

NOTE:

Decel/brake response time can be set to operator preference. See CAN Monitor Unit (CMU)
Menu Structure—Service Mode . (Group 9015-20.)

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Inspect park brake valve. See Park Brake Valve Operation . (Group 9026-05.) Perform Transmission Control
587
 Operational Checkout
Unit (TCU) Calibration . (Group 9015-20.)

4F Transmission Control Lever (TCL) Check

Action:

CAUTION:
Prevent possible injury from machine movement. Make sure there is adequate room
and be aware of bystanders.

Operate engine at 1500 rpm.

Put transmission speed to 2.0.

Make several shifts from neutral to forward, neutral to reverse, and then forward to reverse.

Item Measurement Specification

Engine Speed 1500 rpm

LOOK: Does machine shift smoothly?

LOOK: Does machine operate in forward and reverse?

NOTE:

Transmission control lever shift rate can be set to operator preference. Low has a slower
reaction time and high has a quicker reaction time. See CAN Monitor Unit (CMU) Menu
Structure—Service Mode . (Group 9015-20.)

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Test transmission control lever sensor.

4G Transmission Speed Check

Action:

Operate engine at slow idle.

Check transmission speed. Transmission speed should be defaulted to 1.6.

LOOK: Does transmission speed default to 1.6?

Increase transmission speed to 3.0.

LOOK: Does transmission speed increase to 3.0?

588
 Operational Checkout

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Calibrate TCU. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

4H Tracking and Maximum Speed Check

Action:

NOTE:

Track sag must be at specification and machine must be driven on a level surface for all
tracking checks.

Push decelerator mode switch to ENGINE MODE position.

Operate engine at fast idle.

Put transmission speed to 3.0.

Move park lock lever to the UNLOCK (down) position.

Push decelerator pedal fully to stop.

Move TCL to FORWARD position.

Slowly increase engine speed from slow to fast idle by slowly raising the decelerator pedal.

LOOK: Does machine speed increase as engine rpm increases? Is tracking straight at all speeds?

Repeat check for reverse travel.

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Calibrate machine. Perform Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

See Mistrack/Index Malfunctions and See Machine Full Speed Malfunctions . (Group 9026-15.)

4I Reverse Fan Check (If Equipped)

Action:

589
 Operational Checkout

T194319-UN: Reverse Fan Switch

Push the reverse fan switch to enable manual mode (reverse engine fan indicator light on).

NOTE:

Reverse fan function cannot be operated twice within 1 minute. Wait 1 minute before
attempting to reverse fan direction again.

LISTEN/LOOK: Does fan reverse direction and operate at full speed for 15 seconds?

Fan will change directions and operate at normal speed.

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Verify that function is enabled in the CMU machine configuration menu. See CAN Monitor Unit (CMU) Menu
Structure—Service Mode . (Group 9015-20.)

If function is enabled, see Hydraulic Fan Drive Operation . (Group 9026-05.)

4J Blade Control Lever Check

Action:

T8404AC-UN: Control Valve Linkage and Float Detent

LEGEND:
A - Blade Tilt Right
B - Blade Lift
590
 Operational Checkout
C - Blade Tilt Left
D - Blade Down
E - Blade Float

Push hydraulic enable switch to the LOCKED position to disable the pilot controls.

Move control lever to positions (A—D) and release.

LOOK/FEEL: Does blade control lever move to all positions easily and return to neutral when released?

NOTE:

Blade control lever will not return to neutral when moved to blade float position (E). Lever
must be manually pulled from float position.

Record of Actual Results:

Result:
YES:
Check complete.
NO:
If functions hesitate or do not operate smoothly, see Hydraulic System Diagnose Malfunctions . (Group 9025-
15.) See Hydraulic System Diagnose Malfunctions—IGC . (Group 9025-15.)

4K Hydraulic Enable Circuit Check

Action:

T194312-UN: Hydraulic Enable Switch

Operate engine at slow idle.

Hydraulic enable switch in the LOCKED position. Pilot controls disabled.

Move blade control lever to all positions.

LOOK: Do any blade functions operate?

Record of Actual Results:

591
 Operational Checkout

Result:
YES:
Check hydraulic enable switch and circuit. See System Functional Schematic and Section Legend . (Group
9015-10.)
NO:
Continue check.
Action:

Push hydraulic enable switch to the UNLOCKED position to enable the pilot controls.

Move blade control lever to all positions.

LOOK: Do all blade functions operate?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Check hydraulic enable switch and circuit. See System Functional Schematic and Section Legend . (Group
9015-10.)

4L Hydraulic Controls Check

Action:

Operate engine at slow idle.

NOTE:

For machines equipped with IGC, put blade control in manual mode by pushing the IGC
on/off button located on the joystick handle. The blade control is in manual mode when the
auto blade light on the CMU is off.

Slowly move blade control lever to all positions except blade float detent.

For machines equipped with PAT and IGC, push blade angle buttons on joystick handle to rotate blade in
both directions.

LOOK/FEEL: Do all blade functions operate smoothly, without hesitation?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
See Hydraulic System Diagnose Malfunctions and/or See Hydraulic System Diagnose Malfunctions—IGC .

592
 Operational Checkout
(Group 9025-15.)

4M Quick-Drop Valve Check (Outside Dozers Only)

Action:

Operate engine at fast idle.

Raise blade to maximum height.

NOTE:

Quick-Drop is activated when control lever is in float position or when lever is at the end of
power down position.

Move control lever to float position and record time it takes to lower blade to ground from maximum height.

LOOK: Does it take 1 second or less for blade to lower to ground with Quick-Drop activated?

Raise blade after blade has been lowered with quick drop valve.

LOOK: Does blade raise immediately?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
See Quick-Drop Valve Operation . (Group 9025-05.)

4N Blade Float Check

Action:

Operate engine at slow idle.

Raise front of machine off ground by fully lowering and tilting blade.

Push hydraulic control lever into float detent position.

LOOK: Does front of crawler lower to ground?

FEEL: Does hydraulic control lever stay in float detent position?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
593
 Operational Checkout
Check blade float detent coil and hydraulic enable circuit. See System Functional Schematic and Section
Legend . (Group 9015-10.)

4O Cycle Time Check

Action:

Use the CAN Monitor Unit (CMU) or Service ADVISOR™ Diagnostic Application to read engine rpm and
hydraulic oil temperature.

Item Measurement Specification

Hydraulic Oil Temperature 57—66°C
135—150°F
Engine Speed Fast Idle
Blade Raise—OSD Cycle Time 2.8 seconds
Blade Raise—PAT Cycle Time 2.9 seconds
Blade Power Down—OSD Cycle Time 2.2 seconds
Blade Power Down—PAT Cycle Time 1.8 seconds
Blade Tilt Left—OSD Cycle Time 1.0 seconds
Blade Tilt Left—PAT Cycle Time 1.4 seconds
Blade Tilt Right—750J OSD Cycle Time 1.0 seconds
Blade Tilt Right—PAT Cycle Time 1.4 seconds
Blade Angle Left—PAT and IGC Cycle Time 4.0 seconds
Blade Angle Right—PAT and IGC Cycle Time 4.1 seconds

Do cycle times meet or exceed specification?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Check hydraulic pump. See Hydraulic Pump Flow Test . (Group 9025-25.)

4P Air Conditioner Check—If Equipped

Action:

594
 Operational Checkout
TX1114381A-UN: Air Conditioning Controls
LEGEND:
1 - Air Conditioning Switch
2 - Blower Switch
3 - Temperature Control
4 - Air Duct (8 used)

Operate engine at fast idle.

Turn air conditioner switch (1) to on position. On position is up (snow flake). Position down is not used for
this test.

Turn blower switch (2) to 4th position.

Wait for any warm air in duct system to dissipate.

FEEL: Is air from ducts cool?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
See Air Conditioning System Diagnose Malfunctions . (Group 9031-15.)

Go to Section_9005:Group_10

LW86157,0000161-19-20120525

595
 Table of Contents

Section 9010: Engine

Group 05: Theory of Operation

PowerTech™ E 6.8 L (6068) John Deere Engine

Group 15: Diagnostic Information

PowerTech™ E 6.8 L (6068) John Deere Engine

Engine Cooling System Component Location

Engine Fuel System Component Location

Engine Intake and Exhaust Component Location

Group 25: Tests

Slow and Fast Idle Test

Intake Manifold Pressure Test—Turbocharger Boost

Fuel Supply Pump Pressure Test

596
 PowerTech™ E 6.8 L (6068) John Deere Engine

PowerTech™ E 6.8 L (6068) John Deere Engine

For more information on John Deere PowerTech™ E engines and components, see the following
Component Technical Manuals (CTMs):

POWERTECH™ 4.5L and 6.8L 4045 and 6068 Diesel Engines—Base Engine . (CTM104.)
PowerTech™ E 4.5 and 6.8 L Diesel Engines—Level 16 Electronic Fuel System with Denso HPCR .
(CTM502.)

Go to Section_9010:Group_05

KK70125,0000003-19-20120822

597
 PowerTech™ E 6.8 L (6068) John Deere Engine

PowerTech™ E 6.8 L (6068) John Deere Engine

For more information on John Deere PowerTech™ E engines and components, see the following
Component Technical Manuals (CTMs):

POWERTECH™ 4.5L and 6.8L 4045 and 6068 Diesel Engines—Base Engine . (CTM104.)
PowerTech™ E 4.5 and 6.8 L Diesel Engines—Level 16 Electronic Fuel System with Denso HPCR .
(CTM502.)

Go to Section_9010:Group_05

KK70125,0000003-19-20120822

598
 PowerTech™ E 6.8 L (6068) John Deere Engine

PowerTech™ E 6.8 L (6068) John Deere Engine

For more information on John Deere PowerTech™ E engines and components, see the following
component technical manuals (CTMs):

POWERTECH™ 4.5L and 6.8L 4045 and 6068 Diesel Engines—Base Engine . (CTM104.)
PowerTech™ E 4.5 and 6.8 L Diesel Engines—Level 16 Electronic Fuel System with Denso HPCR .
(CTM502.)
Alternators and Starting Motors . (CTM77.)

Go to Section_9010:Group_15

JW40272,0000027-19-20100722

599
 PowerTech™ E 6.8 L (6068) John Deere Engine

PowerTech™ E 6.8 L (6068) John Deere Engine

For more information on John Deere PowerTech™ E engines and components, see the following
component technical manuals (CTMs):

POWERTECH™ 4.5L and 6.8L 4045 and 6068 Diesel Engines—Base Engine . (CTM104.)
PowerTech™ E 4.5 and 6.8 L Diesel Engines—Level 16 Electronic Fuel System with Denso HPCR .
(CTM502.)
Alternators and Starting Motors . (CTM77.)

Go to Section_9010:Group_15

JW40272,0000027-19-20100722

600
 Engine Cooling System Component Location

Engine Cooling System Component Location

TX1018770-UN: Engine Cooling System

LEGEND:
1 - Fan Shroud
2 - Fan
3 - Radiator
4 - Coolant Overfill Tank
5 - Hydrostatic Oil Cooler
6 - Charge Air Cooler

601
Engine Cooling System Component Location

Go to Section_9010:Group_15

AA95137,000074C-19-20070212

602
 Engine Fuel System Component Location

Engine Fuel System Component Location

TX1018807-UN: Engine Fuel System (right side)

LEGEND:
1 - Fuel Tank
2 - Fuel Leak-Off Line
3 - Primary Fuel Filter/Water Separator
4 - Fuel Supply Pump
5 - Final Fuel Filter
6 - Fuel Supply Line
7 - Fuel Level Sensor

603
 Engine Fuel System Component Location
TX1018805-UN: Engine Fuel System (left side)
LEGEND:
1 - Fuel Tank
2 - Fuel Leak-Off Line
6 - Fuel Supply Line
8 - Fuel Injection Pump
9 - Fuel Injection Nozzle
10 - Fuel Rail
11 - Fuel Rail Pressure Sensor

Go to Section_9010:Group_15

AA95137,000074B-19-20070212

604
 Engine Intake and Exhaust Component Location

Engine Intake and Exhaust Component Location

TX1018810-UN: Engine Intake and Exhaust System (left side)

LEGEND:
1 - Charge Air Cooler
2 - Muffler
3 - Air Filter Housing
4 - Turbocharger Compressor
5 - Exhaust Manifold
6 - Turbocharger Turbine

605
 Engine Intake and Exhaust Component Location

TX1018942-UN: Engine Intake and Exhaust System (right side)

LEGEND:
3 - Air Filter Housing
7 - Intake Manifold

Go to Section_9010:Group_15

AA95137,000074A-19-20070212

606
 Slow and Fast Idle Test

Slow and Fast Idle Test

-: Specifications

SPECIFICATIONS

Engine Coolant Temperature Normal Operating Temperature

Engine Speed (slow idle) 880—910 rpm

Engine Speed (fast idle) 2255—2285 rpm

Use this test to check engine speeds, engine speeds can not be adjusted on this machine.

1. CAUTION:
Prevent possible injury from unexpected machine movement. Machine must be in
neutral when performing this test.

Run engine until it is at normal operating temperature zone on monitor display.

Item Measurement Specification

Engine Coolant Temperature Normal Operating Temperature

2. Cycle engine speed control switch from slow to fast idle.

3. Move engine speed control switch to slow idle.

Check engine speed on the standard display monitor (CMU) to verify that slow idle is to specification.
see CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Item Measurement Specification

Engine Speed (slow idle) 880—910 rpm

4. Move engine speed control switch to fast idle.

Check engine speed on the CMU to verify that fast idle is to specification.

Item Measurement Specification

Engine Speed (fast idle) 2255—2285 rpm
5. IMPORTANT:

Engine rpm can not be adjusted.

If slow or fast idle is out of specifications check the following:

Check diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service
ADVISOR™ Diagnostic Application . (Group 9015-20.)
Fuel filter and system
Air cleaner elements
Engine control unit (ECU). See Engine Control Unit (ECU) Circuit Theory of Operation . (Group
9015-15.)

607
Slow and Fast Idle Test

Go to Section_9010:Group_25

JW40272,00000F7-19-20120816

608
 Slow and Fast Idle Test

Slow and Fast Idle Test

-: Specifications

SPECIFICATIONS

Engine Coolant Temperature Normal Operating Temperature

Engine Speed (slow idle) 880—910 rpm

Engine Speed (fast idle) 2255—2285 rpm

Use this test to check engine speeds, engine speeds can not be adjusted on this machine.

1. CAUTION:
Prevent possible injury from unexpected machine movement. Machine must be in
neutral when performing this test.

Run engine until it is at normal operating temperature zone on monitor display.

Item Measurement Specification

Engine Coolant Temperature Normal Operating Temperature

2. Cycle engine speed control switch from slow to fast idle.

3. Move engine speed control switch to slow idle.

Check engine speed on the standard display monitor (CMU) to verify that slow idle is to specification.
see CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Item Measurement Specification

Engine Speed (slow idle) 880—910 rpm

4. Move engine speed control switch to fast idle.

Check engine speed on the CMU to verify that fast idle is to specification.

Item Measurement Specification

Engine Speed (fast idle) 2255—2285 rpm
5. IMPORTANT:

Engine rpm can not be adjusted.

If slow or fast idle is out of specifications check the following:

Check diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service
ADVISOR™ Diagnostic Application . (Group 9015-20.)
Fuel filter and system
Air cleaner elements
Engine control unit (ECU). See Engine Control Unit (ECU) Circuit Theory of Operation . (Group
9015-15.)

609
Slow and Fast Idle Test

Go to Section_9010:Group_25

JW40272,00000F7-19-20120816

610
 Intake Manifold Pressure Test—Turbocharger Boost

Intake Manifold Pressure Test—Turbocharger Boost

-: Specifications

SPECIFICATIONS

Engine Fast Idle Speed 2250—2300 rpm

Transmission Speed Position 1.6

Engine Rated Speed 2100 rpm

Turbocharger Boost Pressure 137—144 kPa

1.37—1.45 bar
20—21 psi

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JT07248 Manifold Pressure Test Gauge

Hose Barb Test Fitting

This procedure is used only as a guide to determine engine condition. The test must be done in an area that
allows the machine to be driven forward and in reverse. This is to circulate hydrostatic (HST) oil between test
runs. If test is done in a confined area, machine must be supported on stands so tracks can turn to circulate HST
oil.

NOTE:

When testing the turbocharger boost pressure, the test must be done with turbo boost at
maximum pressure. Maximum turbo boost pressure can only be obtained when the machine is
under full load with engine at rated speed.

The preferred method of obtaining full load is to operate the machine in the dirt under field
conditions. Since this is not always practical, an alternative method is to use the following test
procedure to simulate field conditions.

The test requires the procedure be performed a minimum of four times.

1.

T119051B-UN: Intake Manifold

LEGEND:
Arrow - Manifold Test Port Location

611
 Intake Manifold Pressure Test—Turbocharger Boost
Remove test port pipe plug and install hose barb test fitting.

NOTE:

Put gauge in operator's station for ease of reading.

2. Connect JT07248 Manifold Pressure Test Gauge to manifold at location shown.

3. Turn key switch ON. Do not start engine.

4. Enable brake control using CMU menu as follows:

1. On the standard display monitor (CMU), enter service mode by pushing and holding MENU for
approximately 5 seconds until three beeps are heard and “service mode” is temporarily
displayed on the screen.

2. Select MACHINE SETTINGS from the CMU main menu.

3. Select BRAKE MODE from the submenu and set the brake mode to TEST.

For more information on navigation using the CMU, see CAN Monitor Unit (CMU) Menu
Structure—Service Mode . (Group 9015-20.)

5. Disable the decelerator mode switch (S8) on the instrument panel. See Operator's Station Harness (W7)
Component Location . (Group 9015-10.)

NOTE:

Disabling decelerator mode of the foot pedal allows engine speed to be pulled down
from high idle to rated speed when doing this test. The DMod will have to be reset to
operator’s preference after test.

6. NOTE:

Turbocharger boost test must be done with engine at fast idle.

Run engine at fast idle. Verify fast idle speed is to specification.

Item Measurement Specification

Engine Fast Idle Speed 2250—2300 rpm

7. CAUTION:
Unexpected movement of tracks can cause personal injury. Park lock lever must
be in up position for this test. Doing this test with park lever down will cause
tracks to turn.

Move park lock lever to LOCK (up) position and set transmission speed to specification.

612
 Intake Manifold Pressure Test—Turbocharger Boost

Item Measurement Specification

Transmission Speed Position 1.6

8. IMPORTANT:

To prevent damage to multi-function valves, the test software limits the test function to 13 seconds
before returning TCU to neutral. The TCL must be manually returned to neutral to reset test program.
The tracks must be operated between test function to prevent localized overheating of multi-function
valves. Rotating the tracks will circulate some hot oil out of closed loop circuit to the hydrostatic oil
reservoir for cooling.

1. Depress decelerator pedal to lower stop and hold in that position.

2. Move transmission control lever (TCL) to forward detent.

3. Slowly release foot pedal to pull engine down to rated speed. Record engine speed and
highest pressure reading.

Item Measurement Specification

Engine Rated Speed 2100 rpm

If rated engine speed is not obtained with TCL in forward position, it may be necessary
to move the TCL lever to right or left steering position to obtain rated speed.

Pulling the engine down and relieving load, then pulling engine down again will cause
the turbocharger to build pressure so highest reading can be read. Do this as often as
you can during each 13 second shop test mode. This is why test sequence must be
repeated a minimum of four times.

9. Return TCL to neutral for approximately 15 seconds before repeating test procedure.

10. Repeat test procedure at least four times. Use highest reading to compare to specification.

Item Measurement Specification

Turbocharger Boost Pressure 137—144 kPa
1.37—1.44 bar
20—21 psi

11. If boost pressure is too low, check and repair as required the following components:

Restricted air filter elements

Restricted fuel filter elements
Exhaust manifold leaks
Intake manifold leaks
Malfunctioning fuel transfer pump
Low compression pressure
Malfunctioning fuel injection nozzles
Carbon buildup in turbocharger
Turbocharger compressor or turbine wheel rubbing housing
Low fuel delivery from high pressure fuel pump

IMPORTANT:

Any internal inspection and repair of the high pressure fuel pump must be done by an authorized fuel
613
 Intake Manifold Pressure Test—Turbocharger Boost
pump service center.

If boost pressure is too high, greater than twice the minimum specification, remove high pressure fuel
pump and have it tested for high fuel delivery by an authorized fuel pump service center.

12. Set brake mode back to NORMAL and return the CMU to “operator’s mode”. See CAN Monitor Unit
(CMU) Menu Structure—Service Mode . (Group 9015-20.)

Go to Section_9010:Group_25

JW40272,00000F8-19-20120816

614
 Fuel Supply Pump Pressure Test

Fuel Supply Pump Pressure Test

T108450-UN: Fuel Filter

LEGEND:
A - Auxiliary Outlet Port

-: Specifications

SPECIFICATIONS

Engine Speed Slow Idle

Fuel Pressure 15—30 kPa

0.15—0.3 bar
2—4 psi

-: Essential Tools

ESSENTIAL TOOLS

JT05487 Test Fitting

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JT03092 Pressure Gauge 0—200 kPa (0—2 bar) (0—30 psi)

1. Connect fitting and gauge to fuel filter base auxiliary outlet port (A).

2. Run engine at test specification and record fuel pressure.

Item Measurement Specification

Engine Speed Slow Idle
Fuel Pressure 15—30 kPa
0.15—0.3 bar
2—4 psi

3. If fuel pressure is low, check for:

615
 Fuel Supply Pump Pressure Test
Partially closed fuel tank shutoff valve.
Pinched or kinked fuel lines.
Injection pump overflow valve stuck open.
Fuel transfer pump malfunctioning.

4. To help isolate the cause of low pressure, connect a hose to transfer pump inlet and put the other end
into a container of fuel. Repeat test. If fuel pressure increases to normal, the malfunction is between the
tank and fuel transfer pump. If pressure is still low, the malfunction is in the fuel transfer pump or
injection pump overflow valve.

5. If fuel pressure is high, check for:

Plugged fuel filters.

Restricted fuel return hose or leak-off lines.

Go to Section_9010:Group_25

JW40272,00000F9-19-20120816

616
 Table of Contents

Section 9015: Electrical System

Group 05: System Information

Electrical Diagram Information

Group 10: System Diagrams

Fuse and Relay Specifications

System Functional Schematic, Wiring Diagram, and Component Location Legend

System Functional Schematic and Section Legend

JDLink™ System Functional Schematic—MIG/GTT

JDLink™ System Functional Schematic—MTG/SAT

Operator's Station Harness (W7) Component Location

Operator's Station Harness (W7) Wiring Diagram

Canopy Roof Harness (W8) Component Location

Canopy Roof Harness (W8) Wiring Diagram

Cab Roof Harness (W9) Component Location

Cab Roof Harness (W9) Wiring Diagram

Engine Harness (W10) Component Location

Engine Harness (W10) Wiring Diagram

Transmission Harness (W11) Component Location

Transmission Harness (W11) Wiring Diagram

Air Conditioning Harness (W14) Component Location

Air Conditioning Harness (W14) Wiring Diagram

Radio Harness (W15) Component Location

Radio Harness (W15) Wiring Diagram

IGC Machine Harness (W21) and IGC Cab Harness (W22) Component Location—If Equipped

Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped

Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped

Pressure Sensor Harness (W27) Wiring Diagram

JDLink™ System Harnesses Component Location—MIG/GTT

JDLink™ System Harnesses Component Location—MTG/SAT

JDLink™ System Wiring Diagrams—MIG/GTT

JDLink™ System Wiring Diagrams—MTG/SAT

Group 15: Sub-System Diagnostics

617
 Table of Contents
Starting and Charging Circuit Theory of Operation

Controller Area Network (CAN) Circuit Theory of Operation

Engine Control Unit (ECU) Circuit Theory of Operation

Transmission Control Unit (TCU) Circuit Theory of Operation

CAN Monitor Unit (CMU) Circuit Theory of Operation

Integrated Grade Control (IGC) Theory of Operation—If Equipped

JDLink™ Circuit Theory of Operation—If Equipped

Group 20: References

Electrical Component Specifications

Diagnostic Trouble Codes (DTC) Quick Reference List

Service ADVISOR™ Diagnostic Application

Service ADVISOR™ Connection Procedure

Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application

JDLink™ System Identification

JDLink™ Connection Procedure—If Equipped

CAN Monitor Unit (CMU) Menu Structure—Service Mode

Integrated Grade Control (IGC) Checks—If Equipped

Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped

Alternator Test

CAN Circuit Test

Transmission Control Unit (TCU) Calibration

Wire Harness Test

Decelerator/Brake Pedal Adjustment

Engine Speed Control Remove and Install

Rotary Sensor Remove and Install

Transmission Control Lever (TCL) Adjustment

Bussed Sensor Connectors (X6 and X7) Diagnostics

Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector

Install Weather Pack™ Contact

Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Connectors

Replace DEUTSCH DEUTSCH is a trademark of Deutsch Co. Rectangular or Triangular

Connectors

Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Contact

618
 Table of Contents
Repair 32 and 48 Way CINCH™ Connectors

Replace (Pull Type) Metri-Pack™ Connectors

Replace (Push Type) Metri-Pack™ Connectors

619
 Electrical Diagram Information

Electrical Diagram Information

NOTE:

All System Functional Schematics, Circuit Schematics, and Wiring Diagrams are shown with key
switch in the OFF position.

System Functional Schematic Diagram

TX1087288-UN: System Functional Schematic Diagram

LEGEND:
1 - Continuity Chart
2 - Wire Bundle

620
 Electrical Diagram Information
3 - Routing Location Information
4 - Wire Identification
5 - Wire Splice
6 - Coordinate Letter
7 - Coordinate Number
8 - Component Name
9 - Component Identification Number
10 - Component Schematic Symbol

The System Functional Schematic is made up of sections which contain one harness. The harnesses are
separated by dashed lines and are laid out to match their relative position on the machine. Components can
easily be found by using the coordinate system. The coordinate letter (6) is located on the left and right sides of
the schematic while the coordinate number (7) is located on the top and bottom.

Each electrical component is shown by a schematic symbol (10), the component name (8), and a component
identification number (9). A component identification number and name will remain the same throughout the
Operation and Test Technical Manual. This will allow for easy cross-referencing of all electrical drawings
(Schematics, Wiring Diagrams, and Component Location). A continuity chart (1) is included for each multi-
terminal switch.

When two or more wires converge to form a single dark line, it is a wire bundle (2). A wire bundle represents a
group of wires that can be easily followed but are not joined together.

Routing location information (3) is presented to let the reader know when a wire is connected to a component in
another section. TO and FROM statements identify when power is going “To” or coming “From” a component in a
different location. Both the coordinate letter and number will be called out separated by a colon. The component
number and pin number are given at the bottom of the statement. In the example, power is coming from
component X3 ECU connector 3, in coordinate B:27. A wire splice (5) is represented by two or more wires
connected by a dot.

Wiring Diagram

621
 Electrical Diagram Information

TX1088140-UN: Wiring Diagram Example

LEGEND:
1 - Component Identification Number
2 - Connector
3 - Connector Face View
4 - Wire Harness
5 - Wire Number
6 - Wire Splice
7 - Wire End #1 Termination Location
8 - Wire Number
9 - Wire Color
10 - Wire End #2 Termination Location

622
 Electrical Diagram Information
Each harness on the machine is drawn showing connectors, wires, and splices. A “W” component identification
number identifies harnesses. (W6, etc.) The harness is drawn showing spatial arrangement of components and
branches.

A component identification or connector number (1) identifies each component. The wire harness (4) is terminated
by a top or side view of the connector (2). If more than one wire is supplied to the connector, a harness side
connector face view (3) is provided. Each wire number is labeled for the appropriate pin. If only one wire is
supplied to the connector, the wire number (5) is indicated.

An “X” component identification number of 100 or higher identifies splices (6). Each splice lists side A wires and
side B wires to differentiate the side of the harness that the wires come from.

A wire legend is provided for each harness. A component identification number is listed in the “END #1” column
(7) to indicate the termination location of one end of a wire. In the center, the wire number (8) and wire color (9)
are listed. A component identification number in the “END #2” column (10) identifies the opposite end of the wire.

Component Location Diagram

The Component Location Diagram is a pictorial view by harness showing location of all electrical components,
connectors, harness main ground locations and harness band and clamp location. Each component will be
identified by the same identification letter/number and description used in the System Functional Schematic
Diagram.

Go to Section_9015:Group_05

KK70125,00005B4-19-20110216

623
 Electrical Diagram Information

Electrical Diagram Information

NOTE:

All System Functional Schematics, Circuit Schematics, and Wiring Diagrams are shown with key
switch in the OFF position.

System Functional Schematic Diagram

TX1087288-UN: System Functional Schematic Diagram

LEGEND:
1 - Continuity Chart
2 - Wire Bundle

624
 Electrical Diagram Information
3 - Routing Location Information
4 - Wire Identification
5 - Wire Splice
6 - Coordinate Letter
7 - Coordinate Number
8 - Component Name
9 - Component Identification Number
10 - Component Schematic Symbol

The System Functional Schematic is made up of sections which contain one harness. The harnesses are
separated by dashed lines and are laid out to match their relative position on the machine. Components can
easily be found by using the coordinate system. The coordinate letter (6) is located on the left and right sides of
the schematic while the coordinate number (7) is located on the top and bottom.

Each electrical component is shown by a schematic symbol (10), the component name (8), and a component
identification number (9). A component identification number and name will remain the same throughout the
Operation and Test Technical Manual. This will allow for easy cross-referencing of all electrical drawings
(Schematics, Wiring Diagrams, and Component Location). A continuity chart (1) is included for each multi-
terminal switch.

When two or more wires converge to form a single dark line, it is a wire bundle (2). A wire bundle represents a
group of wires that can be easily followed but are not joined together.

Routing location information (3) is presented to let the reader know when a wire is connected to a component in
another section. TO and FROM statements identify when power is going “To” or coming “From” a component in a
different location. Both the coordinate letter and number will be called out separated by a colon. The component
number and pin number are given at the bottom of the statement. In the example, power is coming from
component X3 ECU connector 3, in coordinate B:27. A wire splice (5) is represented by two or more wires
connected by a dot.

Wiring Diagram

625
 Electrical Diagram Information

TX1088140-UN: Wiring Diagram Example

LEGEND:
1 - Component Identification Number
2 - Connector
3 - Connector Face View
4 - Wire Harness
5 - Wire Number
6 - Wire Splice
7 - Wire End #1 Termination Location
8 - Wire Number
9 - Wire Color
10 - Wire End #2 Termination Location

626
 Electrical Diagram Information
Each harness on the machine is drawn showing connectors, wires, and splices. A “W” component identification
number identifies harnesses. (W6, etc.) The harness is drawn showing spatial arrangement of components and
branches.

A component identification or connector number (1) identifies each component. The wire harness (4) is terminated
by a top or side view of the connector (2). If more than one wire is supplied to the connector, a harness side
connector face view (3) is provided. Each wire number is labeled for the appropriate pin. If only one wire is
supplied to the connector, the wire number (5) is indicated.

An “X” component identification number of 100 or higher identifies splices (6). Each splice lists side A wires and
side B wires to differentiate the side of the harness that the wires come from.

A wire legend is provided for each harness. A component identification number is listed in the “END #1” column
(7) to indicate the termination location of one end of a wire. In the center, the wire number (8) and wire color (9)
are listed. A component identification number in the “END #2” column (10) identifies the opposite end of the wire.

Component Location Diagram

The Component Location Diagram is a pictorial view by harness showing location of all electrical components,
connectors, harness main ground locations and harness band and clamp location. Each component will be
identified by the same identification letter/number and description used in the System Functional Schematic
Diagram.

Go to Section_9015:Group_05

KK70125,00005B4-19-20110216

627
 Fuse and Relay Specifications

Fuse and Relay Specifications

IMPORTANT:

Install fuse with correct amperage rating to prevent electrical system damage from overload.

The Vehicle Electrical Center (VEC) is located in the operator's station. See Operator's Station Harness (W7)
Component Location . (Group 9015-10.)

T203636-UN: Vehicle Electrical Center (VEC)

LEGEND:
F1 - Condenser Fan Motor 2 15-Amp Fuse
F2 - Condenser Fan Motor 1 15-Amp Fuse
F3 - Service ADVISOR™ 5-Amp Fuse (Switched Power)
F4 - CMU 5-Amp Fuse (Switched Power)
F5 - Alternator Excitation 5-Amp Fuse
F6 - TCU Power 10-Amp Fuse
F7 - Fuel Heater 10-Amp Fuse
F8 - Dome Light 5-Amp Fuse
F9 - Pilot Enable 5-Amp Fuse (Switched Power)

628
 Fuse and Relay Specifications
F10 - Under-Seat Heater 15-Amp Fuse
F11 - Winch Switch/Solenoids 5-Amp Fuse
F12 - Heater Blower 15-Amp Fuse
F13 - Start Aid 15-Amp Fuse
F14 - Airseat 10-Amp Fuse
F15 - Switch LED (Backlight) Circuit 5-Amp Fuse
F16 - Optional Powerport 10-Amp Fuse
F17 - Spare 15-Amp Fuse
F18 - Heater Valve 5-Amp Fuse
F19 - Horn 5-Amp Fuse
F20 - Radio Memory 5-Amp Fuse
F21 - Front/Rear Wiper Motor 10-Amp Fuse
F22 - Right/Left Wiper Motor 10-Amp Fuse
F23 - Standard Powerport 10-Amp Fuse
F24 - Air Conditioning Compressor Clutch 5-Amp Fuse
F25 - Start Relay 10-Amp Fuse
F26 - ECU 5-Amp Fuse (Switched Power)
F27 - Spare 10-Amp Fuse
F28 - CMU 5-Amp Fuse (Unswitched Power)
F29 - ECU 15-Amp Fuse (Unswitched Power)
F30 - Auxiliary Work Light 20-Amp Circuit Breaker (Marked CB1)
F31 - Standard Work Light 15-Amp Circuit Breaker (Marked CB2)
F33 - Main 125-Amp Fuse
K1 - Condenser Fan 2 Relay
K2 - Condenser Fan 1 Relay
K3 - Optional 10-Amp Converter Relay
K4 - Auxiliary Work Light Relay
K5 - Wiper Relay
K6 - Standard Work Light Relay
K7 - Air Conditioning Compressor Clutch Relay
K8 - Horn Relay
V1 - Alternator Excitation 3-Amp Diode

NOTE:

The following items are located outside of the VEC:

A8—IGC Load Center (IGC Machines Only) ( SE39 , W21 )

F33—Main 125-Amp Fuse ( SE1 , W11 )
K9—Start Relay ( SE2 , W10 )
K10—Accessory Relay 1 ( SE4 , W7 )
K11—Accessory Relay 2 ( SE4 , W7 )
V2—Starter Solenoid 5-Amp Diode ( SE1 , W10 )
V3—Start Relay 1-Amp Diode ( SE2 , W10 )
V4—Air Conditioning Compressor Clutch 5-Amp Diode ( SE3 , W10 )
V5—Door Wiper Diode ( SE26 , W9 )
V6—Front Wiper Diode ( SE25 , W9 )
V7—Rear Wiper Diode ( SE25 , W7 )

Main 125-amp fuse (F33) and IGC Load Center (A8) (if equipped with integrated grade control)
are located in the battery compartment.

629
 Fuse and Relay Specifications

TX1010623-UN: IGC Load Center (If Equipped)

LEGEND:
F101 - IGC Switched Power 15-Amp Fuse (IGC option)
F102 - BCJ Switched Power 5-Amp Fuse (IGC option)
F103 - EHC Switched Power 10-Amp Fuse (IGC option)
F104 - IGC Unswitched Power_1 10-Amp Fuse (IGC option)
F105 - IGC Unswitched Power_2 10-Amp Fuse (IGC option)
F106 - IGC Unswitched Power_3 10-Amp Fuse (IGC option)
K101 - IGC Switched Power Relay (IGC option)
K102 - BCJ and EHC Switched Power Relay (IGC option)

630
 Fuse and Relay Specifications

TX1027203-UN: JDLink™ Inline Fuse Specifications—If Equipped

LEGEND:
F34 - JDLink™ Ground 5-Amp Fuse—If Equipped (S.N. 153829— )
F35 - JDLink™ Switched Power 5-Amp Fuse—If Equipped (S.N. 153829— )
F36 - JDLink™ Unswitched Power 5-Amp Fuse—If Equipped (S.N. 153829— )

Go to Section_9015:Group_10

AA95137,00007BF-19-20100702

631
 Fuse and Relay Specifications

Fuse and Relay Specifications

IMPORTANT:

Install fuse with correct amperage rating to prevent electrical system damage from overload.

The Vehicle Electrical Center (VEC) is located in the operator's station. See Operator's Station Harness (W7)
Component Location . (Group 9015-10.)

T203636-UN: Vehicle Electrical Center (VEC)

LEGEND:
F1 - Condenser Fan Motor 2 15-Amp Fuse
F2 - Condenser Fan Motor 1 15-Amp Fuse
F3 - Service ADVISOR™ 5-Amp Fuse (Switched Power)
F4 - CMU 5-Amp Fuse (Switched Power)
F5 - Alternator Excitation 5-Amp Fuse
F6 - TCU Power 10-Amp Fuse
F7 - Fuel Heater 10-Amp Fuse
F8 - Dome Light 5-Amp Fuse
F9 - Pilot Enable 5-Amp Fuse (Switched Power)

632
 Fuse and Relay Specifications
F10 - Under-Seat Heater 15-Amp Fuse
F11 - Winch Switch/Solenoids 5-Amp Fuse
F12 - Heater Blower 15-Amp Fuse
F13 - Start Aid 15-Amp Fuse
F14 - Airseat 10-Amp Fuse
F15 - Switch LED (Backlight) Circuit 5-Amp Fuse
F16 - Optional Powerport 10-Amp Fuse
F17 - Spare 15-Amp Fuse
F18 - Heater Valve 5-Amp Fuse
F19 - Horn 5-Amp Fuse
F20 - Radio Memory 5-Amp Fuse
F21 - Front/Rear Wiper Motor 10-Amp Fuse
F22 - Right/Left Wiper Motor 10-Amp Fuse
F23 - Standard Powerport 10-Amp Fuse
F24 - Air Conditioning Compressor Clutch 5-Amp Fuse
F25 - Start Relay 10-Amp Fuse
F26 - ECU 5-Amp Fuse (Switched Power)
F27 - Spare 10-Amp Fuse
F28 - CMU 5-Amp Fuse (Unswitched Power)
F29 - ECU 15-Amp Fuse (Unswitched Power)
F30 - Auxiliary Work Light 20-Amp Circuit Breaker (Marked CB1)
F31 - Standard Work Light 15-Amp Circuit Breaker (Marked CB2)
F33 - Main 125-Amp Fuse
K1 - Condenser Fan 2 Relay
K2 - Condenser Fan 1 Relay
K3 - Optional 10-Amp Converter Relay
K4 - Auxiliary Work Light Relay
K5 - Wiper Relay
K6 - Standard Work Light Relay
K7 - Air Conditioning Compressor Clutch Relay
K8 - Horn Relay
V1 - Alternator Excitation 3-Amp Diode

NOTE:

The following items are located outside of the VEC:

A8—IGC Load Center (IGC Machines Only) ( SE39 , W21 )

F33—Main 125-Amp Fuse ( SE1 , W11 )
K9—Start Relay ( SE2 , W10 )
K10—Accessory Relay 1 ( SE4 , W7 )
K11—Accessory Relay 2 ( SE4 , W7 )
V2—Starter Solenoid 5-Amp Diode ( SE1 , W10 )
V3—Start Relay 1-Amp Diode ( SE2 , W10 )
V4—Air Conditioning Compressor Clutch 5-Amp Diode ( SE3 , W10 )
V5—Door Wiper Diode ( SE26 , W9 )
V6—Front Wiper Diode ( SE25 , W9 )
V7—Rear Wiper Diode ( SE25 , W7 )

Main 125-amp fuse (F33) and IGC Load Center (A8) (if equipped with integrated grade control)
are located in the battery compartment.

633
 Fuse and Relay Specifications

TX1010623-UN: IGC Load Center (If Equipped)

LEGEND:
F101 - IGC Switched Power 15-Amp Fuse (IGC option)
F102 - BCJ Switched Power 5-Amp Fuse (IGC option)
F103 - EHC Switched Power 10-Amp Fuse (IGC option)
F104 - IGC Unswitched Power_1 10-Amp Fuse (IGC option)
F105 - IGC Unswitched Power_2 10-Amp Fuse (IGC option)
F106 - IGC Unswitched Power_3 10-Amp Fuse (IGC option)
K101 - IGC Switched Power Relay (IGC option)
K102 - BCJ and EHC Switched Power Relay (IGC option)

634
 Fuse and Relay Specifications

TX1027203-UN: JDLink™ Inline Fuse Specifications—If Equipped

LEGEND:
F34 - JDLink™ Ground 5-Amp Fuse—If Equipped (S.N. 153829— )
F35 - JDLink™ Switched Power 5-Amp Fuse—If Equipped (S.N. 153829— )
F36 - JDLink™ Unswitched Power 5-Amp Fuse—If Equipped (S.N. 153829— )

Go to Section_9015:Group_10

AA95137,00007BF-19-20100702

635
 System Functional Schematic, Wiring Diagram, and Component Location Legend

System Functional Schematic, Wiring Diagram, and Component Location Legend

NOTE:

A1—Transmission Control Unit (TCU) (SE15, W7)

A1 indicates component identification number.

Transmission Control Unit (TCU) indicates component name.
SE15 indicates the section number of system functional schematic where component is
located.
W7 is the identification number of the harness the component is located on. This would
indicate that the TCU is connected to W7 Transmission Harness.

A1—Transmission Control Unit (TCU) ( SE15 , W7 )

A2—Engine Control Unit (ECU) ( SE35 , W10 )
A3—CAN Monitor Unit (CMU) ( SE23 , W7 )
A5—Radio ( SE28 , W15 )
A6—Vehicle Electrical Center (VEC) ( SE5 , SE6 , SE7 , SE8 , SE9 , W7 , W9 )
A8—IGC Load Center (IGC option) ( SE39 , W21 )
A9—Blade Control Joystick (BCJ) (IGC option) ( SE37 , W22 )
A11—Electrohydraulic Controller (EHC) (IGC option) ( SE37 , SE38 , W21 )
A12—Machine Information Gateway (MIG) Controller—If Equipped (S.N. 153829— )
A13— GlobalTRACS® Terminal (GTT) Controller—If Equipped (S.N. 153829— )
A6000—Modular Telematics Gateway (MTG) Control Unit ( SE55 , W6002 )
A6001—GPS/Cellular Antenna ( SE55 , W6002 )
A6002—Satellite (SAT) Control Unit ( SE55 , W6003 )
A6003—Satellite Antenna ( SE55 , W6003 )
B1—Decelerator Sensor ( SE13 , W7 )
B2—Motor Speed Sensor Left ( SE13 , W11 )
B3—Motor Speed Sensor Right ( SE13 , W11 )
B4—Hydrostatic Charge Pressure Sensor (S.N. —173641) ( SE12 , W11 )
B5—Hydrostatic Pressure Sensor Right (S.N. —173658) ( SE12 , W11 )
B6—Hydrostatic Pressure Sensor Left (S.N. —173658) ( SE12 , W11 )
B7—Pump Pressure Control Pilot (PCP) Rear ( SE16 , W10 )
B8—Pump Pressure Control Pilot (PCP) Front ( SE16 , W10 )
B9—Quick-Drop Pressure Switch ( SE19 , W11 )
B10—Fuel Rail Pressure Sensor ( SE34 , W10 )
B11—Fuel Temperature Sensor ( SE34 , W10 )
B12—Engine Coolant Temperature Sensor ( SE34 , W10 )
B13—Manifold Air Temperature Sensor ( SE34 , W10 )
B14—Crankshaft Position Sensor ( SE34 , W10
B15—Camshaft Position Sensor ( SE34 , W10
B16—Ambient Air Temperature Sensor ( SE34 , W10
B17—Engine Oil Pressure Sensor ( SE34 , W10
B18—Water-in-Fuel Sensor ( SE34 , W10
B19—Fuel Level Sensor ( SE23 , W11 )
B20—Hydraulic Oil Temperature Sensor ( SE24 , W11 )
B21—Hydrostatic (transmission) Oil Temperature Sensor ( SE24 , W11 )
B22—Air Filter Restriction Switch ( SE24 , W10
B23—Hydraulic Oil Filter Restriction Switch ( SE23 , W11 )
B24—Hydraulic Fan Oil Filter Restriction Switch ( SE24 , W11 )
B25—Hydrostatic (transmission) Charge Oil Filter Restriction Switch ( SE24 , W11 )
B27—Air Conditioning Freeze Switch ( SE21 , W14 )
B30—Right Speaker ( SE28 , W15 )
B31—Left Speaker ( SE28 , W15 )
B32—TCL Sensor ( SE14 , W7 )
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 System Functional Schematic, Wiring Diagram, and Component Location Legend
B33—Steer Sensor ( SE14 , W7 )
B34—Transmission Speed Control Switch ( SE14 , W7 )
B35—Brake Pressure Sensor (S.N. —173641) ( SE12 , W11 )
B41—Hydrostatic Charge Pressure Sensor (S.N. 173642— ) ( SE12 , W11 )
B42— Brake Pressure Sensor (S.N. 173642— ) ( SE12 , W11 )
B43—Hydrostatic Pressure Sensor Right (S.N. 173659— ) ( SE12 , W11 )
B44—Hydrostatic Pressure Sensor Left (S.N. 173659— ) ( SE12 , W11 )
B46—Fuel Heater Temperature Switch (if equipped) ( SE10 , W11 )
B50—A/C Binary Pressure Switch SE21 , W14 )
E1—Dome Light ( SE32 , W9 )
E2—Standard Work Light Left Front ( SE30 , W10 )
E3—Standard Work Light Right Front ( SE30 , W10 )
E4—Auxiliary Work Light Left Rear ( SE31 , W8 , W9 )
E5—Standard Work Light Right Rear ( SE30 , W8 , W9 )
E6—Auxiliary Work Light Left Front ( SE31 , W8 , W9 )
E7—Auxiliary Work Light Right Front ( SE31 , W8 , W9 )
E9—Auxiliary Work Light Right Rear ( SE31 , W8 , W9 )
F1—Condenser Fan Motor 2 15 Amp Fuse ( VEC ) ( SE6 )
F2—Condenser Fan Motor 1 15 Amp Fuse ( VEC ) ( SE6 )
F3—Service ADVISOR™ Power 5 Amp Fuse ( VEC ) ( SE8 )
F4—CMU Power 5 Amp Fuse ( VEC ) ( SE9 )
F5—Alternator Excitation 5 Amp Fuse ( VEC ) ( SE8 )
F6—TCU Power 10 Amp Fuse ( VEC ) ( SE7 )
F7—Fuel Heater 10 Amp Fuse ( VEC ) ( SE8 )
F8—Dome Light 5 Amp Fuse ( VEC ) ( SE6 )
F9—Pilot Enable Ignition Power 5 Amp Fuse ( VEC ) ( SE8 )
F10—Under-Seat Heater 15 Amp Fuse ( VEC ) ( SE8 )
F11—Winch Switch/Solenoids 5 Amp Fuse ( VEC ) ( SE5 )
F12—Heater Blower 15 A Fuse ( VEC ) ( SE5 )
F13—Start Aid 15 Amp Fuse ( VEC ) ( SE9 )
F14—Airseat 10 Amp Fuse ( VEC ) ( SE9 )
F15—Switch LED (backlight) Circuit 5 Amp Fuse ( VEC ) ( SE8 )
F16—Optional Powerport 10 Amp Fuse ( VEC ) ( SE9 )
F17—Spare 15 Amp Fuse ( VEC ) ( SE7 )
F18—Heater Valve 5 Amp Fuse ( VEC ) ( SE6 )
F19—Horn 5 Amp Fuse ( VEC ) ( SE9 )
F20—Radio Memory 5 Amp Fuse ( VEC ) ( SE8 )
F21—Front/Rear Wiper Motor 10 Amp Fuse ( VEC ) ( SE6 )
F22—Right/Left Wiper Motor 10 Amp Fuse ( VEC ) ( SE6 )
F23—Standard Powerport 10 Amp Fuse ( VEC ) ( SE5 )
F24—Air Conditioning Compressor Clutch 5 Amp Fuse ( VEC ) ( SE6 )
F25—Start Relay 10 Amp Fuse ( VEC ) ( SE9 )
F26—ECU Ignition Power 5 Amp Fuse ( VEC ) ( SE9 )
F27—Spare 10 Amp Fuse ( VEC ) ( SE8 )
F28—CMU Battery Power 5 Amp Fuse ( VEC ) ( SE8 )
F29—ECU Battery Power 15 Amp Fuse ( VEC ) ( SE8 )
F30—Auxiliary Work Light 20 Amp Circuit Breaker (CB1) ( VEC ) ( SE5 )
F31—Standard Work Light 15 Amp Circuit Breaker (CB2) ( VEC ) ( SE5 )
F33—Main 125 Amp Fuse ( SE1 , W21 )
F34— JDLink™ Ground 5 Amp Fuse—If Equipped (S.N. 153829— )
F35—JDLink™ Switched Power 5 Amp Fuse—If Equipped (S.N. 153829— )
F36—JDLink™ Unswitched Power 5 Amp Fuse—If Equipped (S.N. 153829— )
F101—IGC Switched Power 15 Amp Fuse (IGC option) ( SE39 , W21 )
F102—BCJ Switched Power 5 Amp Fuse (IGC option) ( SE39 , W21 )
F103—EHC Switched Power 10 Amp Fuse (IGC option) ( SE39 , W21 )
F104—IGC Unswitched Power 1 10 Amp Fuse (IGC option) ( SE39 , W21 )

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 System Functional Schematic, Wiring Diagram, and Component Location Legend
F105—IGC Unswitched Power 2 10 Amp Fuse (IGC option) ( SE39 , W21 )
F106—IGC Unswitched Power 3 10 Amp Fuse (IGC option) ( SE39 , W21 )
G1—Batteries ( SE1 )
G2—Jump Start Terminal ( SE1 , W10
G3—Alternator ( SE2 , W10
H1—Horn ( SE3 , W10
H2—Monitor Alarm ( SE23 , W7 )
H3—Backup Alarm ( SE15 , W11 )
H4—Warmup Indicator ( SE35 , W7 )
K1—A/C Condenser Motor Fan 2 Relay ( VEC ) ( SE7 )
K2—A/C Condenser Motor Fan 1 Relay ( VEC ) ( SE7 )
K3—Optional 10 Amp Converter Relay ( VEC ) ( SE9 )
K4—Auxiliary Work Light Relay ( VEC ) ( SE5 )
K5—Wiper Relay ( VEC ) ( SE6 )
K6—Standard Work Light Relay ( VEC ) ( SE5 )
K7—Air Conditioning Compressor Clutch Relay ( VEC ) ( SE6 )
K8—Horn Relay ( VEC ) ( SE9 )
K9—Start Relay ( SE2 , W10 )
K10—Accessory Relay 1 ( SE4 , W7 )
K11—Accessory Relay 2 ( SE4 , W7 )
K101—IGC Switched Power Relay (IGC option) ( SE39 , W21 )
K102—BCJ and EHC Switched Power Relay (IGC option) ( SE39 , W21 )
M1—Starter Motor ( SE1 , W10 )
M2—Heater Valve Motor ( SE20 , W11 )
M3—Heater Blower Motor ( SE20 , W14 )
M4—Air Conditioning Condenser Fan Motor ( SE21 , W17 )
M5—Air Conditioning Condenser Fan Motor ( SE21 , W17 )
M6—Wiper Motor Front ( SE25 or SE40 , W9 )
M7—Wiper Motor Left Door ( SE26 or SE41 , W9 )
M8—Wiper Motor Right Door ( SE26 or SE41 , W9 )
M9—Washer Motor Front/Rear ( SE25 or SE40 , W11 )
M10—Washer Motor Left/Right ( SE26 or SE41 , W11 )
M11—Wiper Motor Rear ( SE25 or SE40 , W7 )
M12—Under-Seat Heater Blower Motor ( SE27 )
M13—Air Seat Motor ( SE33 , W7 )
R1—CAN Termination Resistor (120 ohm) ( SE22 , W7 )
R2—CAN Termination Resistor (120 ohm) ( SE22 , W10 )
R3—Heater Valve Resistor (S.N. 141344—153820) ( SE20 )
R4—Cab Heater Blower Resistor ( SE20 , W14 )
R5—Under-Seat Heater Blower Resistor ( SE27 )
R6—Fuel Heater (if equipped) ( SE10 , W11 )
R7—CAN Termination Resistor (120 ohm) (IGC option) ( SE37 , W22 )
R8—CAN Termination Resistor (120 ohm) (IGC option) ( SE37 , W21 )
R10—Engine Speed Control ( SE11 , W7 )
S1—Key Switch ( SE1 , W7 )
S2—Battery Disconnect Switch ( SE1 )
S4—Blade Angle Switch ( SE12 [pilot control], W7 )
S5—Horn Switch ( SE14 , W7 )
S7—Decelerator Mode Switch ( SE11 , W7 )
S8—Hydraulic Enable Switch ( SE19 [pilot control], SE37 [IGC option], W7 [pilot control], W22 [IGC
option])
S9—Heater Temperature Control Switch ( SE20 , W9 )
S10—Heater Blower Switch ( SE20 , W9 )
S11—Air Conditioning On/Off Switch ( SE21 , W9 )
S12—Front/Rear Wiper Motor Switch ( SE25 or SE40 , W9 )
S13—Left/Right Door Wiper Motor Switch ( SE26 or SE41 , W9 )

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 System Functional Schematic, Wiring Diagram, and Component Location Legend
S14—Dome Light Switch ( SE32 , W9 )
S15—Under-Seat Heater Blower Switch ( SE27 , W7 )
S16—Standard Work Light Switch ( SE30 , W7 )
S17—Auxiliary Work Light Switch ( SE31 , W7 )
S18—Park Lock Lever Switch ( SE2 , W7 )
S19—Start Aid Switch ( SE3 , W7 )
S20—Neutral Start Switch ( SE14 , W7 )
S23—Fan Reversing Switch ( SE24 , W7 )
S25—Air Seat Switch ( SE33 , W7 )
U2—12-Volt Power Converter ( SE28 , W11 )
U3—Optional 12-Volt Power Converter ( SE29 , W20 )
V1—Alternator Excitation 3 Amp Diode ( VEC ) ( SE8 , W10 )
V2—Starter Solenoid 5 Amp Diode ( SE1 , W10 )
V3—Start Relay 1 Amp Diode ( SE2 , W10 )
V4—Air Conditioning Compressor Clutch 5 Amp Diode ( SE3 , W10 )
V5—Door Wiper Diode (S.N. —210213) ( SE26 , W9 )
V5—Left Door Wiper Diode (S.N. 210214— ) ( SE41 , W9 )
V6—Front Wiper Diode (S.N. —210213) ( SE25 , W9 )
V6—Front Wiper Diode 1 (S.N. 210214— ) ( SE40 , W9 )
V7—Rear Wiper Diode ( SE25 or SE40 , W7 )
V10—Right Door Wiper Diode (S.N. 210214— ) ( SE41 , W9 )
V11—Front Wiper Diode 2 (S.N. 210214— ) ( SE40 , W9 )
V12—Front/Rear Wiper Diode (S.N. 210214— ) ( SE40 , W9 )
W1—Radio Antenna ( SE28 , W15 )
W2—Ground to Cab Right Rear ( SE21 , W8 , W9 )
W3—Ground to Frame Under Cab ( W11 )
W4—Ground to Cab Left Rear ( W7 )
W5—HIC Valve Ground ( SE24 , W11 )
W6—Ground to Engine on Starter Motor ( W10 )
W7—Operator's Station Harness
W8—Canopy Roof Harness
W9—Cab Roof Harness
W10—Engine Harness
W11—Transmission Harness
W13—Under-Seat Heater Harness
W14—Air Conditioning Harness
W15—Radio Harness
W16—Standard Fan Drive Harness ( W10 )
W17—Condenser Harness ( W14 )
W18—Fuel Tank Harness ( W11 )
W19—Electronic Injector Harness
W20—Optional Power Converter Harness ( W11 )
W21—Integrated Grade Control (IGC) Machine Harness (IGC option)
W22—Integrated Grade Control (IGC) Cab Harness (IGC option)
W27—Pressure Sensor Harness (4 used) ( W11 , W27 )
W30—Machine Information Gateway (MIG) Harness
W31—GlobalTRACS® Terminal (GTT) Harness (S.N. 153829— )
W33— GTT Antenna (S.N. 153829— ) SE53 )
W34—GTT Harness Ground (S.N. 153829— ) ( W31 )
X1—TCU Connector ( SE15 , W7 )
X2—TCU Connector ( SE15 , W7 )
X3—ECU 30-Pin Connector (L—Y) ( SE35 , W10 )
X4—CMU 16-Pin Connector ( SE23 , W7 )
X5—CMU 14-Pin Connector ( SE23 , W7 )
X6—Bussed + 5-Volt Sensor Connector ( SE11 , W7 )
X7—Bussed Ground Sensor Connector ( SE11 , W7 )

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 System Functional Schematic, Wiring Diagram, and Component Location Legend
X8— Service ADVISOR™ Connector ( SE22 , W7 )
X9—Standard 12-Volt Power Outlet ( SE28 , W7 )
X10—ECU 30-Pin Connector ( SE35 , W10 )
X11—Cab Roof Harness-to-Air Conditioning Harness Connector ( SE20 , SE21 , W14 )
X12—Cab Harness-to-Rear Wiper Harness Connector ( W7 , SE25 )
X13—Operator's Station Harness-to-Roof Harness Connector ( W7 , W8 , W9 )
X16—Operator's Station Harness-to-Transmission Harness Connector 1 ( W7 , W11 )
X17—Operator's Station Harness-to-Transmission Harness Connector 2 ( W7 , W11 )
X18—Operator's Station Harness-to-Transmission Harness Connector 3 ( W7 , W11 )
X19—Engine Harness-to-Transmission Harness Connector W10 , W11 )
X20—Optional 12-Volt Power Converter Connector ( SE29 , W11 , W20 )
X21—Transmission Harness-to-Fuel Tank Harness Connector ( W11 , W18 )
X22—Cab/Canopy Harness-to-Under-Seat Harness Connector ( SE26 , W7 )
X23—Engine Harness-to-Electronic Injector Harness Connector ( SE36 , W10 , W19)
X24—Optional 12-Volt Power Outlet ( SE29 , W7 )
X25—Spare Connector Roof ( SE10 , W10 , W9 )
X26—Spare Connector Right Console ( SE10 , W10 , W7 )
X27—Spare Connector Front Console ( SE10 , W10 , W7 )
X28—Engine Harness-to-Standard Fan Drive Harness Connector ( W10 )
X30—Operator's Station Harness-to-Transmission Harness Connector 4 ( W7 , W11 )
X31—VEC 8-Pin Connector (Gray) ( SE5 , W7 )
X32—VEC 8-Pin Connector (Red) ( SE5 , W7 )
X33—VEC 8-Pin Connector (Black) ( SE6 , W9 )
X34—VEC 8-Pin Connector (Orange) ( SE6 , W9 )
X35—VEC 8-Pin Connector (Blue) ( SE7 , W7 )
X36—VEC 8-Pin Connector (Green) ( SE8 , W7 )
X37—VEC 8-Pin Connector (Brown) ( SE9 , W7 )
X38—VEC 2-Pin Connector (Gray) ( SE9 , W7 )
X39—VEC 2-Pin Connector (Black) ( SE9 , W7 )
X40—Operator's Station-to-Cab Roof Harness Connector ( W7 , W9 )
X41—Cab Roof Harness-to-Radio Harness Connector ( SE28 , W9 , W15 )
X42—Optional 12-Volt Terminal Block ( SE29 , W20 )
X43—Cab Roof Harness-to-Dome Light Connector ( SE32 , W9 )
X50—Battery Power Connector ( W11 )
X51—Air Conditioner Harness-to-Condenser Harness Connector ( W14 , W17 )
X52—TCU Programming Connector ( SE15 , W7 )
X57—JDLink™ MMS Direct 4-Pin Connector (ethernet)—If Equipped (S.N. 153829— ) ( W7 )
X58—GT Config Tool Adapter 6-Pin Connector (RS232)—If Equipped (S.N. 153829— ) ( W7 )
X62—Operator's Station Harness-to-GlobalTRACS® Terminal (GTT) Harness 12-Pin Connector (S.N.
153829— ) ( W7 , W31 )
X63—Operator's Station Harness-to-Machine Information Gateway (MIG) Harness 12-Pin Connector
(S.N. 153829— ) ( W7 , W30 )
X64—GlobalTRACS® Terminal (GTT) 70-Pin Connector—If Equipped (S.N. 153829— ) ( W31 )
X65—Machine Information Gateway (MIG) Harness-to-GlobalTRACS® Terminal (GTT) Harness—If
Equipped (S.N. 153829— ) ( W30 , W31 )
X66—Machine Information Gateway (MIG) 30-Pin (L1—Y3) Connector—If Equipped (S.N. 153829— ) (
W30 )
X67—Machine Information Gateway (MIG) 30-Pin (A1—K3) Connector—If Equipped (S.N. 153829— ) (
W30 )
X70—Charge Pressure Sensor Harness Connector (S.N. 173642— ) ( W11 , W27 )
X71—Brake Pressure Sensor Harness Connector (S.N. 173642— ) ( W11 , W27 )
X72—Right Hydrostatic Pressure Sensor Harness Connector (S.N. 173659— ) ( W11 , W27 )
X73—Left Hydrostatic Pressure Sensor Harness Connector (S.N. 173659— ) ( W11 , W27 )
X79—2-Pin Connector (not used) (IGC option) ( SE39 , W21 )
X80—IGC Power Connector (IGC option) ( W21 )
X81—RS232 Connector (IGC option) ( SE37 , W22 )

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 System Functional Schematic, Wiring Diagram, and Component Location Legend
X82—Electrohydraulic Controller (EHC) Connector (IGC option) ( W21 )
X83—Electrohydraulic Controller (EHC) Connector (IGC option) ( W21 )
X84—Alternator W Terminal Signal Connector ( SE39 , W11 , W22 )
X85—Auxiliary Joystick Connector (IGC option) ( SE37 , W21 )
X86—IGC CAN-to-Machine CAN Connector (IGC option) ( SE37 , W21 )
X87A—IGC Ground Connector (IGC option) ( W21 )
X87B—IGC Ground Connector (IGC option) ( W21 )
X88—IGC Harness 24/12-Volt Converter Connector (IGC option) ( W21 )
X89—IGC Machine Harness-to-Transmission Harness Connector (IGC option) ( W21 , W11 )
X90—Auxiliary IGC Actuator Connector (IGC option) ( SE38 , W21 )
X95—IGC Machine Harness-to-IGC Cab Harness Connector (IGC option) ( W21 , W22 )
X96—IGC Interface Connector (IGC option) ( SE38 , W21 )
X97—BCJ Switch Module Connector (IGC option) ( SE37 , W22 )
X98—BCJ Four-Way Axis Module Connector (IGC option) ( SE37 , W22 )
X99—IGC Ground Connector (IGC option) ( W21 )
X100—T24 BLU Splice ( W11 )
X101—G05 BLK Splice ( W11 )
X102—R12 BLK Splice ( W7 , W11 )
X103—G10 BLK Splice ( W11 )
X104—G11 BLK Splice W10 )
X105—H02 GRN Splice ( W10 )
X106—Shield Ground Splice ( W10 )
X107—R15 BLK Splice ( W10 )
X108—G12 BLK Splice ( W10 )
X109—R13 BLK Splice 1 ( W7 , W10 )
X110—M13 LGRN Splice 1 ( W7 , W10 )
X111—M12 YEL Splice 1 ( W7 , W10 )
X112—L02 BRN Splice ( W7 , W10 )
X116—P31 RED Splice ( W7 )
X117—E05 WHT Splice ( W7 )
X118—G07 BLK Splice ( W7 )
X119—P18 RED Splice ( W7 , W9 )
X120—G03 BLK Splice 1 ( W7 )
X121—B01 RED Splice ( W7 )
X122—L06 BRN Splice ( W7 )
X123—G03 BLK Splice 2 ( W7 )
X124—P28 RED Splice ( W7 )
X125—G02 BLK Splice ( W7 )
X126—P03 RED Splice ( W7 )
X127—R13 BLK Splice 2 ( W7 )
X128—M12 YEL Splice 2 ( W7 )
X129—M13 LGRN Splice 2 ( W7 )
X130—P09 RED Splice ( W9 )
X131—G04 BLK Splice 1 ( W8 , W9 )
X132—G04 BLK Splice 2 ( W9 )
X133—L05 BRN Splice ( W8 , W9 )
X134—G09 BLK Splice ( W7 )
X135—T10 BLU Splice ( W7 )
X136—R06 BLK Splice ( W7 )
X137—P14 RED Splice ( W20 )
X150—G20 BLK IGC Splice 1 ( W21 )
X151—P61 RED IGC Splice ( W21 )
X152—P58 RED IGC Splice ( W21 )
X153—P51 RED IGC Splice ( W21 )
X154—P14 RED IGC Splice ( W21 )
X155—G05 BLK IGC Splice ( W21 )

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 System Functional Schematic, Wiring Diagram, and Component Location Legend
X156—G20 BLK IGC Splice 2 ( W21 )
X157—P50 RED IGC Splice ( W21 )
X158—R40 BLK IGC CAN Splice ( W21 )
X159—M18 GRN IGC CAN Splice ( W21 )
X160—M17 YEL IGC CAN Splice ( W21 )
X161—R13 BLK IGC CAN Splice ( W21 )
X162—M13 GRN IGC CAN Splice ( W21 )
X163—M12 YEL IGC CAN Splice ( W21 )
X164—H22 GRN IGC Splice ( W22 )
X165—R13 BLK IGC CAN Splice ( W22 )
X166—M13 GRN IGC CAN Splice ( W22 )
X167—M12 YEL IGC CAN Splice ( W22 )
X168—H22 GRN IGC splice ( W21 )
X169—R41 BLK IGC Splice ( W21 )
X170—G20 BLK IGC Splice ( W21 )
X171—P70 RED Splice ( W7 )
X172—P71 RED Splice ( W7 )
X173—B01 RED Splice ( W7 )
X174—B03 RED Splice ( W7 )
X175—M13 LGRN Splice ( W7 )
X176—M12 YEL Splice ( W7 )
X177—R13 BLK Splice ( W7 )
X178—G71 BLK Splice ( W7 )
X179—R13 BLK Splice ( W7 )
X180—M12 YEL Splice ( W7 )
X181—M13 LGRN Splice ( W7 )
X186—G70 BLK Splice ( W30 )
X187—P70 RED Splice ( W30 )
X188—G71 BLK Splice ( W30 )
X189—R70 BLK Splice ( W31 )
X190—G70 BLK Splice ( W11 )
X191—L02 BRN Splice ( W9 )
X192—P15 RED Splice ( W9 )
X193—P40 RED Splice ( W11 )
X5000—G70 BLK Splice ( W6002 )
X5001—P70 RED Splice ( W6002 )
X6001—Not Used ( SE55 ,
X6002—Not Used ( SE55 ,
X6005—Not Used ( SE55 ,
X6020—Not Used ( W6002 )
X6021—Not Used ( W6002 )
X6022—Not Used ( W6002 )
X6023—Not Used ( W6002 )
X6014—Modular Telematics Gateway (MTG) 48-Pin Connector ( SE55 , W6002 )
X6015—JDLink™ Satellite Module Connector ( SE55 , W6003 )
X6016—Satellite Adapter Harness-to-Universal JDLink™ Harness ( SE55 , W6002 , W6003 )
Y1—Start Aid Solenoid ( SE3 , W10
Y2—Park Brake Solenoid 1 ( SE16 , W11 )
Y3—Motor Shift Solenoid Left ( SE17 , W11 )
Y4—Motor Shift Solenoid Right ( SE17 , W11 )
Y5A—Hydraulic Fan Proportional Relief Solenoid (standard) ( SE17 , W16 )
Y5—Hydraulic Fan Proportional Relief Solenoid (with reversing option) ( SE17 , W10 )
Y6—Hydraulic Fan Reversing Solenoid ( SE17 , W10 )
Y7—Blade Angle Solenoid Left (top) (pilot blade control only) ( SE18 , W11 )
Y8—Blade Angle Solenoid Right (bottom) (pilot blade control only) ( SE18 , W11 )
Y9—Quick-Drop Solenoid ( SE19 , W10 )

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 System Functional Schematic, Wiring Diagram, and Component Location Legend
Y10—Pilot Control Enable Solenoid ( SE19 , W11 )
Y11—Blade Detent Coil ( SE19 , W7 )
Y12—High Pressure Fuel Pump Solenoid ( SE35 , W10 )
Y14—Hydrostatic Oil Cooler Bypass Solenoid ( SE18 , W11 )
Y15—Park Brake Solenoid 2 ( SE16 , W11 )
Y16—Air Conditioning Compressor Clutch Solenoid ( SE3 , W10 )
Y17—Hydrostatic Oil Reservoir Bypass Solenoid ( SE18 , W11 )
Y21—Electronic Injector (cylinder 1) ( SE36 , W19)
Y22—Electronic Injector (cylinder 2) ( SE36 , W19)
Y23—Electronic Injector (cylinder 3) ( SE36 , W19)
Y24—Electronic Injector (cylinder 4) ( SE36 , W19)
Y25—Electronic Injector (cylinder 5) ( SE36 , W19)
Y26—Electronic Injector (cylinder 6) ( SE36 , W19)
Y30—Blade Angle Actuator (IGC option) ( SE38 , W21 )
Y31—Blade Tilt Actuator (IGC option) ( SE38 , W21 )
Y32—Blade Lift Actuator (IGC option) ( SE38 , W21 )

Go to Section_9015:Group_10

WS68074,00037EF-19-20140627

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 System Functional Schematic and Section Legend

System Functional Schematic and Section Legend

SE1—Battery and Power Circuits (24-Volt System)

SE2—Alternator and Start Circuits
SE3—Start Aid, Horn, and A/C Compressor Circuits
SE4—Accessory Circuit
SE5—Vehicle Electrical Center (VEC) Circuit
SE6—Vehicle Electrical Center (VEC) Circuit
SE7—Vehicle Electrical Center (VEC) Circuit
SE8—Vehicle Electrical Center (VEC) Circuit
SE9—Vehicle Electrical Center (VEC) Circuit
SE10—Spare Connector Circuit
SE11—Transmission Control Unit (TCU) Circuit
SE12—Transmission Control Unit (TCU) Circuit
SE13—Transmission Control Unit (TCU) Circuit
SE14—Transmission Control Unit (TCU) Circuit
SE15—Transmission Control Unit (TCU) Circuit
SE16—Transmission Control Unit (TCU) Circuit
SE17—Transmission Control Unit (TCU) Circuit
SE18—Transmission Control Unit (TCU) Circuit
SE19—Pilot Enable and Quick Drop Circuits
SE20—Air Conditioning and Heater Circuit
SE21—Air Conditioning and Heater Circuit
SE22— Service ADVISOR™ Connector Circuit
SE23—CAN Monitor Unit (CMU) Circuit
SE24—CAN Monitor Unit (CMU) Circuit
SE25—Wiper and Washer Circuits (S.N. —210213)
SE26—Wiper and Washer Circuits (S.N. —210213)
SE27—Under-Seat Heater Circuit
SE28—Standard 12-Volt Power Converter and Radio Circuits
SE29—Optional 12-Volt Power Convertor Circuit
SE30—Standard Work Light Circuit
SE31—Auxiliary Work Light Circuit
SE32—Dome Light
SE33—Air Seat Circuit
SE34—Engine Control Unit (ECU) Circuit
SE35—Engine Control Unit (ECU) Circuit
SE36—Engine Control Unit (ECU) Circuit
SE38—Integrated Grade Control (IGC) Circuit
SE38—Integrated Grade Control (IGC) Circuit
SE39—Integrated Grade Control (IGC) Circuit
SE40—Wiper and Washer Circuits (S.N. 210214— )
SE41—Wiper and Washer Circuits (S.N. 210214— )
SE52 —Machine Information Power Circuit (optional)
SE53 — GlobalTRACS® Terminal (GTT) Circuit (optional)
SE54 —Machine Information Gateway (MIG) Circuit (optional)
SE55 —Machine Information and Power Circuit (optional)
SE56 —Modular Telematics Gateway (MTG) Circuit (optional)

644
 System Functional Schematic and Section Legend

TX1103009-UN: 750J System Functional Schematic (SE1, SE2, SE3) (1 of 14)

LEGEND:
F33 - Main 125-Amp Fuse
G1 - Batteries
G2 - Jump Start Terminal
G3 - Alternator
H1 - Horn
K9 - Start Relay
M1 - Starter Motor
S1 - Key Switch
S2 - Battery Disconnect Switch
S18 - Park Lock Lever Switch
S19 - Start Aid Switch
V2 - Starter Solenoid 5-Amp Diode
V3 - Start Relay 1-Amp Diode
V4 - Air Conditioning Compressor Clutch 5-Amp Diode
W4 - Ground to Cab Left Rear
W6 - Ground to Engine on Starter Motor
X19 - Engine Harness-to-Transmission Harness Connector
X30 - Operator's Station Harness-to-Transmission Harness Connector 4
Y1 - Start Aid Solenoid
Y16 - Air Conditioning Compressor Clutch Solenoid

645
 System Functional Schematic and Section Legend
TX1103012-UN: 750J System Functional Schematic (SE4, SE5, SE6) (2 of 14)
LEGEND:
A6 - Vehicle Electrical Center (VEC)
F1 - Condenser Fan Motor 2 15-Amp Fuse ( VEC )
F2 - Condenser Fan Motor 1 15-Amp Fuse ( VEC )
F8 - Dome Light 5-Amp Fuse ( VEC )
F11 - Winch Switch/Solenoids 5-Amp Fuse ( VEC )
F12 - Heater Blower 15 A Fuse ( VEC )
F18 - Heater Valve 5-Amp Fuse ( VEC )
F21 - Front/Rear Wiper Motor 10-Amp Fuse ( VEC )
F22 - Right/Left Wiper Motor 10-Amp Fuse ( VEC )
F23 - Standard Powerport 10-Amp Fuse ( VEC )
F24 - Air Conditioning Compressor Clutch 5-Amp Fuse ( VEC )
F30 - Auxiliary Work Light 20-Amp Circuit Breaker (CB1) ( VEC )
F31 - Standard Work Light 15-Amp Circuit Breaker (CB2) ( VEC )
K4 - Auxiliary Work Light Relay ( VEC )
K5 - Wiper Relay ( VEC )
K6 - Standard Work Light Relay ( VEC )
K7 - Air Conditioning Compressor Clutch Relay ( VEC )
K10 - Accessory Relay 1
K11 - Accessory Relay 2
W4 - Ground to Cab Left Rear
X31 - VEC 8-Pin Connector (Gray)
X32 - VEC 8-Pin Connector (Red)
X33 - VEC 8-Pin Connector (Black)
X34 - VEC 8-Pin Connector (Orange)
X38 - VEC 2-Pin Connector (Gray)
X39 - VEC 2-Pin Connector (Black)

TX1103013-UN: 750J System Functional Schematic (SE7, SE8, SE9) (3 of 14)

LEGEND:
A6 - Vehicle Electrical Center (VEC)
F3 - Service ADVISOR™ Power 5-Amp Fuse ( VEC )
F4 - CMU Power 5-Amp Fuse ( VEC )
F5 - Alternator Excitation 5-Amp Fuse ( VEC )
F6 - TCU Power 10-Amp Fuse ( VEC )
F7 - Fuel Heater 10-Amp Fuse ( VEC )
646
 System Functional Schematic and Section Legend
F9 - Pilot Enable Ignition Power 5-Amp Fuse ( VEC )
F10 - Under-Seat Heater 15-Amp Fuse ( VEC )
F13 - Start Aid 15-Amp Fuse ( VEC )
F14 - Airseat 10-Amp Fuse ( VEC )
F15 - Switch LED (Backlight) Circuit 5-Amp Fuse ( VEC )
F16 - Optional Powerport 10-Amp Fuse ( VEC )
F17 - Spare 15-Amp Fuse ( VEC )
F19 - Horn 5-Amp Fuse ( VEC )
F20 - Radio Memory 5-Amp Fuse ( VEC )
F25 - Start Relay 10-Amp Fuse ( VEC )
F26 - ECU Ignition Power 5-Amp Fuse ( VEC )
F27 - Spare 10-Amp Fuse ( VEC )
F28 - CMU Battery Power 5-Amp Fuse ( VEC )
F29 - ECU Battery Power 15-Amp Fuse ( VEC )
K1 - A/C Condenser Motor Fan 2 Relay ( VEC )
K2 - A/C Condenser Motor Fan 1 Relay ( VEC )
K3 - Optional 10-Amp Converter Relay ( VEC )
K8 - Horn Relay ( VEC )
V1 - Alternator Excitation 3-Amp Diode ( VEC )
W4 - Ground to Cab Left Rear
X35 - VEC 8-Pin Connector (Blue)
X36 - VEC 8-Pin Connector (Green)
X37 - VEC 8-Pin Connector (Brown)

TX1103014-UN: 750J System Functional Schematic (SE10, SE11, SE12) (4 of 14)

LEGEND:
B4 - Hydrostatic Charge Pressure Sensor (S.N. —173641)
B5 - Hydrostatic Pressure Sensor Right (S.N. —173658)
B6 - Hydrostatic Pressure Sensor Left (S.N. —173658)
B35 - Brake Pressure Sensor (S.N. —173641)
B41 - Hydrostatic Charge Pressure Sensor (S.N. 173642— )
B42 - Brake Pressure Sensor (S.N. 173642— )
B43 - Hydrostatic Pressure Sensor Right (S.N. 173659— )
B44 - Hydrostatic Pressure Sensor Left (S.N. 173659— )
B46 - Fuel Heater Temperature Switch (if equipped)
R6 - Fuel Heater (if equipped)

647
 System Functional Schematic and Section Legend
R10 - Engine Speed Control
S4 - Blade Angle Switch
S7 - Decelerator Mode Switch
W2 - Ground to Cab Right Rear
W4 - Ground to Cab Left Rear
X6 - Bussed + 5-Volt Sensor Connector
X7 - Bussed Ground Sensor Connector
X25 - Spare Connector Roof
X26 - Spare Connector Right Console
X27 - Spare Connector Front Console

TX1103016-UN: 750J System Functional Schematic (SE13, SE14, SE15) (5 of 14)

LEGEND:
A1 - Transmission Control Unit (TCU)
B1 - Decelerator Sensor
B2 - Motor Speed Sensor Left
B3 - Motor Speed Sensor Right
B32 - TCL Sensor
B33 - Steer Sensor
B34 - Transmission Speed Control Switch
H3 - Backup Alarm
S5 - Horn Switch
S20 - Neutral Start Switch
W4 - Ground to Cab Left Rear
W6 - Ground to Engine on Starter Motor
X1 - TCU Connector
X2 - TCU Connector
X52 - TCU Programming Connector

648
 System Functional Schematic and Section Legend

TX1103017-UN: 750J System Functional Schematic (SE16, SE17, SE18) (6 of 14)

LEGEND:
B7 - Pump Pressure Control Pilot (PCP) Rear
B8 - Pump Pressure Control Pilot (PCP) Front
W6 - Ground to Engine on Starter Motor
Y2 - Park Brake Solenoid 1
Y3 - Motor Shift Solenoid Left
Y4 - Motor Shift Solenoid Right
Y5 - Hydraulic Fan Proportional Relief Solenoid (with reversing option)
Y5A - Hydraulic Fan Proportional Relief Solenoid (standard)
Y6 - Hydraulic Fan Reversing Solenoid
Y7 - Blade Angle Solenoid Left (Top) (pilot control)
Y8 - Blade Angle Solenoid Right (Bottom) (pilot control)
Y14 - Hydrostatic Oil Cooler Bypass Solenoid
Y15 - Park Brake Solenoid 2
Y17 - Hydrostatic Oil Reservoir Bypass Solenoid

TX1103018-UN: 750J System Functional Schematic (SE19, SE20, SE21) (7 of 14)

LEGEND:
B9 - Quick-Drop Pressure Switch
B27 - Air Conditioning Freeze Switch
B50 - A/C Binary Pressure Switch
M2 - Heater Valve Motor

649
 System Functional Schematic and Section Legend
M3 - Heater Blower Motor
M4 - Air Conditioning Condenser Fan Motor
M5 - Air Conditioning Condenser Fan Motor
R3 - Heater Valve Resistor (S.N. 141344—153820)
R4 - Cab Heater Blower Resistor
S8 - Hydraulic Enable Switch
S9 - Heater Temperature Control Switch
S10 - Heater Blower Switch
S11 - Air Conditioning On/Off Switch
W2 - Ground to Cab Right Rear
W4 - Ground to Cab Left Rear
W6 - Ground to Engine on Starter Motor
X11 - Cab Roof Harness-to-Air Conditioning Harness Connector
Y9 - Quick-Drop Solenoid
Y10 - Pilot Control Enable Solenoid
Y11 - Blade Detent Coil

TX1103019-UN: 750J System Functional Schematic (SE22, SE23, SE24) (8 of 14)

LEGEND:
A3 - CAN Monitor Unit (CMU)
B19 - Fuel Level Sensor
B20 - Hydraulic Oil Temperature Sensor
B21 - Hydrostatic (transmission) Oil Temperature Sensor
B22 - Air Filter Restriction Switch
B23 - Hydraulic Oil Filter Restriction Switch
B24 - Hydraulic Fan Oil Filter Restriction Switch
B25 - Hydrostatic (transmission) Charge Oil Filter Restriction Switch
B26 - Winch Oil Pressure Switch
H2 - Monitor Alarm
R1 - CAN Termination Resistor (120 ohm)
R2 - CAN Termination Resistor (120 ohm)
S23 - Fan Reversing Switch
W3 - Ground to Frame Under Cab
W4 - Ground to Cab Left Rear
W5 - HIC Valve Ground
W6 - Ground to Engine on Starter Motor

650
 System Functional Schematic and Section Legend
X4 - CMU 16-Pin Connector
X5 - CMU 14-Pin Connector
X8 - Service ADVISOR™ Connector
X29 - Automatic Diagnostic Connector (S.N. 139436—153828)

TX1103021-UN: 750J System Functional Schematic (SE25, SE26, SE27) (9 of 14)

LEGEND:
M6 - Wiper Motor Front
M7 - Wiper Motor Left Door
M8 - Wiper Motor Right Door
M9 - Washer Motor Front/Rear
M10 - Washer Motor Left/Right
M11 - Wiper Motor Rear
M12 - Under-Seat Heater Blower Motor
R5 - Under-Seat Heater Blower Resistor
S12 - Front/Rear Door Wiper Motor Switch
S13 - Left/Right Door Wiper Motor Switch
S15 - Under-Seat Heater Blower Switch
V5 - Door Wiper Diode
V6 - Front Wiper Diode
V7 - Rear Wiper Diode
W2 - Ground to Cab Right Rear
W3 - Ground to Frame Under Cab
W4 - Ground to Cab Left Rear
X12 - Cab Harness-to-Rear Wiper Harness Connector
X22 - Cab/Canopy Harness-to-Under-Seat Harness Connector

651
 System Functional Schematic and Section Legend

TX1103023-UN: 750J System Functional Schematic (SE28, SE29, SE30) (10 of 14)
LEGEND:
A5 - Radio
B30 - Right Speaker
B31 - Left Speaker
E2 - Standard Work Light Left Front
E3 - Standard Work Light Right Front
E5 - Standard Work Light Right Rear
S16 - Standard Work Light Switch
U2 - 12-Volt Power Converter
U3 - Optional 12-Volt Power Converter
W1 - Radio Antenna
W2 - Ground to Cab Right Rear
W3 - Ground to Frame Under Cab
W4 - Ground to Cab Left Rear
W6 - Ground to Engine on Starter Motor
X9 - Standard 12-Volt Power Outlet
X20 - Optional 12-Volt Power Converter Connector A
X20 - Optional 12-Volt Power Converter Connector B
X24 - Optional 12-Volt Power Outlet
X41 - Cab Roof Harness-to-Radio Harness Connector
X42 - Optional 12-Volt Terminal Block
X88 - IGC Harness 24/12-Volt Converter Connector (IGC option)
X89 - IGC Machine Harness-to-Transmission Harness Connector (IGC option)

652
 System Functional Schematic and Section Legend

TX1103024-UN: 750J System Functional Schematic (SE31, SE32, SE33) (11 of 14)
LEGEND:
E1 - Dome Light
E4 - Auxiliary Work Light Left Rear
E6 - Auxiliary Work Light Left Front
E7 - Auxiliary Work Light Right Front
E9 - Auxiliary Work Light Right Rear
M13 - Air Seat Motor
S14 - Dome Light Switch
S17 - Auxiliary Work Light Switch
S25 - Air Seat Switch
W2 - Ground to Cab Right Rear
W4 - Ground to Cab Left Rear
X43 - Cab Roof Harness-to-Dome Light Connector

TX1103025-UN: 750J System Functional Schematic (SE34, SE35, SE36) (12 of 14)
LEGEND:
A2 - Engine Control Unit (ECU)
B10 - Fuel Rail Pressure Sensor
B11 - Fuel Temperature Sensor
B12 - Engine Coolant Temperature Sensor
B13 - Manifold Air Temperature Sensor
B14 - Crankshaft Position Sensor

653
 System Functional Schematic and Section Legend
B15 - Camshaft Position Sensor
B16 - Ambient Air Temperature Sensor
B17 - Engine Oil Pressure Sensor
B18 - Water-in-Fuel Sensor
H4 - Warmup Indicator
W6 - Ground to Engine on Starter Motor
X3 - ECU 30-Pin Connector
X10 - ECU 30-Pin Connector
X23 - Engine Harness-to-Electronic Injector Harness Connector
Y12 - High Pressure Fuel Pump Solenoid
Y21 - Electronic Injector (Cylinder 1)
Y22 - Electronic Injector (Cylinder 2)
Y23 - Electronic Injector (Cylinder 3)
Y24 - Electronic Injector (Cylinder 4)
Y25 - Electronic Injector (Cylinder 5)
Y26 - Electronic Injector (Cylinder 6)

TX1103028-UN: 750J System Functional Schematic (SE37, SE38, SE39) (13 of 14)
LEGEND:
A9 - Blade Control Joystick (BCJ) (IGC option)
A11 - Electrohydraulic Controller (EHC) (IGC option)
F101 - IGC Switched Power 15-Amp Fuse (IGC option)
F102 - BCJ Switched Power 5-Amp Fuse (IGC option)
F103 - EHC Switched Power 10-Amp Fuse (IGC option)
F104 - IGC Unswitched Power 1 10-Amp Fuse (IGC option)
F105 - IGC Unswitched Power 2 10-Amp Fuse (IGC option)
F106 - IGC Unswitched Power 3 10-Amp Fuse (IGC option)
K101 - IGC Switched Power Relay (IGC option)
K102 - BCJ and EHC Switched Power Relay (IGC option)
R7 - CAN Termination Resistor (120 ohm) (IGC option)
R8 - CAN Termination Resistor (120 ohm) (IGC option)
S8 - Hydraulic Enable Switch
X79 - 2-Pin Connector (not used) (IGC option)
X81 - RS232 Connector (IGC option)
X82 - Electrohydraulic Controller (EHC) Connector (IGC option)
X83 - Electrohydraulic Controller (EHC) Connector (IGC option)

654
 System Functional Schematic and Section Legend
X84 - Alternator W Terminal Signal Connector
X85 - Auxiliary Joystick Connector (IGC option)
X86 - IGC CAN-to-Machine CAN Connector (IGC option)
X90 - Auxiliary IGC Actuator Connector (IGC option)
X95 - IGC Machine Harness-to-IGC Cab Harness Connector (IGC option)
X96 - IGC Interface Connector (IGC option)
X97 - BCJ Switch Module Connector (IGC option)
X98 - BCJ Four-Way Axis Module Connector (IGC option)
Y30 - Blade Angle Actuator (IGC option)
Y31 - Blade Tilt Actuator (IGC option)
Y32 - Blade Lift Actuator (IGC option)

TX1103029-UN: 750J System Functional Schematic (SE40, SE41, SE42) (14 of 14)
LEGEND:
M6 - Wiper Motor Front
M7 - Wiper Motor Left Door
M8 - Wiper Motor Right Door
M9 - Washer Motor Front/Rear
M10 - Washer Motor Left/Right
M11 - Wiper Motor Rear
S12 - Front/Rear Door Wiper Motor Switch
S13 - Left/Right Door Wiper Motor Switch
V5 - Left Door Wiper Diode
V6 - Front Wiper Diode 1
V7 - Rear Wiper Diode
V10 - Right Door Wiper Diode
V11 - Front Wiper Diode 2
V12 - Front/Rear Wiper Diode
W2 - Ground to Cab Right Rear
W3 - Ground to Frame Under Cab
W4 - Ground to Cab Left Rear
X12 - Cab Harness-to-Rear Wiper Harness Connector

Go to Section_9015:Group_10

WS68074,00037D3-19-20140627

655
 JDLink™ System Functional Schematic—MIG/GTT

JDLink™ System Functional Schematic—MIG/GTT

Machine may be equipped with one of two different JDLink™ systems. See JDLink™ System Identification .
(Group 9015-20.)

JDLink™ System Functional Schematic—If Equipped (S.N. 153829—161691)

TX1148267-UN: JDLink™ Sub-System Schematic—If Equipped (S.N. 153829—161691)

LEGEND:
A12 - Machine Information Gateway (MIG) Controller
A13 - GlobalTRACS® Terminal (GTT) Controller
F34 - JDLink™ Ground 5 Amp Fuse
F35 - JDLink™ Switched Power 5 Amp Fuse
F36 - JDLink™ Unswitched Power 5 Amp Fuse
W2 - Ground to Cab Right Rear
W33 - GTT Antenna
W34 - GTT Harness Ground
X36 - VEC 8-Pin Connector (Green)
X37 - VEC 8-Pin Connector (Brown)
X57 - JDLink™ MMS Direct 4-Pin Connector (ethernet)
X58 - GT Config Tool Adapter 6-Pin Connector (RS-232)
X62 - Operator's Station Harness-to-GlobalTRACS® Terminal (GTT) Harness 12-Pin Connector
X63 - Operator's Station Harness-to-Machine Information Gateway (MIG) Harness 12-Pin Connector
X64 - GlobalTRACS® Terminal (GTT) 70-Pin Connector
X65 - Machine Information Gateway (MIG) Harness-to-GlobalTRACS® Terminal (GTT) Harness
X66 - Machine Information Gateway (MIG) 30-Pin (L1—Y3) Connector
X67 - Machine Information Gateway (MIG) 30-Pin (A1—K3) Connector

JDLink™ System Functional Schematic—If Equipped (S.N. 161692—196449)

656
 JDLink™ System Functional Schematic—MIG/GTT

TX1075026-UN: JDLink™ Sub-System Schematic (S.N. 161692—196449)

LEGEND:
A12 - Machine Information Gateway (MIG) Controller
A13 - GlobalTRACS® Terminal (GTT) Controller
F34 - JDLink™ Ground 5 Amp Fuse
F35 - JDLink™ Switched Power 5 Amp Fuse
F36 - JDLink™ Unswitched Power 5 Amp Fuse
W4 - Ground to Cab Left Rear
W33 - GTT Antenna
W34 - GTT Harness Ground
X36 - VEC 8-Pin Connector (Green)
X37 - VEC 8-Pin Connector (Brown)
X57 - JDLink™ MMS Direct 4-Pin Connector (ethernet)
X58 - GT Config Tool Adapter 6-Pin Connector (RS-232)
X62 - Operator's Station Harness-to-GlobalTRACS® Terminal (GTT) Harness 12-Pin Connector
X63 - Operator's Station Harness-to-Machine Information Gateway (MIG) Harness 12-Pin Connector
X64 - GlobalTRACS® Terminal (GTT) 70-Pin Connector
X65 - Machine Information Gateway (MIG) Harness-to-GlobalTRACS® Terminal (GTT) Harness
X66 - Machine Information Gateway (MIG) 30-Pin (L1—Y3) Connector
X67 - Machine Information Gateway (MIG) 30-Pin (A1—K3) Connector

Go to Section_9015:Group_10

DP27668,00007A4-19-20131125

657
 JDLink™ System Functional Schematic—MTG/SAT

JDLink™ System Functional Schematic—MTG/SAT

Machine may be equipped with one of two different JDLink™ systems. See JDLink™ System Identification .
(Group 9015-20.)

JDLink™ System Functional Schematic—If Equipped (S.N. 196450— )

TX1148270-UN: JDLink™ Sub-System Schematic (S.N. 196450— )

LEGEND:
A6000 - Modular Telematics Gateway (MTG) Control Unit
A6001 - GPS/Cellular Antenna
A6002 - Satellite (SAT) Control Unit
A6003 - Satellite Antenna
F34 - JDLink™ Ground 5-Amp Fuse
F35 - JDLink™ Switched Power 5-Amp Fuse
F36 - JDLink™ Unswitched Power 5-Amp Fuse
W2 - Ground to Cab Right Rear
X36 - VEC 8-Pin Connector (green)
X37 - VEC 8-Pin Connector (brown)
X57 - Not Used
X58 - Not Used
X62 - Not Used
X63 - Cab Harness-to-JDLink™ Harness 12-Pin Connector
X6001 - Cell Phone Antenna Connector
X6002 - GPS Antenna Connector
X6005 - Satellite Antenna Connector
X6014 - Modular Telematics Gateway (MTG) 48-Pin Connector
X6015 - JDLink™ Satellite Module Connector
X6016 - Satellite Adapter Harness-to-Universal JDLink™ Harness Connector

658
JDLink™ System Functional Schematic—MTG/SAT

Go to Section_9015:Group_10

DP27668,00007A5-19-20131125

659
 Operator's Station Harness (W7) Component Location

Operator's Station Harness (W7) Component Location

TX1143611-UN: Operator's Station Harness (W7) Component Location (S.N. 139436—153828)

LEGEND:
A1 - Transmission Control Unit (TCU)
A3 - CAN Monitor Unit (CMU)
A6 - Vehicle Electrical Center (VEC)
B1 - Decelerator Sensor
B32 - TCL Sensor
B33 - Steer Sensor
B34 - Transmission Speed Control Sensor
H2 - Monitor Alarm
H4 - Warmup Indicator
K10 - Accessory Relay 1
K11 - Accessory Relay 2
M11 - Wiper Motor Rear
R1 - CAN Termination Resistor
R3 - Under-Seat Heater Blower Resistor
R5 - CAN Termination Resistor
R10 - Engine Speed Control
S1 - Key Switch
S4 - Blade Angle Switch
S5 - Horn Switch
S7 - Decelerator Mode Switch
S8 - Pilot Control Enable Switch
S15 - Under-Seat Heater Blower Switch
S16 - Standard Work Light Switch
S17 - Auxiliary Work Light Switch
S18 - Park Lock Lever Switch
S19 - Start Aid Switch

660
 Operator's Station Harness (W7) Component Location
S20 - Neutral Start Switch
S23 - Fan Reversing Switch
S25 - Air Seat Switch
V7 - Rear Wiper Diode
W4 - Ground to Cab Left Rear
X1 - TCU Connector
X2 - TCU Connector
X4 - CMU 16-Pin Connector
X5 - CMU 14-Pin Connector
X6 - Bussed +5V Sensor Connector
X7 - Bussed Ground Sensor Connector
X8 - Service ADVISOR™ Connector
X9 - Standard 12-Volt Power Outlet
X12 - Cab Harness-to-Rear Wiper Harness Connector
X13 - Operator's Station Harness-to-Roof Harness Connector
X16 - Operator's Station Harness-to-Transmission Harness Connector 1
X17 - Operator's Station Harness-to-Transmission Harness Connector 2
X18 - Operator's Station Harness-to-Transmission Harness Connector 3
X22 - Cab/Canopy Harness-to-Under-Seat Harness Connector
X24 - Optional 12-Volt Power Outlet
X26 - Spare Connector Right Console
X27 - Spare Connector Front Console
X30 - Operator's Station Harness-to-Transmission Harness Connector 4
X31 - VEC 8-Pin Connector (Gray)
X32 - VEC 8-Pin Connector (Red)
X35 - VEC 8-Pin Connector (Blue)
X36 - VEC 8-Pin Connector (Green)
X37 - VEC 8-Pin Connector (Brown)
X38 - VEC 2-Pin Connector (Gray)
X39 - VEC 2-Pin Connector (Black)
X40 - Operator's Station-to-Cab Roof Harness Connector
X52 - TCU Programming Connector
Y11 - Blade Detent Coil

661
 Operator's Station Harness (W7) Component Location

TX1143615-UN: Operator's Station Harness (W7) Component Location (S.N. 153829— )

LEGEND:
A1 - Transmission Control Unit (TCU)
A3 - CAN Monitor Unit (CMU)
A6 - Vehicle Electrical Center (VEC)
B1 - Decelerator Sensor
B32 - TCL Sensor
B33 - Steer Sensor
B34 - Transmission Speed Control Sensor
F35 - JDLink™ Switched Power 5-Amp Fuse
F36 - JDLink™ Unswitched Power 5-Amp Fuse
H2 - Monitor Alarm
H4 - Warmup Indicator
K10 - Accessory Relay 1
K11 - Accessory Relay 2
M11 - Wiper Motor Rear
R1 - CAN Termination Resistor
R3 - Under-Seat Heater Blower Resistor
R5 - CAN Termination Resistor
R10 - Engine Speed Control
S1 - Key Switch
S4 - Blade Angle Switch
S5 - Horn Switch
S7 - Decelerator Mode Switch
S8 - Pilot Control Enable Switch
S15 - Under-Seat Heater Blower Switch
S16 - Standard Work Light Switch
S17 - Auxiliary Work Light Switch
S18 - Park Lock Lever Switch
S19 - Start Aid Switch
662
 Operator's Station Harness (W7) Component Location
S20 - Neutral Start Switch
S23 - Fan Reversing Switch
S25 - Air Seat Switch
V7 - Rear Wiper Diode
W4 - Ground to Cab Left Rear
X1 - TCU Connector
X2 - TCU Connector
X4 - CMU 16-Pin Connector
X5 - CMU 14-Pin Connector
X6 - Bussed +5V Sensor Connector
X7 - Bussed Ground Sensor Connector
X8 - Service ADVISOR™ Connector
X9 - Standard 12-Volt Power Outlet
X12 - Cab Harness-to-Rear Wiper Harness Connector
X16 - Operator's Station Harness-to-Transmission Harness Connector 1
X17 - Operator's Station Harness-to-Transmission Harness Connector 2
X18 - Operator's Station Harness-to-Transmission Harness Connector 3
X22 - Cab/Canopy Harness-to-Under-Seat Harness Connector
X24 - Optional 12-Volt Power Outlet
X26 - Spare Connector Right Console
X27 - Spare Connector Front Console
X30 - Operator's Station Harness-to-Transmission Harness Connector 4
X31 - VEC 8-Pin Connector (Gray)
X32 - VEC 8-Pin Connector (Red)
X35 - VEC 8-Pin Connector (Blue)
X36 - VEC 8-Pin Connector (Green)
X37 - VEC 8-Pin Connector (Brown)
X38 - VEC 2-Pin Connector (Gray)
X39 - VEC 2-Pin Connector (Black)
X40 - Operator's Station-to-Cab Roof Harness Connector
X52 - TCU Programming Connector
X57 - JDLink™ MMS Direct 4-Pin Connector (ethernet)
X58 - GT Config Tool Adapter 6-Pin Connector (RS232)
X62 - Operator's Station Harness-to- GlobalTRACS® Terminal (GTT) Harness 12-Pin Connector
X63 - Operator's Station Harness-to-Machine Information Gateway (MIG) Harness 12-Pin Connector
Y11 - Blade Detent Coil

Go to Section_9015:Group_10

AA95137,00007E6-19-20130906

663
 Operator's Station Harness (W7) Wiring Diagram

Operator's Station Harness (W7) Wiring Diagram

TX1070765-UN: Operator's Station Harness (W7) Wiring Diagram (1 of 3) (S.N. 139436—153828)

TX1070622-UN: Operator's Station Harness (W7) Wiring Diagram (2 of 3) (S.N. 139436—153828)

LEGEND:
1 - Go to Wiring Diagram (2 of 2)
B32 - TCL Sensor
B33 - Steer Sensor
B34 - Transmission Speed Control Sensor
H4 - Warmup Indicator
K10 - Accessory Relay 1
K11 - Accessory Relay 2
R10 - Engine Speed Control
S4 - Blade Angle Switch
S5 - Horn Switch
S8 - Pilot Control Enable Switch
S18 - Park Lock Lever Switch

664
 Operator's Station Harness (W7) Wiring Diagram
S20 - Neutral Start Switch
S25 - Air Seat Switch
V7 - Rear Wiper Diode
W4 - Ground to Cab Left Rear
X8 - Service ADVISOR™ Connector
X9 - Standard 12-Volt Power Outlet
X12 - Cab Harness-to-Rear Wiper Harness Connector
X13 - Operator's Station Harness-to-Roof Harness Connector
X16 - Operator's Station Harness-to-Transmission Harness Connector 1
X17 - Operator's Station Harness-to-Transmission Harness Connector 2
X18 - Operator's Station Harness-to-Transmission Harness Connector 3
X22 - Cab/Canopy Harness-to-Under-Seat Harness Connector
X24 - Optional 12-Volt Power Outlet
X26 - Spare Connector Right Console
X30 - Operator's Station Harness-to-Transmission Harness Connector 4
X31 - VEC 8-Pin Connector (Gray)
X32 - VEC 8-Pin Connector (Red)
X35 - VEC 8-Pin Connector (Blue)
X36 - VEC 8-Pin Connector (Green)
X37 - VEC 8-Pin Connector (Brown)
X38 - VEC 2-Pin Connector (Gray)
X39 - VEC 2-Pin Connector (Black)
X40 - Operator's Station-to-Cab Roof Harness Connector
X112 - L02 BRN Splice
X116 - P31 RED Splice
X117 - E05 WHT Splice
X118 - G07 BLK Splice
X119 - P18 RED Splice
X120 - G03 BLK Splice 1
X121 - B01 RED Splice
X122 - L06 BRN Splice
X123 - G03 BLK Splice 2
X124 - P28 RED Splice
Y11 - Blade Detent Coil

TX1070624-UN: Operator's Station Harness (W7) Wiring Diagram (3 of 3) (S.N. 139436—153828)

665
 Operator's Station Harness (W7) Wiring Diagram
LEGEND:
B1 - Decelerator Sensor
H2 - Monitor Alarm
M11 - Wiper Motor Rear
R1 - CAN Termination Resistor
R3 - Under-Seat Heater Blower Resistor
R5 - CAN Termination Resistor
S1 - Key Switch
S7 - Decelerator Mode Switch
S15 - Under-Seat Heater Blower Switch
S16 - Standard Work Light Switch
S17 - Auxiliary Work Light Switch
S19 - Start Aid Switch
S23 - Fan Reversing Switch
S25 - Air Seat Switch
X1 - TCU Connector
X2 - TCU Connector
X4 - CMU 16-Pin Connector
X5 - CMU 14-Pin Connector
X6 - Bussed +5V Sensor Connector
X7 - Bussed Ground Sensor Connector
X22 - Cab/Canopy Harness-to-Under-Seat Harness Connector
X27 - Spare Connector Front Console
X52 - TCU Programming Connector
X102 - R12 BLK Splice
X109 - R13 BLK Splice 1
X110 - M13 LGRN Splice 1
X111 - M12 YEL Splice 1
X125 - G02 BLK Splice
X126 - P03 RED Splice
X127 - R13 BLK Splice 2
X128 - M12 YEL Splice 2
X129 - M13 LGRN Splice 2
X134 - G09 BLK Splice
X135 - T10 BLU Splice
X136 - R06 BLK Splice

666
 Operator's Station Harness (W7) Wiring Diagram

TX1079306-UN: Operator's Station Harness (W7) Wiring Diagram (1 of 4) (S.N. 153829—174194)

TX1079307-UN: Operator's Station Harness (W7) Wiring Diagram (2 of 4) (S.N. 153829—174194)

LEGEND:
1 - Continued on Sheet 2 of 3
B32 - TCL Sensor
B33 - Steer Sensor
B34 - Transmission Speed Control Sensor
F35 - JDLink™ Switched Power 5 Amp Fuse
F36 - JDLink™ Unswitched Power 5 Amp Fuse
H4 - Warmup Indicator Light
R10 - Engine Speed Control
S4 - Blade Angle Switch
S5 - Horn Switch
S8 - Pilot Control Enable Switch
S18 - Park Lock Lever Switch
S20 - Neutral Start Switch
S25 - Air Seat Switch
667
 Operator's Station Harness (W7) Wiring Diagram
V7 - Rear Wiper Diode
W4 - Ground-to-Cab Left Rear Ground
X8 - Service ADVISOR™ Connector
X9 - Standard 12 V Power Outlet
X12 - Cab Harness-to-Rear Wiper Harness Connector
X13 - Operator's Station Harness-to-Roof Harness Connector
X16 - Operator's Station Harness-to-Transmission Harness Connector 1
X17 - Operator's Station Harness-to-Transmission Harness Connector 2
X18 - Operator's Station Harness-to-Transmission Harness Connector 3
X22 - Cab/Canopy Harness-to-Under-Seat Harness Connector
X24 - Optional 12 V Power Outlet
X30 - Operator's Station Harness-to-Transmission Harness Connector 4
X38 - VEC 2-Pin Connector (gray)
X39 - VEC 2-Pin Connector (black)
X40 - Operator's Station-to-Cab Roof Harness Connector
X112 - L02 BRN Splice
X116 - P31 RED Splice
X117 - E05 WHT Splice
X118 - G07 BLK Splice
X119 - P18 RED Splice
X120 - G03 BLK Splice 1
X121 - B01 RED Splice
X122 - L06 BRN Splice
X171 - P70 RED Splice
X172 - P71 RED Splice
X173 - B01 RED Splice
X174 - B03 RED Splice
X177 - R13 BLK Splice

TX1079308-UN: Operator's Station Harness (W7) Wiring Diagram (3 of 4) (S.N. 153829—174194)

668
 Operator's Station Harness (W7) Wiring Diagram
LEGEND:
1 - Continued on Sheet 1 of 3
2 - Continued on Sheet 2 of 3
K10 - Accessory Relay 1
K11 - Accessory Relay 2
S4 - Blade Angle Switch
S8 - Pilot Control Enable Switch
X26 - Spare Connector Right Console
X31 - VEC 8-Pin Connector (Gray)
X32 - VEC 8-Pin Connector (Red)
X35 - VEC 8-Pin Connector (Blue)
X36 - VEC 8-Pin Connector (Green)
X37 - VEC 8-Pin Connector (Brown)
X62 - Operators Station Harness to GTT Harness 12 pin Connector
X63 - Operators Station Harness to MGI Harness 12 pin Connector
X123 - G03 BLK Splice 2
X124 - P28 RED Splice
X178 - G71 BLK Splice
X179 - R13 BLK Splice
X180 - M12 YEL Splice
X181 - M13 LGRN Splice
X182 - G70 BLK Splice
Y11 - Blade Detent Coil

TX1079309-UN: Operator's Station Harness (W7) Wiring Diagram (4 of 4) (S.N. 153829—174194)

LEGEND:
2 - Continued on Sheet 2 of 3
B1 - Decelerator Sensor
H2 - Monitor Alarm
R1 - CAN Termination Resistor
R13G - CAN Shielding Wire
R13B - CAN Shielding Wire
S1 - Key Switch
S7 - Decelerator Mode Switch
S15 - Under-Seat Heater Blower Switch
S16 - Standard Work Light Switch
S17 - Auxiliary Work Light Switch
669
 Operator's Station Harness (W7) Wiring Diagram

S19 - Start Aid Switch

S23 - Fan Reversing Switch
X1 - TCU Connector
X2 - TCU Connector
X4 - CMU 16-Pin Connector
X5 - CMU 14-Pin Connector
X6 - Bussed +5V Sensor Connector
X7 - Bussed Ground Sensor Connector
X27 - Spare Connector Front Console
X52 - TCU Programming Connector
X57 - JDLink™ MMS Direct 4-Pin Connector (ethernet)
X58 - GT Config Tool Adapter 6-Pin Connector (RS232)
X109 - R13 BLK Splice 1
X110 - M13 LGRN Splice 1
X111 - M12 YEL Splice 1
X125 - G02 BLK Splice
X126 - P03 RED Splice
X127 - R13 BLK Splice 2
X128 - M12 YEL Splice 2
X129 - M13 LGRN Splice 2
X134 - G09 BLK Splice
X135 - T10 BLU Splice
X136 - R06 BLK Splice

TX1079311-UN: Operator's Station Harness (W7) Wiring Diagram (1 of 4) (S.N. 174195— )

670
 Operator's Station Harness (W7) Wiring Diagram

TX1079313-UN: Operator's Station Harness (W7) Wiring Diagram (2 of 4) (S.N. 174195— )

LEGEND:
1 - Continued on Sheet 2 of 3
B32 - TCL Sensor
B33 - Steer Sensor
B34 - Transmission Speed Control Sensor
F35 - JDLink™ Switched Power 5 Amp Fuse
F36 - JDLink™ Unswitched Power 5 Amp Fuse
H4 - Warmup Indicator Light
R10 - Engine Speed Control
S4 - Blade Angle Switch
S5 - Horn Switch
S8 - Pilot Control Enable Switch
S18 - Park Lock Lever Switch
S20 - Neutral Start Switch
S25 - Air Seat Switch
V7 - Rear Wiper Diode
W4 - Ground-to-Cab Left Rear Ground
X8 - Service ADVISOR™ Connector
X9 - Standard 12 V Power Outlet
X12 - Cab Harness-to-Rear Wiper Harness Connector
X13 - Operator's Station Harness-to-Roof Harness Connector
X16 - Operator's Station Harness-to-Transmission Harness Connector 1
X17 - Operator's Station Harness-to-Transmission Harness Connector 2
X18 - Operator's Station Harness-to-Transmission Harness Connector 3
X22 - Cab/Canopy Harness-to-Under-Seat Harness Connector
X24 - Optional 12 V Power Outlet
X30 - Operator's Station Harness-to-Transmission Harness Connector 4
X38 - VEC 2-Pin Connector (gray)
X39 - VEC 2-Pin Connector (black)
X40 - Operator's Station-to-Cab Roof Harness Connector
X112 - L02 BRN Splice
X116 - P31 RED Splice
X117 - E05 WHT Splice
X118 - G07 BLK Splice

671
 Operator's Station Harness (W7) Wiring Diagram
X119 - P18 RED Splice
X120 - G03 BLK Splice 1
X121 - B01 RED Splice
X122 - L06 BRN Splice
X171 - P70 RED Splice
X172 - P71 RED Splice
X173 - B01 RED Splice
X174 - B03 RED Splice
X177 - R13 BLK Splice

TX1079314-UN: Operator's Station Harness (W7) Wiring Diagram (3 of 4) (S.N. 174195— )

LEGEND:
1 - Continued on Sheet 1 of 3
2 - Continued on Sheet 2 of 3
K10 - Accessory Relay 1
K11 - Accessory Relay 2
S4 - Blade Angle Switch
S8 - Pilot Control Enable Switch
X26 - Spare Connector Right Console
X31 - VEC 8-Pin Connector (Gray)
X32 - VEC 8-Pin Connector (Red)
X35 - VEC 8-Pin Connector (Blue)
X36 - VEC 8-Pin Connector (Green)
X37 - VEC 8-Pin Connector (Brown)
X62 - Operators Station Harness to GTT Harness 12 pin Connector
X63 - Operators Station Harness to MGI Harness 12 pin Connector
X123 - G03 BLK Splice 2
X124 - P28 RED Splice
X178 - G71 BLK Splice
X179 - R13 BLK Splice

672
 Operator's Station Harness (W7) Wiring Diagram
X180 - M12 YEL Splice
X181 - M13 LGRN Splice
X182 - G70 BLK Splice
Y11 - Blade Detent Coil

TX1079315-UN: Operator's Station Harness (W7) Wiring Diagram (4 of 4) (S.N. 174195— )

LEGEND:
2 - Continued on Sheet 2 of 3
B1 - Decelerator Sensor
H2 - Monitor Alarm
R1 - CAN Termination Resistor
R13G - CAN Shielding Wire
R13B - CAN Shielding Wire
S1 - Key Switch
S7 - Decelerator Mode Switch
S15 - Under-Seat Heater Blower Switch
S16 - Standard Work Light Switch
S17 - Auxiliary Work Light Switch
S19 - Start Aid Switch
S23 - Fan Reversing Switch
X1 - TCU Connector
X2 - TCU Connector
X4 - CMU 16-Pin Connector
X5 - CMU 14-Pin Connector
X6 - Bussed +5V Sensor Connector
X7 - Bussed Ground Sensor Connector
X27 - Spare Connector Front Console
X52 - TCU Programming Connector
X57 - JDLink™ MMS Direct 4-Pin Connector (ethernet)
X58 - GT Config Tool Adapter 6-Pin Connector (RS232)
X109 - R13 BLK Splice 1
X110 - M13 LGRN Splice 1
X111 - M12 YEL Splice 1
X125 - G02 BLK Splice
X126 - P03 RED Splice
X127 - R13 BLK Splice 2

673
 Operator's Station Harness (W7) Wiring Diagram
X128 - M12 YEL Splice 2
X129 - M13 LGRN Splice 2
X134 - G09 BLK Splice
X135 - T10 BLU Splice
X136 - R06 BLK Splice

Go to Section_9015:Group_10

AA95137,00007E7-19-20100629

674
 Canopy Roof Harness (W8) Component Location

Canopy Roof Harness (W8) Component Location

T203316-UN: Canopy Roof Harness (W8) Component Location

LEGEND:
E4 - Auxiliary Work Light Left Rear
E5 - Standard Work Light Right Rear
E6 - Auxiliary Work Light Left Front
E7 - Auxiliary Work Light Right Front
E9 - Auxiliary Work Light Right Rear
X13 - Operator's Station Harness-to-Roof Harness Connector
W2 - Ground to Cab Right Rear

675
Canopy Roof Harness (W8) Component Location

Go to Section_9015:Group_10

MF82180,0000023-19-20040901

676
 Canopy Roof Harness (W8) Wiring Diagram

Canopy Roof Harness (W8) Wiring Diagram

T206443-UN: Canopy Roof Harness (W8) Wiring Diagram

LEGEND:
E4 - Auxiliary Work Light Left Rear
E5 - Standard Work Light Right Rear
E6 - Auxiliary Work Light Left Front
E7 - Auxiliary Work Light Right Front
E9 - Auxiliary Work Light Right Rear
X13 - Operator's Station Harness-to-Roof Harness Connector
X131 - G04 BLK Splice 1
X133 - L05 BRN Splice
W2 - Ground to Cab Right Rear

Go to Section_9015:Group_10

MF82180,0000024-19-20040901

677
 Cab Roof Harness (W9) Component Location

Cab Roof Harness (W9) Component Location

TX1038765-UN: Cab Roof Harness (W9) Component Location (S.N. 141344—174194)

LEGEND:
A6 - Vehicle Electrical Center (VEC)
E1 - Dome Light
E4 - Auxiliary Work Light Left Rear
E5 - Standard Work Light Right Rear
E6 - Auxiliary Work Light Left Front
E7 - Auxiliary Work Light Right Front
E9 - Auxiliary Work Light Right Rear
M6 - Wiper Motor Front

678
 Cab Roof Harness (W9) Component Location
M7 - Wiper Motor Left Door
M8 - Wiper Motor Right Door
S9 - Heater Temperature Control Switch
S10 - Heater Blower Switch
S11 - Air Conditioning On/Off Switch
S12 - Front/Rear Door Wiper Motor Switch
S13 - Left/Right Door Wiper Motor Switch
S14 - Dome Light Switch
V5 - Door Wiper Diode
V6 - Front Wiper Diode
W2 - Ground to Cab Right Rear
X11 - Cab Roof Harness-to-Air Conditioning Harness Connector
X13 - Operator's Station Harness-to-Roof Harness Connector
X25 - Spare Connector Roof
X33 - VEC 8-Pin Connector (Black)
X34 - VEC 8-Pin Connector (Orange)
X40 - Operator's Station-to-Cab Roof Harness Connector
X41 - Cab Roof Harness-to-Radio Harness Connector
X43 - Cab Roof Harness Connector-to-Dome Light Connector

679
 Cab Roof Harness (W9) Component Location

TX1079297-UN: Cab Roof Harness (W9) Component Location (S.N. 174195— )

LEGEND:
A6 - Vehicle Electrical Center (VEC)
E1 - Dome Light
E4 - Auxiliary Work Light Left Rear
E5 - Standard Work Light Right Rear
E6 - Auxiliary Work Light Left Front
E7 - Auxiliary Work Light Right Front
E9 - Auxiliary Work Light Right Rear
E10 - Not Used
E11 - Not Used
M6 - Wiper Motor Front
M7 - Wiper Motor Left Door
680
 Cab Roof Harness (W9) Component Location

M8 - Wiper Motor Right Door

S9 - Heater Temperature Control Switch
S10 - Heater Blower Switch
S11 - Air Conditioning On/Off Switch
S12 - Front/Rear Door Wiper Motor Switch
S13 - Left/Right Door Wiper Motor Switch
S14 - Dome Light Switch
V5 - Door Wiper Diode
V6 - Front Wiper Diode
W2 - Ground to Cab Right Rear
X11 - Cab Roof Harness-to-Air Conditioning Harness Connector
X13 - Operator's Station Harness-to-Roof Harness Connector
X25 - Spare Connector Roof
X33 - VEC 8-Pin Connector (Black)
X34 - VEC 8-Pin Connector (Orange)
X40 - Operator's Station-to-Cab Roof Harness Connector
X41 - Cab Roof Harness-to-Radio Harness Connector
X43 - Cab Roof Harness Connector-to-Dome Light Connector

Go to Section_9015:Group_10

MF82180,0000025-19-20100629

681
 Cab Roof Harness (W9) Wiring Diagram

Cab Roof Harness (W9) Wiring Diagram

TX1079292-UN: Cab Roof Harness (W9) Wiring Diagram (S.N. 141344—153828)

LEGEND:
E1 - Dome Light
E4 - Auxiliary Work Light Left Rear
E5 - Standard Work Light Right Rear
E6 - Auxiliary Work Light Left Front
E7 - Auxiliary Work Light Right Front
E9 - Auxiliary Work Light Right Rear
M6 - Wiper Motor Front
M7 - Wiper Motor Left Door
M8 - Wiper Motor Right Door
S9 - Heater Temperature Control Switch
S10 - Heater Blower Switch
S11 - Air Conditioning On/Off Switch
S12 - Front/Rear Door Wiper Motor Switch
S13 - Left/Right Door Wiper Motor Switch
S14 - Dome Light Switch
V5 - Door Wiper Diode
V6 - Front Wiper Diode
W2 - Ground to Cab Right Rear
X11 - Cab Roof Harness-to-Air Conditioning Harness Connector
X13 - Operator's Station Harness-to-Roof Harness Connector
X25 - Spare Connector Roof
X33 - VEC 8-Pin Connector (Black)
X34 - VEC 8-Pin Connector (Orange)
X40 - Operator's Station-to-Cab Roof Harness Connector
X41 - Cab Roof Harness-to-Radio Harness Connector
X131 - G04 BLK Splice 1
X132 - G04 BLK Splice 2
X133 - L05 BRN Splice

682
 Cab Roof Harness (W9) Wiring Diagram

TX1079293-UN: Cab Roof Harness (W9) Wiring Diagram (S.N. 153829—174194)

LEGEND:
E1 - Dome Light
E4 - Auxiliary Work Light Left Rear
E5 - Standard Work Light Right Rear
E6 - Auxiliary Work Light Left Front
E7 - Auxiliary Work Light Right Front
E9 - Auxiliary Work Light Right Rear
M6 - Wiper Motor Front
M7 - Wiper Motor Left Door
M8 - Wiper Motor Right Door
S9 - Heater Temperature Control Switch
S10 - Heater Blower Switch
S11 - Air Conditioning On/Off Switch
S12 - Front/Rear Door Wiper Motor Switch
S13 - Left/Right Door Wiper Motor Switch
S14 - Dome Light Switch
V5 - Door Wiper Diode
V6 - Front Wiper Diode
W2 - Ground to Cab Right Rear
X11 - Cab Roof Harness-to-Air Conditioning Harness Connector
X13 - Operator's Station Harness-to-Roof Harness Connector
X25 - Spare Connector Roof
X33 - VEC 8-Pin Connector (Black)
X34 - VEC 8-Pin Connector (Orange)
X40 - Operator's Station-to-Cab Roof Harness Connector
X41 - Cab Roof Harness-to-Radio Harness Connector
X43 - Cab Roof Harness Connector-to-Dome Light Connector
X131 - G04 BLK Splice 1
X132 - G04 BLK Splice 2
X133 - L05 BRN Splice

683
 Cab Roof Harness (W9) Wiring Diagram

TX1079294-UN: Cab Roof Harness (W9) Wiring Diagram (S.N. 174195—210213)

LEGEND:
E1 - Dome Light
E4 - Auxiliary Work Light Left Rear
E5 - Standard Work Light Right Rear
E6 - Auxiliary Work Light Left Front
E7 - Auxiliary Work Light Right Front
E9 - Auxiliary Work Light Right Rear
E10 - Not Used
E11 - Not Used
M6 - Wiper Motor Front
M7 - Wiper Motor Left Door
M8 - Wiper Motor Right Door
S9 - Heater Temperature Control Switch
S10 - Heater Blower Switch
S11 - Air Conditioning On/Off Switch
S12 - Front/Rear Door Wiper Motor Switch
S13 - Left/Right Door Wiper Motor Switch
S14 - Dome Light Switch
V5 - Door Wiper Diode
V6 - Front Wiper Diode
W2 - Ground to Cab Right Rear
X11 - Cab Roof Harness-to-Air Conditioning Harness Connector
X13 - Operator's Station Harness-to-Roof Harness Connector
X25 - Spare Connector Roof
X33 - VEC 8-Pin Connector (Black)
X34 - VEC 8-Pin Connector (Orange)
X40 - Operator's Station-to-Cab Roof Harness Connector
X41 - Cab Roof Harness-to-Radio Harness Connector
X43 - Cab Roof Harness Connector-to-Dome Light Connector
X131 - G04 BLK Splice 1
X132 - G04 BLK Splice 2
X133 - L05 BRN Splice
X191 - L02 BRN Splice
X192 - P15 RED Splice

684
 Cab Roof Harness (W9) Wiring Diagram

TX1097346-UN: Cab Roof Harness (W9) Wiring Diagram (S.N. 210214— )

LEGEND:
E1 - Dome Light
E4 - Auxiliary Work Light Left Rear
E5 - Standard Work Light Right Rear
E6 - Auxiliary Work Light Left Front
E7 - Auxiliary Work Light Right Front
E9 - Auxiliary Work Light Right Rear
E10 - Not Used
E11 - Not Used
M6 - Wiper Motor Front
M7 - Wiper Motor Left Door
M8 - Wiper Motor Right Door
S9 - Heater Temperature Control Switch
S10 - Heater Blower Switch
S11 - Air Conditioning On/Off Switch
S12 - Front/Rear Door Wiper Motor Switch
S13 - Left/Right Door Wiper Motor Switch
S14 - Dome Light Switch
V5 - Left Door Wiper Diode
V6 - Front Wiper Diode 1
V10 - Right Door Wiper Diode
V11 - Front Wiper Diode 2
V12 - Front/Rear Wiper Diode
W2 - Ground to Cab Right Rear
X11 - Cab Roof Harness-to-Air Conditioning Harness Connector
X13 - Operator's Station Harness-to-Roof Harness Connector
X25 - Spare Connector Roof
X33 - VEC 8-Pin Connector (Black)
X34 - VEC 8-Pin Connector (Orange)
X40 - Operator's Station-to-Cab Roof Harness Connector
X41 - Cab Roof Harness-to-Radio Harness Connector
X43 - Cab Roof Harness Connector-to-Dome Light Connector
X131 - G04 BLK Splice 1
X132 - G04 BLK Splice 2

685
 Cab Roof Harness (W9) Wiring Diagram
X133 - L05 BRN Splice
X191 - L02 BRN Splice
X192 - P15 RED Splice

Go to Section_9015:Group_10

MF82180,0000026-19-20111202

686
 Engine Harness (W10) Component Location

Engine Harness (W10) Component Location

TX1018628-UN: Engine Harness (W10) Component Location (Right Side)

LEGEND:
A2 - Engine Control Unit (ECU)
B13 - Manifold Air Temperature Sensor
B18 - Water-in-Fuel Sensor
E2 - Standard Work Light Left Front
E3 - Standard Work Light Right Front
G3 - Alternator
H1 - Horn
R2 - CAN Termination Resistor
V2 - Starter Solenoid 5-Amp Diode
V3 - Start Relay 1-Amp Diode
X3 - ECU 30-Pin Connector
X10 - ECU 30-Pin Connector
X19 - Engine Harness-to-Transmission Harness Connector
X23 - Engine Harness-to-Electronic Injector Harness Connector
X28 - Engine Harness-to-Standard Fan Drive Harness Connector
Y1 - Start Aid Solenoid
Y9 - Quick-Drop Solenoid

687
 Engine Harness (W10) Component Location

TX1018828-UN: Engine Harness (W10) Component Location (Left Side)

LEGEND:
A2 - Engine Control Unit (ECU)
B7 - Pump Pressure Control Pilot (PCP) Rear
B8 - Pump Pressure Control Pilot (PCP) Front
B10 - Fuel Rail Pressure Sensor
B11 - Fuel Temperature Sensor
B12 - Engine Coolant Temperature Sensor
B14 - Crankshaft Position Sensor
B15 - Camshaft Position Sensor
B16 - Ambient Air Temperature Sensor
B17 - Engine Oil Pressure Sensor
B22 - Air Filter Restriction Switch
E2 - Standard Work Light Left Front
E3 - Standard Work Light Right Front
G3 - Alternator
H1 - Horn
K9 - Start Relay
M1 - Starter Motor
V2 - Starter Solenoid 5-Amp Diode
V3 - Start Relay 1-Amp Diode
V4 - Air Conditioning Compressor Clutch 5-Amp Diode
X19 - Engine Harness-to-Transmission Harness Connector
X28 - Engine Harness-to-Standard Fan Drive Harness Connector
Y5 - Hydraulic Fan Proportional Relief Solenoid (with reversing option)
Y6 - Hydraulic Fan Reversing Solenoid
Y9 - Quick-Drop Solenoid
Y12 - High-Pressure Fuel Pump Solenoid
Y16 - Air Conditioning Compressor Clutch Solenoid

688
Engine Harness (W10) Component Location

Go to Section_9015:Group_10

AA95137,0000789-19-20070226

689
 Engine Harness (W10) Wiring Diagram

Engine Harness (W10) Wiring Diagram

TX1018588-UN: Engine Harness (W10) Wiring Diagram

690
 Engine Harness (W10) Wiring Diagram

TX1018579-UN: Engine Harness (W10) Wiring Diagram (1 of 2)

LEGEND:
B7 - Pump Pressure Control Pilot (PCP) Rear
B8 - Pump Pressure Control Pilot (PCP) Front
B10 - Fuel Rail Pressure Sensor
B11 - Fuel Temperature Sensor
B12 - Engine Coolant Temperature Sensor
B14 - Crankshaft Position Sensor
B15 - Camshaft position Sensor
B16 - Ambient Air Temperature Sensor
B17 - Engine Oil Pressure Sensor
B22 - Air Filter Restriction Switch
E2 - Standard Work Light Left Front
E3 - Standard Work Light Right Front
H1 - Horn
K9 - Start Relay
M1 - Starter Motor
V2 - Starter Solenoid 5-Amp Diode
V3 - Start Relay 1-Amp Diode
V4 - Air Conditioning Compressor Clutch 5-Amp Diode
X19 - Engine Harness-to-Transmission Harness Connector
X28 - Engine Harness-to-Standard Fan Drive Harness Connector
X104 - G11 BLK Splice
X105 - H02 GRN Splice
X107 - R15 BLK Splice
X112 - L02 BRN Splice
Y5 - Hydraulic Fan Proportional Relief Solenoid
Y6 - Hydraulic Fan Reversing Solenoid
Y9 - Quick-Drop Solenoid
Y12 - High Pressure Fuel Pump Solenoid
691
 Engine Harness (W10) Wiring Diagram
Y16 - Air Conditioning Compressor Clutch Solenoid

TX1018580-UN: Engine Harness (W10) Wiring Diagram

LEGEND:
B13 - Manifold Air Temperature Sensor
B18 - Water-in-Fuel Sensor
G3 - Alternator
R2 - CAN Termination Resistor
X3 - ECU 48-Pin Connector
X10 - ECU 32-Pin Connector
X19 - Engine Harness-to-Transmission Harness Connector
X23 - Engine Harness-to-Electronic Injector Harness Connector
X106 - Shield Ground Splice
X108 - G12 BLK Splice
X109 - R13 BLK Splice 1
X110 - M13 LGRN Splice 1
X111 - M12 YEL Splice 1
X113 - P30 RED Splice
Y1 - Start Aid Solenoid

Go to Section_9015:Group_10

WS68074,0000B54-19-20070226

692
 Transmission Harness (W11) Component Location

Transmission Harness (W11) Component Location

TX1063244-UN: Transmission Harness (W11) Component Location (S.N. 139436—153828)

LEGEND:
B2 - Motor Speed Sensor Left
B3 - Motor Speed Sensor Right
B4 - Hydrostatic Charge Pressure Sensor
B5 - Right Hydrostatic Pressure Sensor (S.N. —173658)
B6 - Left Hydrostatic Pressure Sensor (S.N. —173658)
B9 - Quick-Drop Pressure Switch
B19 - Fuel Level Sensor
B20 - Hydraulic Oil Temperature Sensor
B21 - Transmission Oil Temperature Sensor
B23 - Hydraulic Oil Filter Restriction Switch
B24 - Hydraulic Fan Oil Filter Restriction Switch
B25 - Hydrostatic Charge Oil Filter Restriction Switch
B35 - Charge Pressure Sensor
F33 - Main 125-Amp Fuse
H3 - Backup Alarm
M2 - Heater Valve Motor
M9 - Washer Motor Front/Rear
M10 - Washer Motor Left/Right
U2 - Standard 12 V Power Converter
U3 - Optional 12 V Power Converter
W3 - Ground to Frame Under Cab
W5 - HIC Valve Ground
W18 - Fuel Tank Harness
W20 - Optional Power Converter Harness
X16 - Operator's Station Harness-to-Transmission Harness Connector 1
X17 - Operator's Station Harness-to-Transmission Harness Connector 2

693
 Transmission Harness (W11) Component Location
X18 - Operator's Station Harness-to-Transmission Harness Connector 3
X19 - Engine Harness-to-Transmission Harness Connector
X20 - Optional 12 V Power Converter Connector
X21 - Transmission Harness-to-Fuel Tank Harness Connector Harness
X29 - Automatic Diagnostic Connector
X30 - Operator's Station Harness-to-Transmission Harness Connector 4
X42 - Optional 12 V Terminal Block
X50 - Battery Power Connector
X84 - Alternator W Signal-to-IGC Hour Meter Connector
Y2 - Park Brake Solenoid 1
Y3 - Motor Shift Solenoid Left
Y4 - Motor Shift Solenoid Right
Y7 - Blade Angle Solenoid Left (top) (pilot control only)
Y8 - Blade Angle Solenoid Right (bottom) (pilot control only)
Y10 - Pilot Control Enable Solenoid
Y14 - Hydrostatic Oil Cooler Bypass Solenoid
Y15 - Park Brake Solenoid 2
Y17 - Hydrostatic Oil Reservoir Bypass Solenoid

TX1079359-UN: Transmission Harness (W11) Component Location (S.N. 153829—173641)

LEGEND:
B2 - Motor Speed Sensor Left
B3 - Motor Speed Sensor Right
B4 - Hydrostatic Charge Pressure Sensor (S.N. —173641)
B5 - Right Hydrostatic Pressure Sensor (S.N. —173658)
B6 - Left Hydrostatic Pressure Sensor (S.N. — 173658)
B9 - Quick-Drop Pressure Switch
B20 - Hydraulic Oil Temperature Sensor
B21 - Transmission Oil Temperature Sensor
B23 - Hydraulic Oil Filter Restriction Switch
B24 - Hydraulic Fan Oil Filter Restriction Switch
B25 - Hydrostatic Charge Oil Filter Restriction Switch
B35 - Brake Pressure Sensor (S.N. —173641)
F33 - Main 125-Amp Fuse
F34 - JDLink™ Ground 5-Amp Fuse
H3 - Backup Alarm

694
 Transmission Harness (W11) Component Location
M2 - Heater Valve Motor
M9 - Washer Motor Front/Rear
M10 - Washer Motor Left/Right
S2 - Battery Disconnect Switch
U2 - Standard 12 V Power Converter
U3 - Optional 12 V Power Converter
W3 - Ground to Frame Under Cab
W5 - HIC Valve Ground
X16 - Operator's Station Harness-to-Transmission Harness Connector 1
X17 - Operator's Station Harness-to-Transmission Harness Connector 2
X18 - Operator's Station Harness-to-Transmission Harness Connector 3
X19 - Engine Harness-to-Transmission Harness Connector
X21 - Transmission Harness-to-Fuel Tank Harness Connector Harness
X30 - Operator's Station Harness-to-Transmission Harness Connector 4
Y2 - Park Brake Solenoid 1
Y3 - Motor Shift Solenoid Left
Y4 - Motor Shift Solenoid Right
Y7 - Blade Angle Solenoid Left (top) (pilot control only)
Y8 - Blade Angle Solenoid Right (bottom) (pilot control only)
Y10 - Pilot Control Enable Solenoid
Y14 - Hydrostatic Oil Cooler Bypass Solenoid
Y15 - Park Brake Solenoid 2
Y17 - Hydrostatic Oil Reservoir Bypass Solenoid

TX1079357-UN: Transmission Harness (W11) Component Location (S.N. 173642—183063)

LEGEND:
B2 - Motor Speed Sensor Left
B3 - Motor Speed Sensor Right
B9 - Quick-Drop Pressure Switch
B20 - Hydraulic Oil Temperature Sensor
B21 - Transmission Oil Temperature Sensor
B23 - Hydraulic Oil Filter Restriction Switch
B24 - Hydraulic Fan Oil Filter Restriction Switch
B25 - Hydrostatic Charge Oil Filter Restriction Switch
B41 - Hydrostatic Charge Pressure Sensor
B42 - Brake Pressure Sensor

695
 Transmission Harness (W11) Component Location
B43 - Right Hydrostatic Pressure Sensor (S.N. 173659— )
B44 - Left Hydrostatic Pressure Sensor (S.N. 173659— )
F33 - Main 125-Amp Fuse
F34 - JDLink™ Ground 5-Amp Fuse
H3 - Backup Alarm
M2 - Heater Valve Motor
M9 - Washer Motor Front/Rear
M10 - Washer Motor Left/Right
S2 - Battery Disconnect Switch
U2 - Standard 12 V Power Converter
U3 - Optional 12 V Power Converter
W3 - Ground to Frame Under Cab
W5 - HIC Valve Ground
W27 - Pressure Sensor Harness (2 used, S.N. 173642—173658; 4 used, S.N. 173659— )
X16 - Operator's Station Harness-to-Transmission Harness Connector 1
X17 - Operator's Station Harness-to-Transmission Harness Connector 2
X18 - Operator's Station Harness-to-Transmission Harness Connector 3
X19 - Engine Harness-to-Transmission Harness Connector
X21 - Transmission Harness-to-Fuel Tank Harness Connector Harness
X30 - Operator's Station Harness-to-Transmission Harness Connector 4
X70 - Charge Pressure Sensor Harness Connector
X71 - Brake Pressure Sensor Harness Connector
X72 - Right Hydrostatic Pressure Sensor Harness Connector
X73 - Left Hydrostatic Pressure Sensor Harness Connector
Y2 - Park Brake Solenoid 1
Y3 - Motor Shift Solenoid Left
Y4 - Motor Shift Solenoid Right
Y7 - Blade Angle Solenoid Left (top) (pilot control only)
Y8 - Blade Angle Solenoid Right (bottom) (pilot control only)
Y10 - Pilot Control Enable Solenoid
Y14 - Hydrostatic Oil Cooler Bypass Solenoid
Y15 - Park Brake Solenoid 2
Y17 - Hydrostatic Oil Reservoir Bypass Solenoid

TX1242204-UN: Transmission Harness (W11) Component Location (S.N. 183064— )

LEGEND:
B2 - Motor Speed Sensor Left
B3 - Motor Speed Sensor Right
B9 - Quick-Drop Pressure Switch
B20 - Hydraulic Oil Temperature Sensor
B21 - Transmission Oil Temperature Sensor
B23 - Hydraulic Oil Filter Restriction Switch
B24 - Hydraulic Fan Oil Filter Restriction Switch
B25 - Hydrostatic Charge Oil Filter Restriction Switch
B41 - Hydrostatic Charge Pressure Sensor
B42 - Brake Pressure Sensor
B43 - Hydrostatic Pressure Sensor Right
B44 - Hydrostatic Pressure Sensor Left
696
 Transmission Harness (W11) Component Location

B46 - Fuel Heater Temperature Switch (if equipped)

F33 - Main 125-Amp Fuse
F34 - JDLink™ Ground 5-Amp Fuse
H3 - Backup Alarm
M2 - Heater Valve Motor
M9 - Washer Motor Front/Rear
M10 - Washer Motor Left/Right
R6 - Fuel Heater (if equipped)
S2 - Battery Disconnect Switch
U2 - Standard 12 V Power Converter
U3 - Optional 12 V Power Converter
W3 - Ground to Frame Under Cab
W5 - HIC Valve Ground
W27 - Pressure Sensor Harness (4 used)
X16 - Operator's Station Harness-to-Transmission Harness Connector 1
X17 - Operator's Station Harness-to-Transmission Harness Connector 2
X18 - Operator's Station Harness-to-Transmission Harness Connector 3
X19 - Engine Harness-to-Transmission Harness Connector
X21 - Transmission Harness-to-Fuel Tank Harness Connector Harness
X30 - Operator's Station Harness-to-Transmission Harness Connector 4
X70 - Charge Pressure Sensor Harness Connector
X71 - Brake Pressure Sensor Harness Connector
X72 - Right Hydrostatic Pressure Sensor Harness Connector
X73 - Left Hydrostatic Pressure Sensor Harness Connector
Y2 - Park Brake Solenoid 1
Y3 - Motor Shift Solenoid Left
Y4 - Motor Shift Solenoid Right
Y7 - Blade Angle Solenoid Left (top) (pilot control only)
Y8 - Blade Angle Solenoid Right (bottom) (pilot control only)
Y10 - Pilot Control Enable Solenoid
Y14 - Hydrostatic Oil Cooler Bypass Solenoid
Y15 - Park Brake Solenoid 2
Y17 - Hydrostatic Oil Reservoir Bypass Solenoid

Go to Section_9015:Group_10

AA95137,00007BE-19-20170725

697
 Transmission Harness (W11) Wiring Diagram

Transmission Harness (W11) Wiring Diagram

TX1079406-UN: Transmission Harness (W11) Wiring Diagram (1 of 2) (S.N. 139436—153828)

698
 Transmission Harness (W11) Wiring Diagram

TX1079407-UN: Transmission Harness (W11) Wiring Diagram (2 of 2) (S.N. 139436—153828)

LEGEND:
B2 - Motor Speed Sensor Left
B3 - Motor Speed Sensor Right
B4 - Hydrostatic Charge Pressure Sensor
B5 - Hydrostatic Pressure Sensor Right
B6 - Hydrostatic Pressure Sensor Left
B9 - Quick-Drop Pressure Switch
B20 - Hydraulic Oil Temperature Sensor
B21 - Transmission Oil Temperature Sensor
B23 - Hydraulic Oil Filter Restriction Switch
B24 - Hydraulic Fan Oil Filter Restriction Switch
B25 - Hydrostatic Charge Oil Filter Restriction Switch
B35 - Brake Pressure Sensor
M2 - Heater Valve Motor
M9 - Washer Motor Front/Rear
M10 - Washer Motor Left/Right
U2 - Standard 12 V Power Converter
W3 - Ground to Frame Under Cab
W5 - HIC Valve Ground
X16 - Operator's Station Harness-to-Transmission Harness Connector 1
X17 - Operator's Station Harness-to-Transmission Harness Connector 2
X18 - Operator's Station Harness-to-Transmission Harness Connector 3
X19 - Engine Harness-to-Transmission Harness Connector
X20 - Optional 12 V Power Converter Connector
X29 - Automatic Diagnostic Connector
X30 - Operator's Station Harness-to-Transmission Harness Connector 4
X50 - Battery Power Connector
X84 - Alternator W Signal-to-IGC Hour Meter Connector
X100 - T24 BLU Splice
X101 - G05 BLK Splice
X102 - R12 BLK Splice
X103 - G10 BLK Splice
Y2 - Park Brake Solenoid 1
Y3 - Motor Shift Solenoid Left

699
 Transmission Harness (W11) Wiring Diagram
Y4 - Motor Shift Solenoid Right
Y7 - Blade Angle Solenoid Left (top) (pilot control only)
Y8 - Blade Angle Solenoid Right (bottom) (pilot control only)
Y10 - Pilot Control Enable Solenoid
Y14 - Hydrostatic Oil Reservoir Bypass Solenoid
Y15 - Park Brake Solenoid 2
Y17 - Hydrostatic Oil Cooler Bypass Solenoid

TX1079408-UN: Transmission Harness (W11) Wiring Diagram (1 of 2) (S.N. 153829—173641)

700
 Transmission Harness (W11) Wiring Diagram

TX1079409-UN: Transmission Harness (W11) Wiring Diagram (2 of 2) (S.N. 153829—173641)

LEGEND:
B2 - Motor Speed Sensor Left
B3 - Motor Speed Sensor Right
B4 - Hydrostatic Charge Pressure Sensor
B5 - Right Hydrostatic Pressure Sensor (S.N. —173658)
B6 - Left Hydrostatic Pressure Sensor (S.N. —173658)
B9 - Quick-Drop Pressure Switch
B20 - Hydraulic Oil Temperature Sensor
B21 - Transmission Oil Temperature Sensor
B23 - Hydraulic Oil Filter Restriction Switch
B24 - Hydraulic Fan Oil Filter Restriction Switch
B25 - Hydrostatic Charge Oil Filter Restriction Switch
B35 - Brake Pressure Sensor
F34 - JDLink™ Ground 5-Amp Fuse
G1 - Batteries
M2 - Heater Valve Motor
M9 - Washer Motor Front/Rear
M10 - Washer Motor Left/Right
U2 - Standard 12 V Power Converter
W3 - Ground to Frame Under Cab
W5 - HIC Valve Ground
X16 - Operator's Station Harness-to-Transmission Harness Connector 1
X17 - Operator's Station Harness-to-Transmission Harness Connector 2
X18 - Operator's Station Harness-to-Transmission Harness Connector 3
X19 - Engine Harness-to-Transmission Harness Connector
X20 - Optional 12 V Power Converter Connector
X30 - Operator's Station Harness-to-Transmission Harness Connector 4
X50 - Battery Power Connector
X84 - Alternator W Signal-to-IGC Hour Meter Connector (later machines)
X100 - T24 BLU Splice
X101 - G05 BLK Splice
X102 - R12 BLK Splice
X103 - G10 BLK Splice
Y2 - Park Brake Solenoid 1

701
 Transmission Harness (W11) Wiring Diagram
Y3 - Motor Shift Solenoid Left
Y4 - Motor Shift Solenoid Right
Y7 - Blade Angle Solenoid Left (top) (pilot control only)
Y8 - Blade Angle Solenoid Right (bottom) (pilot control only)
Y10 - Pilot Control Enable Solenoid
Y14 - Hydrostatic Oil Reservoir Bypass Solenoid
Y15 - Park Brake Solenoid 2
Y17 - Hydrostatic Oil Cooler Bypass Solenoid

TX1079411-UN: Transmission Harness (W11) Wiring Diagram (1 of 2) (S.N. 173642—174194)

702
 Transmission Harness (W11) Wiring Diagram

TX1079412-UN: Transmission Harness (W11) Wiring Diagram (S.N. 173642—174194)

LEGEND:
B2 - Motor Speed Sensor Left
B3 - Motor Speed Sensor Right
B9 - Quick-Drop Pressure Switch
B20 - Hydraulic Oil Temperature Sensor
B21 - Transmission Oil Temperature Sensor
B23 - Hydraulic Oil Filter Restriction Switch
B24 - Hydraulic Fan Oil Filter Restriction Switch
B25 - Hydrostatic Charge Oil Filter Restriction Switch
F34 - JDLink™ Ground 5-Amp Fuse
G1 - Batteries
M2 - Heater Valve Motor
M9 - Washer Motor Front/Rear
M10 - Washer Motor Left/Right
U2 - Standard 12 V Power Converter
W3 - Ground to Frame Under Cab
W5 - HIC Valve Ground
X16 - Operator's Station Harness-to-Transmission Harness Connector 1
X17 - Operator's Station Harness-to-Transmission Harness Connector 2
X18 - Operator's Station Harness-to-Transmission Harness Connector 3
X19 - Engine Harness-to-Transmission Harness Connector
X20 - Optional 12 V Power Converter Connector
X30 - Operator's Station Harness-to-Transmission Harness Connector 4
X50 - Battery Power Connector
X70 - Charge Pressure Sensor Harness Connector
X71 - Brake Pressure Sensor Harness Connector
X72 - Right Hydrostatic Pressure Sensor Harness (S.N. 173659— )
X73 - Left Hydrostatic Pressure Sensor Harness (S.N. 173659— )
X84 - Alternator W Signal-to-IGC Hour Meter Connector (Later Machines)
X100 - T24 BLU Splice
X101 - G05 BLK Splice
X102 - R12 BLK Splice
X103 - G10 BLK Splice
Y2 - Park Brake Solenoid 1

703
 Transmission Harness (W11) Wiring Diagram
Y3 - Motor Shift Solenoid Left
Y4 - Motor Shift Solenoid Right
Y7 - Blade Angle Solenoid Left (top) (pilot control only)
Y8 - Blade Angle Solenoid Right (bottom) (pilot control only)
Y10 - Pilot Control Enable Solenoid
Y14 - Hydrostatic Oil Reservoir Bypass Solenoid
Y15 - Park Brake Solenoid 2
Y17 - Hydrostatic Oil Cooler Bypass Solenoid

TX1079413-UN: Transmission Harness (W11) Wiring Diagram (1 of 2) (S.N. 174195—183063)

704
 Transmission Harness (W11) Wiring Diagram

TX1079414-UN: Transmission Harness (W11) Wiring Diagram (2 of 2) (S.N. 174195—183063)

LEGEND:
B2 - Motor Speed Sensor Left
B3 - Motor Speed Sensor Right
B9 - Quick-Drop Pressure Switch
B20 - Hydraulic Oil Temperature Sensor
B21 - Transmission Oil Temperature Sensor
B23 - Hydraulic Oil Filter Restriction Switch
B24 - Hydraulic Fan Oil Filter Restriction Switch
B25 - Hydrostatic Charge Oil Filter Restriction Switch
F34 - JDLink™ Ground 5 Amp Fuse
M2 - Heater Valve Motor
M9 - Washer Motor Front/Rear
M10 - Washer Motor Left/Right
U2 - Standard 12 V Power Converter
W3 - Ground to Frame Under Cab
W5 - HIC Valve Ground
X16 - Operator's Station Harness-to-Transmission Harness Connector 1
X17 - Operator's Station Harness-to-Transmission Harness Connector 2
X18 - Operator's Station Harness-to-Transmission Harness Connector 3
X19 - Engine Harness-to-Transmission Harness Connector
X20 - Optional 12 V Power Converter Connector
X30 - Operator's Station Harness-to-Transmission Harness Connector 4
X50 - Battery Power Connector
X68 - JDLink™ Ground Connector
X70 - Charge Pressure Sensor Harness Connector
X71 - Brake Pressure Sensor Harness Connector
X72 - Right Hydrostatic Pressure Sensor Harness Connector
X73 - Left Hydrostatic Pressure Sensor Harness Connector
X84 - Alternator W Signal-to-IGC Hour Meter Connector
X100 - T24 BLU Splice
X101 - G05 BLK Splice
X102 - R12 BLK Splice
X103 - G10 BLK Splice
X190 - G70 BLK Splice

705
 Transmission Harness (W11) Wiring Diagram
Y2 - Park Brake Solenoid 1
Y3 - Motor Shift Solenoid Left
Y4 - Motor Shift Solenoid Right
Y7 - Blade Angle Solenoid Left (top) (pilot control only)
Y8 - Blade Angle Solenoid Right (bottom) (pilot control only)
Y10 - Pilot Control Enable Solenoid
Y14 - Hydrostatic Oil Reservoir Bypass Solenoid
Y15 - Park Brake Solenoid 2
Y17 - Hydrostatic Oil Cooler Bypass Solenoid

TX1079415-UN: Transmission Harness (W11) Wiring Diagram (1 of 2) (S.N. 183064— )

706
 Transmission Harness (W11) Wiring Diagram

TX1079416-UN: Transmission Harness (W11) Wiring Diagram (2 of 2) (S.N. 183064— )

LEGEND:
B2 - Motor Speed Sensor Left
B3 - Motor Speed Sensor Right
B9 - Quick-Drop Pressure Switch
B20 - Hydraulic Oil Temperature Sensor
B21 - Transmission Oil Temperature Sensor
B23 - Hydraulic Oil Filter Restriction Switch
B24 - Hydraulic Fan Oil Filter Restriction Switch
B25 - Hydrostatic Charge Oil Filter Restriction Switch
B46 - Fuel Heater Temperature Switch (if equipped)
F34 - JDLink™ Ground 5 Amp Fuse
M2 - Heater Valve Motor
M9 - Washer Motor Front/Rear
M10 - Washer Motor Left/Right
R6 - Fuel Heater (if equipped)
U2 - Standard 12 V Power Converter
W3 - Ground to Frame Under Cab
W5 - HIC Valve Ground
X16 - Operator's Station Harness-to-Transmission Harness Connector 1
X17 - Operator's Station Harness-to-Transmission Harness Connector 2
X18 - Operator's Station Harness-to-Transmission Harness Connector 3
X19 - Engine Harness-to-Transmission Harness Connector
X20 - Optional 12 V Power Converter Connector
X30 - Operator's Station Harness-to-Transmission Harness Connector 4
X50 - Battery Power Connector
X68 - JDLink™ Ground Connector
X70 - Charge Pressure Sensor Harness Connector
X71 - Brake Pressure Sensor Harness Connector
X72 - Right Hydrostatic Pressure Sensor Harness Connector
X73 - Left Hydrostatic Pressure Sensor Harness Connector
X84 - Alternator W Signal-to-IGC Hour Meter Connector
X100 - T24 BLU Splice
X101 - G05 BLK Splice
X102 - R12 BLK Splice

707
 Transmission Harness (W11) Wiring Diagram
X103 - G10 BLK Splice
X190 - G70 BLK Splice
Y2 - Park Brake Solenoid 1
Y3 - Motor Shift Solenoid Left
Y4 - Motor Shift Solenoid Right
Y7 - Blade Angle Solenoid Left (top) (pilot control only)
Y8 - Blade Angle Solenoid Right (bottom) (pilot control only)
Y10 - Pilot Control Enable Solenoid
Y14 - Hydrostatic Oil Reservoir Bypass Solenoid
Y15 - Park Brake Solenoid 2
Y17 - Hydrostatic Oil Cooler Bypass Solenoid

T206603-UN: Fuel Tank Harness (W18) Wiring Diagram

708
 Transmission Harness (W11) Wiring Diagram
LEGEND:
B19 - Fuel Level Sensor
H3 - Backup Alarm
X21 - Transmission Harness-to-Fuel Tank Harness Connector Harness

T206604-UN: Optional Power Converter Harness (W20) Wiring Diagram

LEGEND:
U3 - Standard 12 V Power Converter
X20 - Optional 12 V Power Converter Connector
X42 - Optional 12 V Terminal Block
X137 - P14 RED Splice

709
Transmission Harness (W11) Wiring Diagram

Go to Section_9015:Group_10

AA95137,00007BD-19-20100722

710
 Air Conditioning Harness (W14) Component Location

Air Conditioning Harness (W14) Component Location

TX1044592-UN: Air Conditioning Harness (W14) Component Location

LEGEND:
B22 - Air Conditioning Freeze Switch
B50 - A/C High/Low (Binary) Pressure Switch
M3 - Heater Blower Motor
M4 - Condenser Fan Motor
M5 - Condenser Fan Motor
R3 - Heater Valve Resistor
R4 - Cab Heater Blower Resistor
W14 - Condenser Harness

711
 Air Conditioning Harness (W14) Component Location
X11 - Cab Roof Harness-to-Air Conditioning Harness Connector
X51 - Air Conditioning Harness-to-Condenser Harness Connector

Go to Section_9015:Group_10

AA95137,00007BC-19-20080624

712
 Air Conditioning Harness (W14) Wiring Diagram

Air Conditioning Harness (W14) Wiring Diagram

TX1075038-UN: Air Conditioning Harness (W14) Wiring Harness

LEGEND:
B22 - Air Conditioning Freeze Switch
B50 - A/C High/Low Pressure (Binary) Switch
M3 - Heater Blower Motor
M4 - Condenser Fan Motor
M5 - Condenser Fan Motor
R3 - Heater Valve Resistor
R4 - Cab Heater Blower Resistor
W14 - Condenser Harness
X11 - Cab Roof Harness-to-Air Conditioning Harness Connector
X51 - Air Conditioning Harness-to-Condenser Harness Connector

Go to Section_9015:Group_10

AA95137,00007BB-19-20100329

713
 Radio Harness (W15) Component Location

Radio Harness (W15) Component Location

T203317-UN: Radio Harness (W15) Component Location

LEGEND:
A5 - Radio (12 V)
B30 - Right Speaker
B31 - Left Speaker
W1 - Radio Antenna
X41 - Cab Roof Harness-to-Radio Harness Connector

Go to Section_9015:Group_10

AA95137,00007BA-19-20070208

714
 Radio Harness (W15) Wiring Diagram

Radio Harness (W15) Wiring Diagram

T203318-UN: Radio Harness (W15) Wiring Diagram

LEGEND:
A5 - Radio (12 V)
B30 - Right Speaker
B31 - Left Speaker
X41 - Cab/Canopy Harness-to-Radio Harness Connector

Go to Section_9015:Group_10

AA95137,00007B9-19-20070208

715
 IGC Machine Harness (W21) and IGC Cab Harness (W22) Component Location—If Equipped

IGC Machine Harness (W21) and IGC Cab Harness (W22) Component Location—If
Equipped

TX1009748-UN: IGC Harnesses (W21 and W22) Component Location

LEGEND:
A8 - IGC Load Center
A9 - Blade Control Joystick (BCJ)
A11 - Electrohydraulic Controller (EHC)
R7 - CAN Termination (120 ohm) Resistor
R8 - CAN Termination (120 ohm) Resistor
W21 - Integrated Grade Control (IGC) Machine Harness
W22 - Integrated Grade Control (IGC) Cab Harness
X79 - 2-Pin Connector (not used)
X80 - IGC Power Connector
X81 - RS232 Connector
X82 - Electrohydraulic Controller (EHC) Connector
X83 - Electrohydraulic Controller (EHC) Connector
X84 - Alternator W Signal-to-IGC Hour Meter Connector
X85 - Auxiliary Joystick Connector
X86 - Machine CAN Connector
X87 - IGC Ground Connector
X88 - IGC Harness 24/12 Volt Converter Connector
X89 - IGC Machine Harness-to-Transmission Harness Connector
X90 - Auxiliary IGC Actuator Connector
X95 - IGC Machine Harness-to-IGC Cab Harness Connector
X96 - IGC Interface Connector
X97 - BCJ Switch Module Connector
X98 - BCJ 4-Way Axis Module Connector
Y30 - Blade Angle Actuator
Y31 - Blade Tilt Actuator

716
 IGC Machine Harness (W21) and IGC Cab Harness (W22) Component Location—If Equipped
Y32 - Blade Lift Actuator

Go to Section_9015:Group_10

AA95137,00007B6-19-20080620

717
 Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped

Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped

TX1074991-UN: IGC Machine Harness (W21) Wiring Diagram Legend

TX1011269-UN: IGC Machine Harness (W21) Wiring Diagram (1 of 2)

LEGEND:
1 - Continued on Sheet 2 of 2
A8 - IGC Load Center
R8 - CAN Termination 120 ohm Resistor
X79 - 2-Pin Connector (not used)
X80 - IGC Power Connector
X81 - RS232 Connector
X82 - Electrohydraulic Controller (EHC) Connector
X83 - Electrohydraulic Controller (EHC) Connector
X84 - Alternator W Signal-to-IGC Hour Meter Connector
X85 - Auxiliary Joystick Connector
X87A - IGC Ground Connector
X87B - IGC Ground Connector

718
 Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped
X88 - IGC Harness 24/12 Volt Converter Connector
X89 - IGC Machine Harness-to-Transmission Harness Connector
X90 - Auxiliary IGC Actuator Connector
X99 - IGC Ground Connector
X150 - G20 BLK IGC Splice 1
X151 - P62 RED IGC Splice
X152 - P58 RED IGC Splice
X153 - P51 RED IGC Splice
X155 - G05 BLK IGC Splice
X156 - G20 BLK IGC Splice 2
X157 - P50 RED IGC Splice
X199 - P14 RED IGC Splice
Y30 - Blade Angle Actuator
Y31 - Blade Tilt Actuator
Y32 - Blade Lift Actuator

NOTE:

Pin arrangement of connectors X95 and X96 is viewed from the pin side of connector. All other
connectors are viewed from wire harness side of connector.

TX1011270-UN: IGC Machine Harness (W21) Wiring Diagram (2 of 2)

LEGEND:
1 - Continued on Sheet 1 of 2
X95 - IGC Machine Harness-to-IGC Cab Harness Connector
X96 - IGC Interface Connector
X158 - R40 BLK IGC CAN Splice
X159 - M18 GRN IGC CAN Splice
X160 - M17 YEL IGC CAN Splice
X161 - R13 BLK IGC CAN Splice

719
 Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped
X162 - M13 GRN IGC CAN Splice
X163 - M12 YEL IGC CAN Splice
X168 - H22 GRN IGC Splice
X169 - R41 BLK IGC Splice
X170 - G20 BLK IGC Splice

Go to Section_9015:Group_10

AA95137,00007B7-19-20120817

720
 Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped

Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped

TX1115709-UN: IGC Cab Harness (W22) Wiring Diagram

LEGEND:
R7 - CAN Termination (120 ohm) Resistor
S8 - Pilot Control Enable Switch
X81 - RS232 Connector
X85 - Auxiliary Joystick Connector
X86 - Machine CAN Connector
X95 - IGC Machine Harness-to-IGC Cab Harness Connector
X97 - Blade Control Joystick (BCJ) Switch Module (A9) Connector
X98 - Blade Control Joystick (BCJ) Module (A9) Connector
X164 - H22 GRN IGC Splice
X165 - R13 BLK IGC CAN Splice
X166 - M13 GRN IGC CAN Splice
X167 - M12 YEL IGC CAN Splice

NOTE:

Pin arrangement of connector X95 is viewed from the pin side of connector. All other connectors
are viewed from wire harness side of connector.

Go to Section_9015:Group_10

AA95137,00007B8-19-20120614

721
 Pressure Sensor Harness (W27) Wiring Diagram

Pressure Sensor Harness (W27) Wiring Diagram

TX1063214-UN: Pressure Sensor Harness (W27) Wiring Diagram

LEGEND:
B - Pressure Sensor Connector
X - Pressure Sensor Harness Connector

Go to Section_9015:Group_10

JW40272,00004E5-19-20090924

722
 JDLink™ System Harnesses Component Location—MIG/GTT

JDLink™ System Harnesses Component Location—MIG/GTT

Machine may be equipped with one of two different JDLink™ systems. See JDLink™ System Identification .
(Group 9015-20.)

JDLink™ Harnesses (W30 and W31) Component Location—If Equipped (S.N. 153829—
196449)

TX1026421-UN: JDLink™ System Harnesses (W30 and W31) Component Location—If Equipped (S.N. 153829—
196449)
LEGEND:
A12 - Machine Information Gateway (MIG) Controller
A13 - GlobalTRACS® Terminal (GTT) Controller
W30 - Machine Information Gateway (MIG) Harness
W31 - GlobalTRACS® Terminal (GTT) Harness
W33 - GlobalTRACS® Terminal (GTT) Antenna
W34 - GlobalTRACS® Terminal (GTT) Controller Ground
X62 - Operator's Station Harness-to-GlobalTRACS® Terminal (GTT) Harness 12-Pin Connector
X63 - Operator's Station Harness-to-Machine Information Gateway (MIG) Harness 12-Pin Connector
X64 - GlobalTRACS® Terminal (GTT) 70-Pin Connector
X65 - Machine Information Gateway (MIG) Harness-to-GlobalTRACS® Terminal (GTT) Harness
X66 - Machine Information Gateway (MIG) 30-Pin (L1—Y3) Connector
X67 - Machine Information Gateway (MIG) 30-Pin (A1—K3) Connector

Go to Section_9015:Group_10

DP27668,00007A6-19-20131125

723
 JDLink™ System Harnesses Component Location—MTG/SAT

JDLink™ System Harnesses Component Location—MTG/SAT

Machine may be equipped with one of two different JDLink™ systems. See JDLink™ System Identification .
(Group 9015-20.)

JDLink™ Harnesses (W6002 and W6003) Component Location—If Equipped (S.N. 196450
—)

TX1086784-UN: JDLink™ Harnesses (W6002 and W6003) Component Location (S.N. 196450— )
LEGEND:
A6000 - JDLink™ Modular Telematics Gateway (MTG) Control Unit
A6001 - GPS/Cellular Antenna
A6002 - Satellite (SAT) Module Control Unit (if equipped)
A6003 - Satellite Antenna (if equipped)

724
 JDLink™ System Harnesses Component Location—MTG/SAT
W6002 - Universal JDLink™ Harness
W6003 - Satellite Adapter Harness
X63 - Main Cab/Canopy Harness-to-JDLink™ Harness 12-Pin Connector
X6014 - Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector
X6015 - Satellite (SAT) Module Control Unit 48-Pin Connector
X6016 - Satellite Adapter Harness-to-Universal JDLink™ Harness 6-Pin Connector

Go to Section_9015:Group_10

DP27668,00007A7-19-20131125

725
 JDLink™ System Wiring Diagrams—MIG/GTT

JDLink™ System Wiring Diagrams—MIG/GTT

Machine may be equipped with one of two different JDLink™ systems. See JDLink™ System Identification .
(Group 9015-20.)

Machine Information Gateway (MIG) Harness (W30) Wiring Diagram—If Equipped (S.N.
153829—161691)

TX1026202-UN: MIG Wiring Harness (W30) Diagram—If Equipped (S.N. 153829—161691)

LEGEND:
X63 - Cab Harness-to-Machine Information Gateway (MIG) Harness 12-Pin Connector
X65 - Machine Information Gateway (MIG) Harness-to- GlobalTRACS® Terminal (GTT) Harness 12-Pin Connector
X66 - Machine Information Gateway (MIG) 30-Pin Connector 1
X67 - Machine Information Gateway (MIG) 30-Pin Connector 2
X186 - G70 BLK Splice
X187 - P70 RED Splice
X188 - G71 BLK Splice

Machine Information Gateway (MIG) Harness (W30) Wiring Diagram—If Equipped (S.N.
161692—196449)

726
 JDLink™ System Wiring Diagrams—MIG/GTT

TX1041205-UN: Machine Information Gateway (MIG) Wiring Harness (W30) Diagram—If Equipped (S.N. 161692—
196449)
LEGEND:
X63 - Cab Harness-to-Machine Information Gateway (MIG) Harness 12-Pin Connector
X65 - Machine Information Gateway (MIG) Harness-to-GlobalTRACS® Terminal (GTT) Harness 12-Pin Connector
X66 - Machine Information Gateway (MIG) 30-Pin Connector 1
X67 - Machine Information Gateway (MIG) 30-Pin Connector 2
X186 - G70 BLK Splice
X187 - P70 RED Splice
X188 - G71 BLK Splice

GlobalTRACS® Terminal (GTT) Harness (W31) Wiring Diagram—If Equipped (S.N. 153829
—196449)

727
 JDLink™ System Wiring Diagrams—MIG/GTT

TX1148030-UN: GTT Wiring Harness (W31) Diagram (S.N. 153829—196449)

LEGEND:
W34 - Frame Ground at Cab/Canopy Right Front
X62 - Cab Harness-to-GlobalTRACS Terminal (GTT) Harness 12-Pin Connector
X64 - GlobalTRACS® Terminal (GTT) 70-Pin Connector
X65 - Machine Information Gateway (MIG) Harness-to-GlobalTRACS® Terminal (GTT) Harness 12-Pin Connector
X189 - R70 BLK Splice

Go to Section_9015:Group_10

DP27668,00007A8-19-20131125

728
 JDLink™ System Wiring Diagrams—MTG/SAT

JDLink™ System Wiring Diagrams—MTG/SAT

Machine may be equipped with one of two different JDLink™ systems. See JDLink™ System Identification .
(Group 9015-20.)

JDLink™ Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram—If

Equipped (S.N. 196450— )

TX1086381-UN: JDLink™ Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram
LEGEND:
A6000 - Modular Telematics Gateway (MTG) Control Unit
X63 - JDLink™ 12-Pin Connector
X5000 - G70 BLK Splice
X5001 - P70 RED Splice
729
 JDLink™ System Wiring Diagrams—MTG/SAT
X6014 - Modular Telematics Gateway (MTG) 48-Pin Connector
X6016 - Satellite Adapter Harness-to-Universal JDLink™ Harness Connector
X6020 - Not Used
X6021 - Not Used
X6022 - Not Used
X6023 - Not Used

JDLink™ Satellite (SAT) Harness (W6003) Wiring Diagram—If Equipped (S.N. 196450— )

TX1083072-UN: JDLink™ Satellite (SAT) Harness (W6003) Wiring Diagram—If Equipped (S.N. 196450— )
LEGEND:
A6002 - Satellite (SAT) Control Unit
X6015 - JDLink™ Satellite Module Connector
X6016 - Satellite Adapter Harness-to-Universal JDLink™ Harness Connector

730
JDLink™ System Wiring Diagrams—MTG/SAT

Go to Section_9015:Group_10

DP27668,00007A9-19-20131125

731
 Starting and Charging Circuit Theory of Operation

Starting and Charging Circuit Theory of Operation

TX1075008-UN: Starting and Charging Circuit Schematic

LEGEND:
A2 - Engine Control Unit (ECU)
A6 - Vehicle Electrical Center (VEC)
B14 - Crankshaft Position Sensor
F5 - Alternator Excitation 5-Amp Fuse (VEC )
F25 - Start Relay 10-Amp Fuse (VEC )
F33 - Main 125-Amp Fuse
G1 - Batteries
G2 - Jump Start Terminal
G3 - Alternator
K9 - Start Relay
K10 - Accessory Relay 1
M1 - Starter Motor
S1 - Key Switch
S2 - Battery Disconnect Switch
S18 - Park Lock Lever Switch
V1 - Alternator Excitation 3-Amp Diode ( VEC )
V2 - Starter Solenoid 5-Amp Diode
V3 - Start Relay 1-Amp Diode
W4 - Ground to Cab Left Rear
W6 - Ground to Engine on Starter Motor
X10 - ECU 30-Pin Connector
X17 - Operator's Station Harness-to-Transmission Harness Connector 2
X18 - Operator's Station Harness-to-Transmission Harness Connector 3
X19 - Engine Harness-to-Transmission Harness Connector
X36 - VEC 8-Pin Connector (Green)
X37 - VEC 8-Pin Connector (Brown)
X38 - VEC 2-Pin Connector (Gray)
Y1 - Start Aid Solenoid

Starting Circuit— Unswitched power is supplied to the following components:

Starter Motor (M1),

732
 Starting and Charging Circuit Theory of Operation
Key Switch (S1)
Start Relay (K9)
Accessory Relay 1 (K10)

When the park lock lever is in the LOCK (up) position, park lock lever switch (S20) will provide ground to pin C2
(coil) of start relay (K9).

NOTE:

The park lock lever switch also provides signals to the transmission control unit for park brake
control. For information on park brake control, see Transmission Control Unit (TCU) Circuit
Theory of Operation . (Group 9015-15.)

When key switch (S1) is turned to the START position, current from the key switch terminal ST flows through start
relay fuse (F25) to pin C1 (coil) of the start relay, energizing the relay. With the start relay energized, current flows
to the starter motor solenoid, engaging the starter motor. The start relay diode (V2) protects the start circuit from
voltage spikes when the start relay de-energizes.

As the starter motor cranks the engine, the crankshaft position sensor (B14) sends a signal representing engine
rpm to the engine control unit (ECU) (A2). When the ECU detects this signal, it knows the crankshaft is turning.
The ECU then sends a signal to high pressure fuel pump solenoid (Y12) to provide high pressure fuel to the
electronic fuel injectors. At the same time, the ECU sends a predetermined amount of current to the electronic fuel
injectors to start the fuel injection process, and thus start the engine. For more information on the ECU, pump
control solenoid, and electronic fuel injectors, see Engine Control Unit (ECU) Circuit Theory of Operation . (Group
9015-15.)

Charging Circuit— Alternator (G3) provides power to all machine circuits and charges the batteries when the
engine is running. Terminal B+ of the alternator is connected to battery positive (+) at all times.

When key switch (S1) is in the ON position, current flows through alternator excitation fuse (F5) and alternator
excitation diode (V1) to the D+ terminal of the alternator. The current then flows through the alternator field
windings causing excitation of the windings. Alternator excitation diode (V1) prevents current feedback from the
alternator if the alternator circuitry is improperly connected or if there is a major malfunction. See Alternator Test
for more information. (Group 9015-20.)

Go to Section_9015:Group_15

CS33148,0002207-19-20070223

733
 Starting and Charging Circuit Theory of Operation

Starting and Charging Circuit Theory of Operation

TX1075008-UN: Starting and Charging Circuit Schematic

LEGEND:
A2 - Engine Control Unit (ECU)
A6 - Vehicle Electrical Center (VEC)
B14 - Crankshaft Position Sensor
F5 - Alternator Excitation 5-Amp Fuse (VEC )
F25 - Start Relay 10-Amp Fuse (VEC )
F33 - Main 125-Amp Fuse
G1 - Batteries
G2 - Jump Start Terminal
G3 - Alternator
K9 - Start Relay
K10 - Accessory Relay 1
M1 - Starter Motor
S1 - Key Switch
S2 - Battery Disconnect Switch
S18 - Park Lock Lever Switch
V1 - Alternator Excitation 3-Amp Diode ( VEC )
V2 - Starter Solenoid 5-Amp Diode
V3 - Start Relay 1-Amp Diode
W4 - Ground to Cab Left Rear
W6 - Ground to Engine on Starter Motor
X10 - ECU 30-Pin Connector
X17 - Operator's Station Harness-to-Transmission Harness Connector 2
X18 - Operator's Station Harness-to-Transmission Harness Connector 3
X19 - Engine Harness-to-Transmission Harness Connector
X36 - VEC 8-Pin Connector (Green)
X37 - VEC 8-Pin Connector (Brown)
X38 - VEC 2-Pin Connector (Gray)
Y1 - Start Aid Solenoid

Starting Circuit— Unswitched power is supplied to the following components:

Starter Motor (M1),

734
 Starting and Charging Circuit Theory of Operation
Key Switch (S1)
Start Relay (K9)
Accessory Relay 1 (K10)

When the park lock lever is in the LOCK (up) position, park lock lever switch (S20) will provide ground to pin C2
(coil) of start relay (K9).

NOTE:

The park lock lever switch also provides signals to the transmission control unit for park brake
control. For information on park brake control, see Transmission Control Unit (TCU) Circuit
Theory of Operation . (Group 9015-15.)

When key switch (S1) is turned to the START position, current from the key switch terminal ST flows through start
relay fuse (F25) to pin C1 (coil) of the start relay, energizing the relay. With the start relay energized, current flows
to the starter motor solenoid, engaging the starter motor. The start relay diode (V2) protects the start circuit from
voltage spikes when the start relay de-energizes.

As the starter motor cranks the engine, the crankshaft position sensor (B14) sends a signal representing engine
rpm to the engine control unit (ECU) (A2). When the ECU detects this signal, it knows the crankshaft is turning.
The ECU then sends a signal to high pressure fuel pump solenoid (Y12) to provide high pressure fuel to the
electronic fuel injectors. At the same time, the ECU sends a predetermined amount of current to the electronic fuel
injectors to start the fuel injection process, and thus start the engine. For more information on the ECU, pump
control solenoid, and electronic fuel injectors, see Engine Control Unit (ECU) Circuit Theory of Operation . (Group
9015-15.)

Charging Circuit— Alternator (G3) provides power to all machine circuits and charges the batteries when the
engine is running. Terminal B+ of the alternator is connected to battery positive (+) at all times.

When key switch (S1) is in the ON position, current flows through alternator excitation fuse (F5) and alternator
excitation diode (V1) to the D+ terminal of the alternator. The current then flows through the alternator field
windings causing excitation of the windings. Alternator excitation diode (V1) prevents current feedback from the
alternator if the alternator circuitry is improperly connected or if there is a major malfunction. See Alternator Test
for more information. (Group 9015-20.)

Go to Section_9015:Group_15

CS33148,0002207-19-20070223

735
 Controller Area Network (CAN) Circuit Theory of Operation

Controller Area Network (CAN) Circuit Theory of Operation

TX1086490-UN: Controller Area Network (CAN) Schematic

LEGEND:
A1 - Transmission Control Unit (TCU)
A2 - Engine Control Unit (ECU)
A3 - CAN Monitor Unit (CMU)
A6 - Vehicle Electrical Center (VEC)
A12 - Machine Information Gateway (MIG) Controller
A6000 - Modular Telematics Gateway (MTG) Control Unit
F3 - Service ADVISOR™ Power 5-Amp Fuse (VEC)
R1 - CAN Termination Resistor (120-ohm)
R2 - CAN Termination Resistor (120-ohm)
W4 - Ground to Cab Left Rear
W6 - Ground To Engine on Starter Motor
X1 - TCU Connector
X3 - ECU 30-Pin Connector
X4 - CMU 16-Pin Connector
X8 - Service ADVISOR™ Connector
X18 - Operator's Station Harness-to-Transmission Harness Connector 3
X19 - Engine Harness-to-Transmission Harness Connector
X35 - VEC 8-Pin Connector (blue)
X38 - VEC 2-Pin Connector (gray)
X64 - GlobalTRACS® Terminal (GTT) 70-Pin Connector
X6014 - Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector

NOTE:

For diagnostics of the controller area network (CAN), see CAN Circuit Test . (Group 9015-20.)

This machine uses a controller area network (CAN) that allows the following devices to communicate with each
other:

Transmission Control Unit (TCU) (A1)

Engine Control Unit (ECU) (A2)
CAN Monitor Unit (CMU) (A3)

736
 Controller Area Network (CAN) Circuit Theory of Operation
Vehicle Electrical Center (VEC) (A6)
JDLink™ Machine Information Gateway (MIG) (if equipped) (S.N. —196449)
JDLink™ Modular Telematics Gateway (MTG) (A6000) Control Unit (S.N. 196450— )

Operations and functions of the individual devices on CAN 1 are covered separately.

See Engine Control Unit (ECU) Circuit Theory of Operation . (Group 9015-15.)
See Transmission Control Unit (TCU) Circuit Theory of Operation . (Group 9015-15.)
See Can Monitor Unit (CMU) Circuit Theory of Operation . (Group 9015-15.)
For the JDLink™ MIG (S.N. —196449), see General Information in JDLink™ (MTG) Technical Manual.
(TM114519.)
For the JDLink™ MTG (S.N. 196450— ), see General Information in JDLink™ (MTG) Diagnosis and
Test Manual. (TM114519.)

The CAN consists of two buses, CAN High and CAN Low. These two buses (wires) carry signals opposite to each
other to overcome noise interference and minimize communication errors. The high and low buses, along with a
ground wire, are weaved together forming what is called a twisted triple. The twisted triple provides an additional
method of reducing interference and thus help the devices communicate with minimal errors.

The CAN is an arbitration based system. This means that a low priority message will always allow a high priority
message to go first. Each CAN device checks to see if the bus is idle before it transmits a signal. Whichever
device gets on the bus first will be able to transmit its signal.

When collision occurs, that is, when two or more devices are transmitting at the same time, the device with the
lowest ID will have higher priority to access the bus. The device that loses arbitration will immediately retransmit
its signal when the device with the higher priority has completed its transmission.

The CAN also includes the following components:

CAN Termination Resistor (R1)

CAN Termination Resistor (R2)
Service ADVISOR™ Connector (X8)

The termination resistors are 120 ohm resistors that help prevent signal errors. These resistors are located at
opposite ends of the CAN bus.

The Service ADVISOR™ diagnostic connector provides an interface for connecting diagnostic equipment such as
a laptop. For connection information, see Service ADVISOR™ Connection Procedure . (Group 9015-20.)

Go to Section_9015:Group_15

WS68074,00037DC-19-20151112

737
 Engine Control Unit (ECU) Circuit Theory of Operation

Engine Control Unit (ECU) Circuit Theory of Operation

TX1075006-UN: Engine Control Unit (ECU) Circuit Schematic

LEGEND:
1 - From Batteries (G1)
2 - Electronic Injectors
A1 - Transmission Control Unit (TCU)
A2 - Engine Control Unit (ECU)
A3 - CAN Monitor Unit (CMU)
A6 - Vehicle Electrical Center (VEC)
B10 - Fuel Rail Pressure Sensor
B11 - Fuel Temperature Sensor
B12 - Engine Coolant Temperature Sensor
B13 - Manifold Air Temperature Sensor
B14 - Crankshaft Position Sensor
B15 - Camshaft Position Sensor
B16 - Ambient Air Temperature Sensor
B17 - Engine Oil Pressure Sensor
B18 - Water-in-Fuel Sensor
F26 - ECU Ignition Power 5-Amp Fuse (VEC)
F29 - ECU Battery Power 15-Amp Fuse (VEC)
F33 - Main 125-Amp Fuse
H4 - Warmup Indicator
S1 - Key Switch
W6 - Ground to Engine on Starter Motor
X1 - TCU Connector
X3 - ECU 30-Pin Connector
X4 - CMU 16-Pin Connector
X10 - ECU 30-Pin Connector
X16 - Operator's Station Harness-to-Transmission Harness Connector 1
X17 - Operator's Station Harness-to-Transmission Harness Connector 2
X18 - Operator's Station Harness-to-Transmission Harness Connector 3
X19 - Engine Harness-to-Transmission Harness Connector
X23 - Engine Harness-to-Electronic Injector Harness Connector
X36 - VEC 8-Pin Connector (Green)
X37 - VEC 8-Pin Connector (Brown)
738
 Engine Control Unit (ECU) Circuit Theory of Operation
X38 - VEC 2-Pin Connector (Gray)
X39 - VEC 2-Pin Connector (Black)
Y12 - High Pressure Fuel Pump Solenoid
Y21 - Electronic Injector (Cylinder 1)
Y22 - Electronic Injector (Cylinder 2)
Y23 - Electronic Injector (Cylinder 3)
Y24 - Electronic Injector (Cylinder 4)
Y25 - Electronic Injector (Cylinder 5)
Y26 - Electronic Injector (Cylinder 6)

Engine Control Unit (ECU) (A2)— For component location, see Engine Harness (W10) Component Location .
(Group 9015-10.)

The ECU uses information received from various sensors to determine the correct amount of fuel and injection
timing based on load, temperatures, and operator input. Some of the data calculated by the ECU is transmitted
across the CAN data line to other controllers. For more information concerning the CAN data line, see Controller
Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.)

The ECU also detects malfunctions in the sensors and sensor circuits, or abnormal operating conditions. When
this happens, the ECU will generate a diagnostic trouble code (DTC). For a complete list of engine diagnostic
trouble codes, see Diagnostic Trouble Code (DTC) Quick Reference List—Engine Control Unit (ECU) . (Group
9001-20.)

Whenever an engine DTC occurs, the information is captured or recorded. The information generated is called a
Snapshot. The Snapshot information is categorized in two types; Snapshot Capture and Snapshot Recording. For
more information, see Snapshot Instructions . (CTM502.)

The ECU contains a barometric air pressure (BAP) sensor that is located inside the ECU. This sensor is used to
determine the pressure of the ambient air at the mounting location of the ECU. The BAP sensor helps the ECU
determine the air density for calculating the correct air/fuel ratio. This sensor cannot be repaired or replaced
without replacing the entire ECU.

The ECU also contains a temperature sensor that is located inside the ECU. This sensor is used to determine the
internal temperature of the ECU. If the ECU temperature exceeds specification, the ECU will limit the speed of the
engine in an attempt to protect the ECU from permanent damage. This sensor cannot be repaired or replaced
without replacing the entire ECU.

Unswitched battery power is available at pins L1, L4, M1, and M4 of ECU connector (X3), through fuse (F29).
When key switch (S1) is turned to the ON or START position, current from fuse (F26) flows to pin B2 of ECU
connector (X26), causing the ECU to power up.

Warmup Indicator (H4)— For component location, see Operator's Station Harness (W7) Component Location .
(Group 9015-10.)

When key switch (S1) is turned to the ON or START position, power is available at the anode of warmup indicator
(H4), through fuse (F26). When the transmission oil temperature is below 0°C (32°F), the ECU will provide a
ground to the cathode of the warmup indicator, causing the indicator to come on. During that time, the ECU limits
the engine speed to 900 rpm in neutral and 1200 rpm in forward and reverse.

The transmission control unit (TCU) also limits the transmission speed to 1.7 during the time the warmup indicator
is lit. The transmission oil temperature is monitored by the CAN Monitor Unit (CMU) (A3), which transmits this
information across the CAN data line to the ECU.

For more information on the warmup indicator, see Warm-Up Indicator . (Operator's Manual.)
For more information on the TCU, see Transmission Control Unit (TCU) Circuit Theory of Operation .

739
 Engine Control Unit (ECU) Circuit Theory of Operation
(Group 9015-15.)
For more information on the CMU and monitoring transmission oil temperature, see CAN Monitor Unit
(CMU) Circuit Theory of Operation . (Group 9015-15.)
For more information concerning the CAN data line, see Controller Area Network (CAN) Circuit Theory
of Operation . (Group 9015-15.)

Fuel Rail Pressure Sensor (B10)— For component location, see Engine Harness (W10) Component Location .
(Group 9015-10.)

The ECU supplies a 5-volt reference voltage and ground to the fuel rail pressure sensor at pins E2 and D3 of
ECU connector (X10). The fuel rail pressure sensor sends an analog signal representing fuel rail pressure to pin
E3 of ECU connector (X10). The ECU uses this signal to monitor the high pressure side of the fuel system and
apply derate conditions when needed. If the ECU senses a value that is out of valid range, the ECU will derate
fuel delivery by 50%. The fuel delivery will recover to full power when the problem is corrected. For information on
engine deration, see OEM Engines - Derate Specifications . (CTM502.)

For information on how pressure sensors operate, see Measuring Pressure . (CTM502.)

For sensor specifications, see Electrical Component Specifications . (Group 9015-20.)

Engine Coolant Temperature (ECT) Sensor (B12)— For component location, see Engine Harness (W10)
Component Location . (Group 9015-10.)

The ECU senses resistance from the engine coolant temperature sensor at pins D2 and C4 of ECU connector
(X10). The ECU transmits the engine coolant temperature information across the CAN data line to the CMU.

The CMU displays the temperature on the engine coolant temperature gauge. See Display Monitor Functions .
(Operator's Manual.)

The engine coolant temperature can also be displayed in the CMU service menu as a live value. See CAN
Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

The ECU uses the signal from the engine coolant temperature sensor to monitor the coolant temperature and
apply derate conditions when needed. If the engine coolant temperature reaches 111°C (232°F), the ECU will
derate fuel by 80% of full power. If the coolant temperature reaches 113°C (235°F), the ECU will derate fuel by
40% of full power. The fuel delivery will recover to full power when the engine coolant temperature drops below
the derate threshold temperature. If the ECU senses a value that is out of valid range, the ECU will use the
default temperature of 90°C (194°F). High ECT engine protection is disabled. For information on engine deration,
see OEM Engines - Derate Specifications . (CTM502.)

For information on how temperature sensors operate, see Measuring Temperature . (CTM502.)

For sensor specifications, see Electrical Component Specifications . (Group 9015-20.)

Ambient Air Temperature Sensor (B16)— For component location, see Engine Harness (W10) Component
Location . (Group 9015-10.)

The ECU senses resistance from the ambient air temperature sensor at terminals G4 and C3 of ECU connector
(X3). The ECU transmits the signal representing ambient air temperature across the CAN data line to the CMU
and the TCU. The TCU uses the ambient air temperature to calculate proportional fan speed. For more
information on the proportional fan circuit, see Transmission Control Unit (TCU) Circuit Theory of Operation .
(Group 9015-15.)

For information on how temperature sensors operate, see Measuring Temperature . (CTM502.)

For sensor specifications, see Electrical Component Specifications . (Group 9015-20.)

740
 Engine Control Unit (ECU) Circuit Theory of Operation
Engine Oil Pressure Sensor (B17)— For component location, see Engine Harness (W10) Component Location .
(Group 9015-10.)

The ECU supplies a 5-volt reference voltage and ground to the engine oil pressure sensor at pins F3 and D2 of
ECU connector (X10). The engine oil pressure sensor sends an analog signal representing engine oil pressure to
pin A3 of ECU connector (X10).

The ECU transmits the engine oil pressure information across the CAN data line to the CMU. See Display Monitor
Functions . (Operator's Manual.)

The engine oil pressure can also be displayed in the CMU service menu as a live value. See CAN Monitor Unit
(CMU) Menu Structure—Service Mode . (Group 9015-20.)

The ECU uses the engine oil pressure sensor to monitor the oil pressure and apply derate conditions when
needed. If the oil pressure is below threshold pressure, the ECU will derate the engine fuel delivery by as
indicated in the following table:

-: Oil Pressure Versus Engine Deration

Oil Pressure Engine Speed Engine Derate

1 kPa (0.01 bar) (0.15 psi) Less Than 700 rpm 40% of full power

146 kPa (1.46 bar) (21.2 psi) More Than 700 rpm 40% of full power

202 kPa (2.02 bar) (29.3 psi) More Than 700 rpm 80% of full power

284 kPa (2.84 bar) (41.2 psi) More Than 2000 rpm 40% of full power

311 kPa (3.11 bar) (45.1 psi) More Than 2000 rpm 80% of full power

If the ECU senses a value that is out of valid range, the ECU will use the default pressure of 500 kPa (5 bar) (72.5
psi). Low oil pressure engine protection is disabled. For information on engine deration, see OEM Engines -
Derate Specifications . (CTM502.)

For information on how pressure sensors operate, see Measuring Pressure . (CTM502.)

For sensor specifications, see Electrical Component Specifications . (Group 9015-20.)

Water In Fuel (WIF) Sensor (B18)— For component location, see Engine Harness (W10) Component Location .
(Group 9015-10.)

The WIF sensor measures the amount of resistance of the fluid in the water separator bowl. Since water is a
better conductor of electricity than fuel, and if water is present in the separator bowl, the ECU senses a resistance
drop between pins B2 and D2 of ECU connector (X10).

If the ECU senses low resistance indicating water in fuel, the ECU will derate fuel delivery by 50% of full power.
The fuel delivery will recover to full power when the problem is corrected. For information on engine deration, see
OEM Engines - Derate Specifications . (CTM502.)

For sensor specifications, see Electrical Component Specifications . (Group 9015-20.)

Fuel Temperature Sensor (B11)— For component location, see Engine Harness (W10) Component Location .
(Group 9015-10.)

The ECU senses resistance from the fuel temperature sensor at pins D2 and F4 of ECU connector (X10). The
ECU transmits the fuel temperature information across the CAN data line to the CMU so it can be displayed in the
CMU service menu as a live value. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-

741
 Engine Control Unit (ECU) Circuit Theory of Operation
20.)

The ECU uses the signal from the fuel temperature sensor to monitor the fuel temperature and apply derate
conditions when needed. If the ECU senses fuel temperature above 100°C (220°F), the ECU will derate the fuel
delivery by 80% of full power. The fuel delivery will recover to full power when the fuel temperature drops below
the derate threshold temperature. If the ECU senses a value that is out of valid range, the ECU will use the
default temperature of 40°C (104°F). High fuel temperature engine protection is disabled. For information on
engine deration, see OEM Engines - Derate Specifications . (CTM502.)

For information on how temperature sensors operate, see Measuring Temperature . (CTM502.)

For sensor specifications, see Electrical Component Specifications . (Group 9015-20.)

Manifold Air Temperature (MAT) Sensor (B13)— For component location, see Engine Harness (W10)
Component Location . (Group 9015-10.)

The ECU senses resistance from the MAT sensor at pins C2 and D2 of ECU connector (X10). The ECU transmits
the MAT sensor information across the CAN data line to the CMU where it can be displayed in the CMU service
menu as a live value. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

The manifold air temperature can cause an engine fuel derate condition if it reaches 88°C (190°F). The ECU will
derate fuel 2% per minute up to 20%. If the manifold air temperature falls below the derate temperature, the ECU
will recovery fuel delivery 2% per minute until power is fully restored. For information on engine deration, see
OEM Engines - Derate Specifications . (CTM502.)

For information on how temperature sensors operate, see Measuring Temperature . (CTM502.)

For more information on the MAT sensor, see electrical component specifications . (Group 9015-20.)

Crankshaft Position Sensor (B14)— For component location, see Engine Harness (W10) Component Location .
(Group 9015-10.)

The ECU detects the signal from the crankshaft position sensor at pins B4 and D4 of ECU connector (X10). The
ECU uses this signal to determine when the number one cylinder is at top dead center. The ECU also uses this
signal to calculate engine (crankshaft) speed and sends this information across the CAN data line to the CMU,
where it appears in the monitor display window as engine rpm.

The crankshaft speed can also be displayed in the CMU service menu as a live value. See CAN Monitor Unit
(CMU) Menu Structure—Service Mode . (Group 9015-20.)

For information on how speed sensors operate, see Measuring Speed and Position . (CTM502.)

For sensor specifications, see Electrical Component Specifications . (Group 9015-20.)

Camshaft Position Sensor (B70)— For component location, see Engine Harness (W10) Component Location .
(Group 9015-10.)

The ECU detects the signal from the camshaft position sensor at pins A4 and E4 of ECU connector (X10). The
ECU uses this signal to determine which cylinder is approaching top dead center. The ECU uses this signal to
calculate camshaft speed and transmits the information across the CAN data line to the CMU so it can be
displayed in the CMU service menu as a live value. See CAN Monitor Unit (CMU) Menu Structure—Service Mode
. (Group 9015-20.)

For information on how speed sensors operate, see Measuring Speed and Position . (CTM502.)

For sensor specifications, see Electrical Component Specifications . (Group 9015-20.)

742
 Engine Control Unit (ECU) Circuit Theory of Operation
High-Pressure Fuel Pump Solenoid (Y12)— For component location, see Engine Harness (W10) Component
Location . (Group 9015-10.)

The high-pressure fuel pump solenoid regulates delivery of fuel to the high pressure common rail (HPCR). ECU
sends a signal out pins H1 and H2 of ECU connector (X10) to the high-pressure fuel pump solenoid. When the
solenoid is energized, fuel is allowed to discharge from the fuel outlet on the high-pressure fuel pump to the
HPCR. For more information, see Pump Control Valve (PCV) . (CTM502.)

Electronic Injectors (Y21—Y26)— The ECU controls the injection timing and the amount of fuel injected by
energizing and de-energizing the electronic injectors (Y21—Y26). For more information on the electronic injectors,
see Electronic Injector (EI) Operation . (CTM502.)

Go to Section_9015:Group_15

CS33148,0002204-19-20140722

743
 Transmission Control Unit (TCU) Circuit Theory of Operation

Transmission Control Unit (TCU) Circuit Theory of Operation

TX1190461-UN: Transmission Control Unit (TCU) Circuit Theory of Operation (Inputs)

LEGEND:
1 - Accessory Power
2 - Ignition Power
3 - To Controller Area Network (CAN)
A1 - Transmission Control Unit (TCU)
A6 - Vehicle Electrical Center (VEC)
B1 - Decelerator Sensor
B32 - TCL Sensor
B33 - Steer Sensor
B34 - Transmission Speed Control Switch
F6 - TCU Power 10-Amp Fuse (VEC)
F15 - Switch LED (Backlight) Circuit 5-Amp Fuse (VEC)
R10 - Engine Speed Control
S4 - Blade Angle Switch
S7 - Decelerator Mode Switch
S18 - Park Lock Lever Switch
S20 - Neutral Start Switch
W4 - Ground to Cab Left Rear
W6 - Ground to Engine on Starter Motor
X1 - TCU Connector
X2 - TCU Connector
X6 - Bussed + 5-Volt Sensor Connector
X7 - Bussed Ground Sensor Connector
X17 - Operator's Station Harness-to-Transmission Harness Connector 2
X19 - Engine Harness-to-Transmission Harness Connector
X35 - VEC 8-Pin Connector (Blue)
X39 - VEC 2-Pin Connector (Black)
X52 - TCU Programming Connector

744
 Transmission Control Unit (TCU) Circuit Theory of Operation

TX1075067-UN: Transmission Control Unit (TCU) Circuit Theory of Operation (Feedback)

LEGEND:
2 - Ignition Power
3 - To Controller Area Network (CAN)
A1 - Transmission Control Unit (TCU)
A6 - Vehicle Electrical Center (VEC)
B2 - Motor Speed Sensor Left
B3 - Motor Speed Sensor Right
B4 - Hydrostatic Charge Pressure Sensor (S.N. —173641)
B5 - Hydrostatic Pressure Sensor Right (S.N. —173658)
B6 - Hydrostatic Pressure Sensor Left (S.N. —173658)
B35 - Brake Pressure Sensor (S.N. —173641)
B41 - Hydrostatic Charge Pressure Sensor (S.N. 173642— )
B42 - Brake Pressure Sensor (S.N. 173642— )
B43 - Hydrostatic Pressure Sensor Right (S.N. 173659— )
B44 - Hydrostatic Pressure Sensor Left (S.N. 173659— )
F6 - TCU Power 10-Amp Fuse (VEC)
W6 - Ground to Engine on Starter Motor
X1 - TCU Connector
X2 - TCU Connector
X6 - Bussed + 5-Volt Sensor Connector
X7 - Bussed Ground Sensor Connector
X16 - Operator's Station Harness-to-Transmission Harness Connector 1
X17 - Operator's Station Harness-to-Transmission Harness Connector 2
X19 - Engine Harness-to-Transmission Harness Connector
X30 - Operator's Station Harness-to-Transmission Harness Connector 4
X35 - VEC 8-Pin Connector (Blue)
X39 - VEC 2-Pin Connector (Black)

745
 Transmission Control Unit (TCU) Circuit Theory of Operation

TX1079477-UN: Transmission Control Unit (TCU) Circuit Theory of Operation (Outputs)

LEGEND:
2 - Ignition Power
3 - To Controller Area Network (CAN)
A1 - Transmission Control Unit (TCU)
A6 - Vehicle Electrical Center (VEC)
B7 - Pump Pressure Control Pilot (PCP) Rear
B8 - Pump Pressure Control Pilot (PCP) Front
F6 - TCU Power 10-Amp Fuse ( VEC )
H3 - Backup Alarm
W6 - Ground to Engine on Starter Motor
X1 - TCU Connector
X2 - TCU Connector
X16 - Operator's Station Harness-to-Transmission Harness Connector 1
X17 - Operator's Station Harness-to-Transmission Harness Connector 2
X19 - Engine Harness-to-Transmission Harness Connector
X21 - Transmission Harness-to-Fuel Tank Harness Connector
X28 - Engine Harness-to-Standard Fan Drive Harness Connector
X35 - VEC 8-Pin Connector (Blue)
X39 - VEC 2-Pin Connector (Black)
Y2 - Park Brake Solenoid 1
Y3 - Motor Shift Solenoid Left
Y4 - Motor Shift Solenoid Right
Y5 - Hydraulic Fan Proportional Relief Solenoid (with reversing option)
Y5A - Hydraulic Fan Proportional Relief Solenoid (standard)
Y6 - Hydraulic Fan Reversing Solenoid
Y7 - Blade Angle Solenoid Left (Top) (pilot blade control only)
Y8 - Blade Angle Solenoid Right (Bottom) (pilot blade control only)
Y14 - Hydrostatic Oil Cooler Bypass Solenoid
Y15 - Park Brake Solenoid 2
Y17 - Hydrostatic Oil Reservoir Bypass Solenoid

Transmission control unit (TCU) (A1) receives information from various sensors, mostly commands from the
operator, and uses this information to control travel direction, travel speed, engine speed, and steering. The TCU
transmits some of this information across the CAN data line for use by the engine control unit (ECU) and the CAN
monitor unit (CMU).

746
 Transmission Control Unit (TCU) Circuit Theory of Operation
For more information on the ECU, see Engine Control Unit (ECU) Circuit Theory of Operation . (Group
9015-15.)
For more information on the CMU, see CAN Monitor Unit (CMU) Circuit Theory of Operation . (Group
9015-15.)
For more information on the CAN data line, see Controller Area Network (CAN) Circuit Theory of
Operation . (Group 9015-15.)
For location of transmission electrical components, see Transmission Harness (W11) Component
Location . (Group 9015-10.)

The TCU transmits any TCU diagnostic trouble codes (DTC) that may occur across the CAN data line to the
CMU. The TCU diagnostic trouble codes, transmission settings, and other diagnostic information can be
accessed using the CMU menu structure. For more information, see CAN Monitor Unit (CMU) Menu Structure—
Service Mode . (Group 9015-20.)

When key switch (S1) is in the ON or START position, switched power is available from TCU power fuse (F6) at
pins 1 and 18 on TCU connector (X2). The TCU provides 5-volt power to pin 1 on connector (X6) from pin 3 on
TCU connector (X1). Pin 1 on bussed ground connector (X7) is connected to ground at pin 22 on TCU connector
(X1).

When the engine is started, the TCU will keep the transmission in neutral, regardless of the position of the
transmission control lever (TCL). If the transmission control lever is not in neutral during start-up, the TCU
requires the transmission control lever to be moved first to neutral position, then to forward or reverse position
before travel can be obtained. The TCU does this by monitoring the status of neutral switch (S3) at pin 14 on TCU
connector (X1).

Also, if the park lock lever is moved to the UNLOCK (down) position while the TCL is in either forward or reverse
position, it will be necessary to return the TCL to neutral, then back to forward or reverse before the TCU allows
machine movement.

Neutral Switch (S20)— The neutral switch is located in the transmission control lever. The TCU knows the
position of the TCL by monitoring the status of the neutral switch. When the TCL is in the neutral position, the
neutral switch is closed and provides a ground to pin 14 on TCU connector X2. Moving the TCL out of neutral
removes the ground from pin 14.

If the neutral switch causes a DTC, the forward and reverse functions will be disabled.

Park Lock Lever Switch (S18)— When the park lock lever is in the LOCK (up) position, the park lock lever
switch provides a ground to pin 12 on TCU connector X1. With the park lock lever at this position, the TCU will not
allow an output to the park brake solenoids (Y2 and Y15). Park brake solenoids remain de-energized.

If these solenoids cause a DTC, the forward and reverse functions will be disabled.

When the park lock lever is in the UNLOCK (down) position, the park lock lever switch provides a ground to pin
11 on TCU connector (X1). With the park lock lever at this position, the TCU energizes the park brake solenoids.

The park lock lever switch also provides an interlock for the starting circuit. When park lock lever is in the LOCK
(up) position, the park lock lever switch provides a ground to the coil of the start relay. For more information on the
starting circuit, see Starting and Charging Circuit Theory of Operation . (Group 9015-15.)

Transmission Speed Control Switch (B34)— The transmission speed control switch is used by the operator to
control ground speed. The transmission speed control switch receives 5-volt power from pin 12 on bussed 5-volt
connector (X6) and a ground reference from pin 10 on bussed ground connector (X7).

When neither UP or DOWN buttons are pushed, the transmission speed control sensor sends approximately 2.20
volts to pin 17 of TCU connector X1. When the UP button is pushed, approximately 3.00 volts is sent to pin 17 of
TCU connector X1. When the DOWN button is pushed, approximately 0.90 volts is sent to pin 17 of TCU
connector X1. The values of the up, down, and null voltages are stored in the TCU during calibration.
747
 Transmission Control Unit (TCU) Circuit Theory of Operation

When either the UP or DOWN buttons are pushed, the TCU transmits the transmission speed across the CAN
data line to the CMU. The CMU displays the transmission speed in the display window.

If this sensor causes a DTC, the maximum machine speed will be limited to 4.1 km/h (2.55 mph).

TCL Sensor (B32)— The TCL sensor is a rotary sensor located on a rotating shaft within the TCL assembly. The
TCL sensor receives 5-volt power from pin 10 on bussed 5-volt connector (X6) and a ground reference from pin
11 on bussed ground connector (X7).

When the TCL is moved into forward and reverse positions, the rotating shaft turns a keyed slot on the sensor,
which changes the resistance measured by the TCU at pin 23 on TCU connector (X1).

When the TCL is put at certain positions during TCU calibration, the resistance measured at those positions is
stored in the TCU memory.

If the TCL sensor causes a DTC, the forward and reverse functions will be disabled.

Steer Sensor (B33)— The steer sensor is a rotary sensor located on a rotating shaft within the TCL assembly.
The steer sensor receives 5-volt power from pin 11 on bussed 5-volt connector (X6) and a ground reference from
pin 12 on bussed ground connector (X7).

When the TCL is moved to left and right positions, the rotating shaft turns a keyed slot on the sensor, which
changes the resistance measured by the TCU at pin 24 on TCU connector (X1).

When the TCL is put at certain positions during TCU calibration, the resistance measured at those positions is
stored in the TCU memory.

If this sensor causes a DTC, the steer functions will be disabled and the maximum machine speed will be limited
to 4.1 km/h (2.55 mph).

Decelerator Mode Switch (S7)— The decelerator mode switch allows the operator the option of using the
decelerator pedal to control engine speed or transmission speed. When the switch is pushed to engine mode, the
decelerator mode switch provides a ground to the pin 10 on TCU connector (X1). When the TCU detects this
ground, it decreases engine speed when the decelerator pedal is pushed.

When the switch is pushed to the transmission mode, the ground is removed from pin 10 on TCU connector (X1).
When the decelerator is pressed down in the transmission mode, transmission speed will decrease but engine
speed will remain constant.

Decelerator Sensor (B1)— The decelerator sensor is a rotary sensor located on a rotating shaft on the
decelerator pedal. The decelerator sensor receives 5-volt power from pin 2 on bussed 5-volt connector (X6) and a
ground reference from pin 2 on bussed ground connector (X7).

When the decelerator pedal is pushed down, the rotating shaft turns a keyed slot on the sensor, which changes
the resistance measured by the TCU at pin 18 on TCU connector (X1).

When the decelerator pedal is put at certain positions during TCU calibration, the resistance measured at those
positions (including brake positions) is stored in the TCU memory.

If this sensor causes a DTC, the maximum machine speed will be limited to creep. If this sensor causes a
calibration code, the TCU default values will be used for this sensor.

Engine Speed Control (R10)— The engine speed control is a potentiometer which receives 5-volt power from
pin 9 on bussed 5-volt connector (X6) and a ground reference from pin 8 on bussed ground connector (X7).

748
 Transmission Control Unit (TCU) Circuit Theory of Operation
Turning the engine speed control sensor varies the amount of voltage sent to pin 14 on TCU connector (X1). This
signal represents desired engine speed, which the TCU compares with values recorded during TCU calibration,
then transmits the engine speed command as a percentage across the CAN data line. The ECU detects this
signal and responds by increasing or decreasing engine speed accordingly.

The ECU detects the signal representing actual engine speed from crankshaft position sensor (B14). The ECU
transmits the engine speed signal across the CAN data line. The TCU detects the actual engine speed signal and
compares it to the desired engine speed command signal for antistall purposes. If the load on the engine causes
the engine to pull down, the TCU will send the appropriate current to PCP solenoids (B7 and B8) to decrease
pump displacement and prevent the engine from stalling. The TCU uses the engine speed to determine the pump
speeds. For more information on the ECU, see Engine Control Unit (ECU) Circuit Theory of Operation . (Group
9015-15.)

If machine is started and the TCU does not measure the voltage at pin 14 on TCU connector (X1) that represents
slow idle command, the engine speed control sensor must be rotated to slow idle position before the engine
speed can be increased.

If this sensor causes a DTC, engine speed will be limited to slow idle and machine speed will be limited to creep.
If this sensor causes a calibration code, the TCU default values will be used for this sensor.

Blade Angle Operation (PAT Machines)— Blade angle switch (S4) angles the blade on power angle tilt (PAT)
machines. The blade angle switch receives 5-volt power from pin 8 on bussed 5-volt connector (X6) and a ground
reference from pin 9 on bussed ground connector (X7).

When neither the left or right buttons are pressed, the blade angle switch applies a voltage to pin 19 on TCU
connector (X1). When either the left or right buttons are pressed, a different voltage is applied to the TCU. The
values of the left, right, and null voltages are stored in the TCU during calibration.

When the left button is pressed, the TCU interprets the voltage as being a blade angle left command and applies
voltage from pin 24 on TCU connector (X2) to blade angle solenoid left (top) (Y7). The blade angle solenoid left
(top) will energize and shift the valve spool and allow pilot oil to pass to the left blade angle pilot inlet on the angle
section of the hydraulic control valve.

When the right button is pressed, the TCU interprets the voltage as being a blade angle right command and
applies voltage from pin 20 on TCU connector (X2) to blade angle solenoid right (bottom) (Y8). The blade angle
solenoid right (bottom) will energize and shift the valve spool and allow pilot oil to pass to the right blade angle
pilot inlet on the angle section of the hydraulic control valve.

If the blade angle switch causes a DTC, both right and left blade angle functions will be disabled. If either blade
angle solenoid causes a DTC, the corresponding direction will be disabled.

For more information on the blade angle operation, see Blade Angle Operation . (Group 9025-05.)

Motor Speed Sensor (B2 and B3)— The motor speed sensors are feedback devices used by the TCU to
determine actual track speed. The sensors enable the TCU to control tracking, thus allowing the machine to move
in the desired motion. The TCU monitors track speeds and slows the faster track to match the slower track.

Each sensor receives 5-volt power from bussed 5-volt connector (X6) and a ground reference from bussed
ground connector (X7).

Motor speed sensor left (B2) sends a pulsed signal to pin 20 of TCU connector (X1). Motor speed sensor right
(B3) sends a pulsed signal to pin 21 of TCU connector (X1). If one of these sensors causes a DTC, the tracker
function will be disabled and mistracking will occur.

For motor speed sensor specifications, see Electrical Component Specifications . (Group 9015-20.)

749
 Transmission Control Unit (TCU) Circuit Theory of Operation
Hydrostatic Charge Pressure Sensor (B4 or B41)

NOTE:

The hydrostatic charge pressure sensor is B4 for (S.N. —173641) and B41 for (S.N. 173642— ).

The hydrostatic charge pressure sensor provides the TCU with a variable resistance based on charge pressure.
The charge pressure sensor receives 5-volt power from pin 5 on bussed 5-volt connector (X6) and a ground
reference from pin 5 on bussed ground connector (X7).

The TCU measures sensor resistance at pin 1 of TCU connector (X1). The TCU transmits this information across
the CAN data line to the CMU. The charge pressure can be displayed on the monitor display window.

If the charge pressure drops below 1310 kPa (13.1 bar) (190 psi) for more than 10 seconds while the engine is
running, machine speed will ramp down and the machine will stop. Forward and reverse functions will be disabled,
the engine speed will be limited to slow idle, and a diagnostic trouble code (DTC) will be generated. When the
malfunction is fixed, the key switch must be cycled to clear the code.

If the charge pressure exceeds 3447 kPa (34.5 bar) (500 psi) and the transmission oil temperature is above 32°C
(90°F), or if the charge pressure exceeds 5170 kPa (51.7 bar) (750 psi) at any temperature, the TCU will transmit
this information across the CAN data line to the ECU, which will then limit the engine speed to 1200 rpm. When
the malfunction is fixed, the key switch must be cycled to clear the code.

For charge pressure sensor specifications, see Electrical Component Specifications . (Group 9015-20.)

Brake Pressure Sensor (B35 or B42)

NOTE:

The brake pressure sensor is B35 for (S.N. —173641) and B42 for (S.N. 173642— ).

The brake pressure sensor provides the TCU with a variable resistance based on brake pressure. The brake
pressure sensor receives 5-volt power from pin 7 on bussed 5-volt connector (X6) and a ground reference from
pin 7 on bussed ground connector (X7).

The TCU measures sensor resistance at pin 16 on TCU connector (X1). The TCU transmits this information
across the CAN data line to the CMU. The brake pressure can be displayed on the monitor display window.

If the brake pressure exceeds 345 kPa (3.5 bar) (50 psi) when the park brake is engaged and the engine is
running, or if brake pressure falls below 1379 kPa (14 bar) (200psi) when the park brake is disengaged and
engine is running, maximum machine speed will be limited to creep and a diagnostic trouble code (DTC) will be
generated. When the malfunction is fixed, the key switch must be cycled to clear the code.

For brake pressure sensor specifications, see Electrical Component Specifications . (Group 9015-20.)

Hydrostatic Pressure Sensors (B5 or B43 and B6 or B44)

NOTE:

The hydrostatic pressure sensor is B5 or B6 for (S.N. —173658) and B43 or B44 for (S.N.
173659— ).

The hydrostatic pressure sensors provide the TCU with a variable resistance based on the hydrostatic system
750
 Transmission Control Unit (TCU) Circuit Theory of Operation
pressure. The hydrostatic pressure sensors receive 5-volt power from pin 6 on bussed 5-volt connector (X6) and
a ground reference from pin 6 on bussed ground connector (X7).

The TCU measures resistance of hydrostatic pressure sensor right (B5 or B43) at pin 15 on TCU connector (X1).
The TCU measures resistance of hydrostatic pressure sensor left (B6 or B44) at pin 2 on TCU connector (X1).
The TCU transmits this information across the CAN data line to the CMU. The brake pressure can be displayed
on the monitor display window.

For hydrostatic pressure sensor specifications, see Electrical Component Specifications . (Group 9015-20.)

Pump Pressure Control Pilot (PCP) (B7 and B8)— The rear and front PCPs control the displacement of the
rear and front hydrostatic pumps, respectively. When the TCU receives a signal from any one of the operator
controlled input sensors, the TCU applies positive or negative voltage to the PCPs, which causes electromagnetic
valves to move accordingly. Movement of the electromagnetic valves creates differential control pressures, which
varies the pump displacement and thus controls machine movement.

For forward movement, the TCU will increase positive voltage (i.e. +3.5 V to +4.0 V) to increase pump
displacement and decrease positive voltage (i.e. +3.5 V to +3.0 V) to decrease pump displacement.

For reverse movement, the TCU will increase negative voltage (i.e. -3.5 V to -4.0 V) to increase pump
displacement and decrease negative voltage (i.e. -3.5 V to -3.0 V) to decrease pump displacement.

The TCU also applies voltage to the rear PCP in proportion to the front PCP for steering and counter-rotation
commands. For more information on PCP operations, see Pump Pressure Control Pilot (PCP) Operation . (Group
9026-05.)

If one of these component causes a DTC, either the forward or reverse functions will be disabled.

Motor Shift Solenoids (Y3 and Y4) —The TCU applies a frequency-varied signal to the motor shift solenoid left
(Y3) and motor shift solenoid right (Y4) to control the displacement of the hydrostatic motors. As transmission
speed increases, the TCU applies a higher frequency signal to the motor shift solenoids to reduce the motor
displacement. The motor shift solenoid activation, along with the motor displacement control valve (MDCV),
control motor displacement. The TCU will also reduce voltage to pump pressure control pilot (PCP) rear (B8) and
pump pressure control pilot (PCP) front (B9) as motor displacement decreases for smooth acceleration.

If one of these components cause a DTC, the maximum machine speed will be limited to 4.1 km/h (2.55 mph).

For more information on the motor shift solenoids in motor operation, see Hydrostatic Motor Operation . (Group
9026-05.) For solenoid specifications, see Electrical Component Specifications . (Group 9015-20.)

Park Brake Solenoids (Y2 and Y15)— Park brake solenoid 1 (Y2) and park brake solenoid 2 (Y15) control the
charge pressure which releases the park brake. When the engine is running and park lock lever (S20) is moved to
the UNLOCK (down) position, pin 11 on TCU connector (X1) is connected to ground. If the decelerator is not fully
depressed to the brake stop, the TCU will send current from pin 15 on TCU connector (X2) to the park brake
solenoids, energizing both solenoids. Charge pressure oil will then be allowed to release the park brake. The park
brake solenoid will be de-energized if the engine quits running, the park lock lever is raised, or if the decelerator
pedal is pressed into the brake range. For more information on the park brake, see Park Brake Valve Operation .
(Group 9026-05.)

If these solenoids cause a DTC, the forward and reverse functions will be disabled.

Hydraulic Fan Proportional Relief Solenoid (Y5 or Y5A)— The proportional fan controls the cooling capacity of
the cooling package by varying the speed of the fan. The TCU automatically controls the speed of the fan by
monitoring engine coolant temperature, transmission oil temperature, ambient air temperature, manifold air
temperature, and hydraulic oil temperature (if equipped with hydraulic oil cooler).

Hydrostatic oil temperature sensor (B21) and hydraulic oil temperature sensor (B20) are monitored by the CAN
751
 Transmission Control Unit (TCU) Circuit Theory of Operation
monitor unit (CMU) (A3). The CMU transmits this information across the CAN data line to the TCU.

Engine coolant temperature sensor (B12), manifold air temperature sensor (B13), and ambient air temperature
sensor (B16) are monitored by engine control unit (ECU) (A2). The ECU transmits this information across the
CAN data line to the TCU.

NOTE:

Hydraulic oil temperature is only used to calculate fan speed if machine is equipped with a
hydraulic oil cooler. If machine is equipped with a hydraulic oil cooler, the option must be set in
the CAN Monitor Unit (CMU). For more information, see CAN Monitor Unit (CMU) Menu Structure
—Service Mode . (Group 9015-20.)

The TCU sends a varied amount of current from pin 14 on TCU connector (X2) to the hydraulic fan proportional
relief solenoid (Y5 or Y5A). The current sent to the solenoid is inversely proportional to the fan speed; as more
current is applied to the solenoid, more oil bypasses the fan motor, slowing the fan speed down. As the current
decreases, less oil is bypassing the fan motor and the fan will accelerate towards full speed.

NOTE:

The TCU can also receive a hydraulic proportional fan speed command from the CMU for testing
purposes. For more information, see CAN Monitor Unit (CMU) Menu Structure—Service Mode .
(Group 9015-20.)

The TCU uses certain reference values for determining fan speed. The first set of values the TCU interprets is the
hydraulic oil temperature, engine coolant temperature, and the transmission oil temperature. The TCU assigns a
solenoid current based on the highest fluid temperature. If the highest temperature is below 70°C (158°F), the
TCU will assign a solenoid current value of 650 mA (minimum speed). If the highest temperature is above 100°C
(212°F), the TCU will assign a current value of 0 mA (maximum speed). If the highest temperature falls within
those two points, the TCU will assign a current value in linear relationship between to those two points.

-: Fluid Temperature Table

Proportional Relief Solenoid Current Temperature

650 mA 70°C
158°F

0 mA 104°C
219°F

Once the TCU determines a solenoid current based on fluid temperatures, the TCU applies two multipliers to this
value. The first is proportional to the manifold air temperature and the second is proportional to the manifold air
temperature minus the ambient air temperature. The three values are multiplied together and the TCU applies the
calculated current to the hydraulic fan proportional relief valve solenoid.

NOTE:

Only three points are shown for simplicity. Multipliers exist at 0.1 increments and have a
corresponding temperature, linear to the points listed.

-: Fan Speed Percentage

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 Transmission Control Unit (TCU) Circuit Theory of Operation

Multiplier Manifold Air Temperature

0.0 50°C
122°F

0.5 55°C
131°F

1.0 60°C
140°F

-: Fan Speed Percentage

Multiplier Manifold Air Temperature-Ambient Air Temperature

0.0 21°C
70°F

0.5 28°C
82.4°F

1.0 35°C
95°F

If the manifold air temperature is 60°C (140°F) or higher, the fan will operate at 100% of the rated speed based on
fluid and differential air temperature. For more information, see Hydraulic Reversing Fan Drive Operation . (Group
9026-05.)

Hydraulic Fan Reversing Solenoid (Y6) (Optional)— The reverse fan function reverses the fan direction to
purge the cooling system of debris. The reverse fan function can be operated in manual and automatic mode.
Automatic mode is the default and will automatically reverse directions unless manual mode is activated. The
frequency at which the fan will reverse is adjustable in the CAN Monitor Unit (CMU). For more information, see
CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Manual mode is activated by pushing fan reversing switch (S23) into the momentary position. In the momentary
position, pin N on CMU connector (X5) will be connected to ground. The CMU transmits this information across
the CAN data line to the TCU. Once the manual reverse cycle is complete, the function will return to automatic
mode.

When the internal timer in the TCU reaches full count or if manual mode is selected and the TCL lever is in neutral
or reverse positions, the TCU will begin the reversing sequence. The reversing function works in conjunction with
hydraulic fan proportional relief solenoid (Y5 or Y5A). The TCU ramps up the hydraulic fan proportional relief
solenoid current to slow the fan down to minimum fan speed (approximately 500 rpm). Once the fan speed is at a
minimum, the TCU will send current from pin 13 on TCU connector (X2) to hydraulic fan reversing solenoid (Y6),
activating the solenoid and reversing the fan drive direction.

When the reverse fan reversing solenoid is activated, the TCU will ramp down the current applied to hydraulic fan
proportional relief solenoid until maximum fan speed (approximately 1900 rpm) is reached. The TCU will operate
the fan at maximum speed for 15 seconds then ramp up the hydraulic fan proportional relief solenoid current until
the fan is at minimum speed.

Once the fan is slowed down to minimum speed, the TCU will remove power from the hydraulic fan reversing
solenoid and ramp down the hydraulic fan proportional relief solenoid current to normal operating fan speed.

The reverse fan sequence cannot be activated again for one minute after it was completed. If the reverse fan was
in automatic mode prior to manual mode being activated, the timer is stopped then started again after the reverse

753
 Transmission Control Unit (TCU) Circuit Theory of Operation
fan sequence is completed.

For more information, see Hydraulic Reversing Fan Drive Operation . (Group 9026-05.)

Hydrostatic Oil Cooler Bypass Solenoid (Y14) and Hydrostatic Oil Reservoir Bypass Solenoid (Y17)— The
hydrostatic oil cooler bypass solenoid (Y14) controls the oil flow to the hydrostatic oil cooler. The hydrostatic oil
reservoir bypass solenoid (Y17) is a variable solenoid that controls the case drain oil flow to the hydrostatic oil
reservoir. These two solenoids are used to control hydrostatic oil temperature.

The TCU is dependant on the oil temperature measured by the hydrostatic oil temperature sensor (B21), which is
hard-wired to the CMU and broadcast across the CAN to the TCU, to control both the hydrostatic oil cooler
bypass solenoid and hydrostatic oil reservoir bypass solenoid.

When the TCU applies power from pin 16 (wire T35 BLU) on TCU connector (X2), the hydrostatic oil cooler
bypass solenoid (Y14) energizes and oil bypasses the cooler. When the TCU applies power from pin 5 (wire T27
BLU) on TCU connector (X2), the hydrostatic oil reservoir bypass solenoid (Y17) energizes and oil is allowed to
flow directly to the reservoir.

Upon machine startup, the TCU energizes the hydrostatic oil reservoir bypass solenoid (Y17) to allow oil to flow to
the reservoir. The hydrostatic oil cooler bypass solenoid (Y14) is not energized, which allows oil to also flow
through the oil cooler. The TCU keeps the machine in this state for 1 minute, after which the solenoid operation is
controlled based on the hydrostatic oil temperature:

Oil temperature below 50°C (122°F): Both the hydrostatic oil cooler bypass solenoid (Y14) and
hydrostatic oil reservoir bypass solenoid (Y17) are energized. Oil does not flow through the cooler, but
rather flows directly to the reservoir.

NOTE:

If oil temperature is greater than 50°C (122°F) but then drops to below 40°C (104°F), the
TCU will energize the hydrostatic oil cooler bypass solenoid (Y14) and hydrostatic oil
reservoir bypass solenoid (Y17) to route oil directly to the reservoir.

Oil temperature 50—75°C (122—167°F): Only the hydrostatic oil reservoir bypass solenoid (Y17) is
energized. Oil is allowed to flow through the cooler, as well as directly to the reservoir.
Oil temperature 76—85°C (168—185°F): The hydrostatic oil cooler bypass solenoid (Y14) remains de-
energized, and power applied to the hydrostatic oil reservoir bypass solenoid (Y17) is decreased
proportionally as oil temperature increases until all flow is going through the cooler.
Oil temperature is greater than 86°C (187°F): Both solenoids are de-energized and all oil flow goes
through oil cooler.

If the hydrostatic oil cooler bypass solenoid (Y14) causes a DTC, hydrostatic oil will always flow through the oil
cooler.

If the hydrostatic oil reservoir bypass solenoid (Y17) causes a DTC, case drain oil pressure will rise and overcome
the internal spring force of the solenoid and drain to reservoir.

For more information on the hydrostatic oil cooler bypass, see Oil Cooler and Reservoir Bypass Operation .
(Group 9026-05.)

Backp Alarm (H6)— When key switch (S1) is in the ON position and reverse travel is selected, the TCU will send
current from pin 19 on TCU connector (X2) to backup alarm (H3), activating the alarm.

Go to Section_9015:Group_15

CS33148,0002292-19-20150413

754
 CAN Monitor Unit (CMU) Circuit Theory of Operation

CAN Monitor Unit (CMU) Circuit Theory of Operation

TX1070739-UN: CAN Monitor Unit (CMU) Circuit Schematic

LEGEND:
1 - Battery Power
2 - Accessory Power
3 - Ignition Power
4 - To Controller Area Network (CAN)
A3 - CAN Monitor Unit (CMU)
B19 - Fuel Level Sensor
B20 - Hydraulic Oil Temperature Sensor
B21 - Hydrostatic Oil Temperature Sensor
B22 - Air Filter Restriction Switch
B23 - Hydraulic Oil Filter Restriction Switch
B24 - Hydraulic Fan Oil Filter Restriction Switch
B25 - Hydrostatic Charge Oil Filter Restriction Switch
H2 - Monitor Alarm
R1 - CAN Termination Resistor (120 ohm)
R2 - CAN Termination Resistor (120 ohm)
S23 - Fan Reversing Switch
W3 - Ground to Frame Under Cab
W4 - Ground to Cab Left Rear
W5 - HIC Valve Ground
W6 - Ground on Starter Motor
X8 - Service ADVISOR™ Connector
X29 - Automatic Diagnostic Connector

CAN Monitor Unit (CMU) (A3)— The CMU receives unswitched power from the CMU battery power fuse (F28).
The CMU receives switched power from the CMU ignition power fuse (F4).

When powered up, the CMU performs a self-test by activating all indicators: lights, gauges, and LCD display. For
more information on CMU, see Display Monitor and see Display Monitor Functions . (Operator's Manual.)

The CMU contains a menu structure designed for monitoring certain machine functions for operational and/or
diagnostic purposes. The menus also provide a means of adjusting certain machine and monitor settings. For
more information on the CMU menu structure, see CAN Monitor Unit (CMU) Menu Structure—Service Mode .
(Group 9015-20.)

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 CAN Monitor Unit (CMU) Circuit Theory of Operation
The CMU uses the controller area network (CAN) data line to communicate with the controllers on the machine.
For more information, see Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.)

The following electrical components are hard wired directly to the CMU:

Fuel Level Sensor (B19)

Monitor Alarm (H2)
Reversing Fan Switch (S23)
Hydraulic Oil Filter Restriction Switch (B23)
Hydraulic Fan Oil Filter Restriction Switch (B24)
Hydrostatic (transmission) Charge Oil Filter Restriction Switch (B25)
Hydraulic Oil Temperature Sensor (B20)
Hydrostatic (transmission) Oil Temperature Sensor (B21)
Air Filter Restriction Switch (B22)

Fuel Level Sensor (B19)— is a resistive (rheostat) type sensor attached to a float arm. The changing fuel level
causes the float arm to move up and down relative to the fuel level. The float arm moves the wiper in the rheostat
causing resistance to change relative to the movement of the float arm. This resistance is sensed by the CMU at
pins F and N on CMU connector (X4). The CMU uses this information to determine the position of the needle on
the fuel gauge and moves the needle accordingly.

Monitor Alarm (H2)— is activated during monitor self test, during certain monitor selections, and when the STOP
light is on. The CMU provides power at pin M on CMU connector (X4), and ground at pin D on CMU connector
(X4).

Reversing Fan Switch (S23)— Pushing the reversing fan switch to the momentary position provides a ground to
pin N on CMU connector (X5), which causes the reverse fan light to come on. At the same time, the CMU
transmits across the CAN data line a signal representing the command to manually reverse the fan. When the
TCU receives this signal, it reduces fan speed then reverses the fan direction. For more information on reversing
fan operation, see Transmission Control Unit (TCU) Circuit Theory of Operation . (Group 9015-15.)

Other settings are available in the CMU menu structure for test purposes. These commands are also transmitted
across the CAN data line and received by the TCU for execution. For information on TCU operation, see
Transmission Control Unit (TCU) Circuit Theory of Operation . (Group 9015-15.)

Hydraulic Oil Filter Restriction Switch (B23)— This normally closed switch applies ground to pin F of CMU
connector X5 when closed. This switch opens when the hydraulic oil differential pressure at the filter is greater
than specification, causing the hydraulic oil filter restriction light to come on.

Hydraulic Fan Oil Filter Restriction Switch (B24)— This normally closed switch applies ground to pin G of CMU
connector X5 when closed. This switch opens when the hydraulic fan oil differential pressure at the filter is greater
than specification, causing the hydraulic fan oil filter restriction light to come on.

Hydrostatic (transmission) Charge Oil Filter Restriction Switch (B25)— This normally closed switch applies
ground to pin J of CMU connector X5 when closed. This switch opens when the hydrostatic oil differential
pressure at the filter is greater than specification, causing the hydrostatic charge oil filter restriction light to come
on.

Hydraulic Oil Temperature Sensor (B20)— provides the CMU with a variable resistance based on hydraulic oil
temperature. The CMU senses resistance at pin K on CMU connector (X5), then uses this information to
determine the position of the needle on the hydraulic oil temperature gauge and moves the needle accordingly.
The CMU then transmits the signal representing hydraulic oil temperature across the CAN data line. The TCU
receives this signal and uses it for calculation of proportional fan speed.

For more information on fan speed operation, see Transmission Control Unit (TCU) Circuit Theory of Operation .
(Group 9015-15.)

756
 CAN Monitor Unit (CMU) Circuit Theory of Operation
For more information on the hydraulic oil temperature sensor, see Electrical Component Specifications . (Group
9015-20.)

Hydrostatic (transmission) Oil Temperature Sensor (B21)— provides the CMU with a variable resistance
based on hydrostatic oil temperature. The CMU senses resistance at pin A on CMU connector (X5), then uses
this information to determine the position of the needle on the transmission oil temperature gauge and moves the
needle accordingly. The CMU then transmits the signal representing hydrostatic oil temperature across the CAN
data line. The TCU receives this signal and uses it for calculation of proportional fan speed.

For more information on fan speed operation, see Transmission Control Unit (TCU) Circuit Theory of Operation .
(Group 9015-15.)

For more information on the hydrostatic oil temperature sensor, see Electrical Component Specifications . (Group
9015-20.)

Air Filter Restriction Switch (B22)— is a normally open switch that closes once the engine air filter becomes
restricted. Ground is applied to pin E on CMU connector (X5), causing the engine air filter restriction light to come
on.

Go to Section_9015:Group_15

LW86157,0000125-19-20100329

757
 Integrated Grade Control (IGC) Theory of Operation—If Equipped

Integrated Grade Control (IGC) Theory of Operation—If Equipped

TX1074988-UN: Integrated Grade Control (IGC) Circuit Schematic

LEGEND:
A3 - CAN Monitor Unit (CMU)
A8 - IGC Load Center
A9 - Blade Control Joystick (BCJ)
A11 - Electrohydraulic Controller (EHC)
F16 - Optional Powerport 10-Amp Fuse (VEC)
F33 - Main 125-Amp Circuit Breaker
F101 - IGC Switched Power 15-Amp Fuse
F102 - BCJ Switched Power 5-Amp Fuse
F103 - EHC Switched Power 10-Amp Fuse
F104 - IGC Unswitched Power 1 10-Amp Fuse
F105 - IGC Unswitched Power 2 10-Amp Fuse
F106 - IGC Unswitched Power 3 10-Amp Fuse
G3 - Alternator
K101 - IGC Switched Power Relay
K102 - BCJ and EHC Switched Power Relay
R7 - CAN Termination Resistor (120 ohm)
R8 - CAN Termination Resistor (120 ohm)
S2 - Battery Disconnect Switch
S8 - Hydraulic Enable Switch
W3 - Ground to Frame Under Cab
X19 - Engine Harness-to-Transmission Harness Connector
X4 - CMU 16-Pin Connector
X79 - 2-Pin Connector (not used)
X81 - RS232 Connector
X82 - Electrohydraulic Controller (EHC) Connector
X83 - Electrohydraulic Controller (EHC) Connector
X84 - Alternator W Terminal Signal Connector
X85 - Auxiliary Joystick Connector
X86 - IGC CAN-to-Machine CAN Connector
X87 - IGC Ground Connector
X90 - Auxiliary IGC Actuator Connector
X95 - IGC Machine Harness-to-IGC Cab Harness Connector
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 Integrated Grade Control (IGC) Theory of Operation—If Equipped
X96 - IGC Interface Connector
X97 - BCJ Switch Module Connector
X98 - BCJ Four-Way Axis Module Connector
Y30 - Blade Angle Actuator
Y31 - Blade Tilt Actuator
Y32 - Blade Lift Actuator

The IGC system is an electric-over-hydraulic, plug and play control system designed to be an integral part of a
fully automatic system using global positioning system (GPS) and/or laser guidance equipment provided by a
third party.

The base system consists of the following components:

IGC Load Center (A8)

Electrohydraulic Controller (EHC) (A11)
Blade Control Joystick (BCJ) (A9)
Electrohydraulic Actuators (Y30—Y32)

IGC Load Center (A8)— The IGC load center provides power to electrohydraulic controller (EHC) (A11), the four-
way axis module of blade control joystick (BCJ) (A9), and the grade control supplier's equipment [IGC interface
connector (X96)].

Unswitched battery power is provided to the IGC load center through main 125 amp fuse (F33). Switched power
is provide to the IGC load center through optional powerport 10-amp fuse (F16).

The IGC load center consists of the following components:

IGC Switched Power 15-Amp Fuse (F101)

BCJ Switched Power 5-Amp Fuse (F102)
EHC Switch Power 10-Amp Fuse (F103)
IGC Unswitched Power _1 10-Amp Fuse (F104)
IGC Unswitched Power _2 10-Amp Fuse (F105)
IGC Unswitched Power _3 10-Amp Fuse (F106)
IGC Switched Power Relay (K101)
BCJ and EHC Switched Power Relay (K102)

Electrohydraulic Controller (EHC) (A11)— The EHC is the machine's control center for the IGC system. The
EHC powers up when switched power from 10-amp fuse (F103) is supplied to the EHC at terminals 1 and 18 of
connector (X83). Ground is provided at terminal 23 of EHC connector (X83).

When powered up, the EHC provides 5 volts at terminal 3 of EHC connector (X82). The 5 volts are sent to
terminal 1 of BCJ switch module connector (X97), terminal 1 of auxiliary joystick connector (X85), and terminal 2
of hydraulic enable switch (S8). The EHC provides a ground for the 5-volt circuit at terminal 22 of EHC connector
(X82). This ground is available at terminal 6 of the BCJ switch module connector and terminal 4 of the auxiliary
joystick connector.

Putting the hydraulic enable switch to the DISABLED position sends 5 volts to terminal 17 of EHC connector
(X82). When the EHC detects 5 volts at terminal 17 and no voltage at terminal 18, the EHC disables all outputs to
the electrohydraulic actuators (Y30—Y32). During this time, the blade controls will not function in manual or auto
modes.

Putting the hydraulic enable switch to the ENABLED position, sends 5 volts to terminal 18 of EHC connector
(X82). When the EHC detects 5 volts at terminal 18 and no voltage at terminal 17, the EHC enables all outputs to
the electrohydraulic actuators allowing the blade controls to operate when commanded.

If the EHC detects voltage at terminals 17 and 18 at the same time, or no voltage at either terminal at the same

759
 Integrated Grade Control (IGC) Theory of Operation—If Equipped
time, the EHC will disable the outputs and generate a diagnostic trouble code (DTC). The DTC information is
transmitted across the machine CAN data line to the CAN monitor unit (CMU) to alert the operator. For complete
list of possible codes generated by the EHC, see Diagnostic Trouble Code (DTC) Quick Reference List—
Electrohydraulic Controller (EHC) . (Group 9001-40.)

When in manual mode, or manual override when in auto mode, the EHC receives blade control commands from
the blade control joystick, then sends corresponding signals to the appropriate electrohydraulic actuators to move
the blade to the desired position.

When in auto mode, the EHC receives blade control commands from the grade control supplier's equipment, then
sends corresponding signals to the appropriate electrohydraulic actuators to move the blade to the desired
position.

Only when the EHC detects the appropriate signals from each of the following components, will it activate the
auto blade light on the CMU to indicate that the system is in auto mode:

IGC on/off switch

Pilot control enable switch (ENABLED position)
Park brake switch (park lock lever at UNLOCKED position)
Blade control joystick (BCJ) (neutral position)
CAN monitor unit (CMU)
Transmission control unit (TCU)
Grade control supplier's controller

The EHC communicates with the grade control supplier's equipment across the IGC CAN data line. The IGC CAN
data line connects terminals 10 and 11 of EHC connector (X82) to terminals G (shield), H, and J of IGC interface
connector (X96).

The EHC communicates with the BCJ module (A10) and CAN monitor unit (CMU) (A3) using the machine CAN
data line. The machine CAN data line connects terminals 7 and 8 of EHC connector (X82) to terminals 3 and 4 of
the BCJ module and terminals C and K of CMU connector (X4).

NOTE:

For EHC diagnostics, see Integrated Grade Control (IGC) Checks—If Equipped . (Group 9015-
20.)

For complete list of EHC diagnostic trouble codes, see Diagnostic Trouble Code (DTC) Quick
Reference List—Electrohydraulic Controller (EHC) . (Group 9001-40.)

Blade Control Joystick (BCJ)— The BCJ consists of a four-way axis module and a switch module (located in the
joystick handle).

Four-Way Axis Module: The BCJ four-way axis module controls blade lift and tilt in correlation with
joystick lever movement. Data representing position of the joystick lever is transmitted across the
machine CAN data line to the EHC. The EHC converts the data representing joystick position to a
corresponding analog signal, then sends this signal to the appropriate electrohydraulic actuator to move
the blade to the desired position. The data representing joystick position is also sent to the CMU where it
can be displayed on the CMU menu structure for diagnostic purposes.

NOTE:

For information on accessing the CMU menu structure, see CAN Monitor Unit (CMU)
Menu Structure—Service Mode . (Group 9015-20.)

For BCJ diagnostics, see Integrated Grade Control (IGC) Checks—If Equipped . (Group
9015-20.)
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 Integrated Grade Control (IGC) Theory of Operation—If Equipped
For BCJ diagnostic trouble codes, see Diagnostic Trouble Code (DTC) Quick Reference
List—Blade Control Joystick (BCJ) . (Group 9001-50.)

Switch Module: The BCJ switch module contain switches that control auto/manual mode (IGC on/off),
blade angle, blade height increment/decrement, and screen swap (not used). The information from the
various switches is transmitted through separate wires to individual inputs on the EHC. The EHC
transmits the BCJ switch information across the machine CAN data line to the CMU where it can be
displayed on the CMU menu structure for diagnostic purposes.
IGC On/Off Switch: Pushing the IGC on/off switch button sends a signal out terminal 4 of the
BCJ switch module connector (X97) to terminal 21 of EHC connector (X83). When the EHC
receives a signal at this input, the EHC toggles the IGC system to either manual and auto
mode, depending on which mode the system is presently in. Before the EHC does this, it must
detect inputs from the grade control supplier's controller, the CAN monitor unit (CMU), the
blade control joystick (BCJ), the transmission control unit (TCU) (park lock lever in DOWN
position), and the hydraulic enable switch in the ENABLED position.
Screen Swap Switch (not used): Pushing the screen swap button sends a signal out terminal 5
of the BCJ switch module connector (X97) to terminal 22 of EHC connector (X83). The screen
swap switch has no function at this time so the EHC ignores this signal.
Blade Angle Switch: Pushing the upper button of the blade angle (rotate) switch sends
approximately 3.00 volts out terminal 2 of the BCJ switch module connector (X97) to terminal
20 of EHC connector (X82). This causes the EHC to send current out terminal 12 of EHC
connector (X83) to terminal 1 of blade angle actuator (Y30) (blade rotates to right). Pushing the
lower button of the blade angle (rotate) switch sends approximately 0.90 volts to terminal 20 of
EHC connector (X82). This causes the EHC to send current out terminal 5 of EHC connector
(X83) to terminal 4 of blade angle actuator (Y30) (blade rotates to left). When the blade angle
switch is in neutral position, the BCJ switch module sends approximately 2.20 volts to terminal
20 of EHC connector (X82), causing the EHC to prevent any current flow to either terminal 1 or
4 of the blade angle actuator. Blade angle stays in neutral
Blade Height Incr/Decr Switch: Pushing the upper button of the blade incr/decr switch sends
approximately 3.00 volts out terminal 2 of the BCJ switch module connector (X97) to terminal
21 of EHC connector (X82). If the system is in auto mode, the EHC will send an appropriate
signal out terminal 24 of EHC connector (X83) to terminal 1 of blade lift actuator (Y32) (blade
rises slightly). Pushing the lower button of the blade incr/decr switch sends approximately 0.90
volts to terminal 21 of EHC connector (X82). If the system is in auto mode, the EHC will send
an appropriate signal out terminal 24 of EHC connector (X83) to terminal 1 of blade lift actuator
(Y32) (blade lowers slightly). When the blade incr/decr switch is in neutral position, the BCJ
switch module sends approximately 2.20 volts to terminal 21 of EHC connector (X82), causing
the EHC to take no action in regard to the blade increment and decrement.

Electrohydraulic Actuators— The base IGC system uses three electrohydraulic actuators:

Blade angle actuator (Y30)

Blade tilt actuator (Y31)
Blade lift actuator (Y32)

An auxiliary actuator can be added using connector (X90) to accommodate optional equipment such as a ripper.

Each electrohydraulic actuator uses two pairs of solenoid valves to control the position of the actuator spool. One
pair of solenoid valves control oil pressure at one end of the actuator spool. The other pair controls oil pressure at
the opposite end of the actuator spool. Each pair contains a normally closed solenoid valve that controls supply
(pressure) oil and a normally open solenoid valve that controls venting to tank. When in the neutral state, no
current flows to either pair of solenoids, causing oil at both ends of the spool to vent to tank. With no oil pressure
at either end of the spool, the centering springs will hold the spool at center (neutral) position. For more
information on hydraulic operation of the actuators, see Hydraulic Control Valve Operation—IGC . (Group 9025-
05.)

761
 Integrated Grade Control (IGC) Theory of Operation—If Equipped
Blade Angle Actuator (Y30): The blade angle actuator uses on/off type solenoid valves. Ground from IGC ground
connector (X87) is provided to terminals 2 and 3 of the actuator.

When the EHC sends current to pin 1 of the actuator connector, the corresponding pair of solenoids are
energized, causing the actuator spool to move to maximum stroke. With the actuator spool shifted, the blade
rotates to the right. When the EHC sends current to pin 4 of the actuator connector, the other pair of solenoids are
energized, causing the actuator spool to move in the opposite direction to maximum stroke. With the actuator
spool shifted in the opposite direction, the blade rotates to the left.

Blade Tilt Actuator (Y31): The blade tilt actuator uses proportional type solenoid valves. The EHC provides power
out terminal 19 of EHC connector (X83) to terminal 4 of the actuator. A ground from IGC ground connector (X87)
is provided to terminal 3 of the actuator.

For blade tilt operation, the EHC sends an analog signal out terminal 20 of EHC connector (X83) to terminal 1 of
the blade tilt actuator. Depending on the blade operation, the analog signal will be one of three different voltage
levels as follows:

Blade tilt left = 6 volts (approximate)

Neutral = 12 volts (approximate)
Blade tilt right = 18 volts (approximate)

The actuator's on-board controller converts the analog signal to individual pulse width modulated (PWM) signals
that control each of the four proportional solenoid valves, which in turn, controls the position of the actuator spool.
The position of the spool is monitored by an integral feedback sensor, which measures spool position relative to
the input signal. When the feedback sensor detects the spool has reached the intended position, the on-board
controller will stop the modulated signals to the four solenoids.

The actuator has a built-in status light. If the actuator is operating correctly, the status light on the actuator will be
green. If the actuator spool goes farther that the intended position as commanded by the input signal, the status
light on the actuator will turn to red and a signal will be sent out terminal 2 of the actuator to terminal 4 of EHC
connector (X83). When the EHC receives this signal, the EHC generates a diagnostic trouble code (DTC) and
transmits the DTC information across the machine CAN data line to the CAN monitor unit (CMU) to alert the
operator. For complete list of possible codes generated by the EHC, see Diagnostic Trouble Code (DTC) Quick
Reference List—Electrohydraulic Controller (EHC) . (Group 9001-40.)

Blade Lift Actuator (Y32): The blade lift actuator uses proportional type solenoid valves. The EHC provides power
out terminal 19 of EHC connector (X83) to terminal 4 of the actuator. A ground from IGC ground connector (X87)
is provided to terminal 3 of the actuator.

For blade lift operation, the EHC sends an analog signal out terminal 24 of EHC connector (X83) to terminal 1 of
the blade lift actuator. Depending on the blade operation, the analog signal will be one of four different voltage
levels as follows:

Blade float = 6 volts (approximate)

Blade lower = 8 volts (approximate)
Neutral = 12 volts (approximate)
Blade raise = 18 volts (approximate)

The actuator's on-board controller converts the analog signal to individual pulse width modulated (PWM) signals
that control each of the four proportional solenoid valves, which in turn, controls the position of the actuator spool.
The position of the spool is monitored by an integral feedback sensor, which measures spool position relative to
the input signal. When the feedback sensor detects the spool has reached the intended position, the on-board
controller will stop the modulated signals to the four solenoids.

The actuator has a built-in status light. If the actuator is operating correctly, the status light on the actuator will be
green. If the actuator spool goes farther that the intended position as commanded by the input signal, the status
light on the actuator will turn to red and a signal will be sent out terminal 2 of the actuator to terminal 10 of EHC
762
 Integrated Grade Control (IGC) Theory of Operation—If Equipped
connector (X83). When the EHC receives this signal, the EHC generates a diagnostic trouble code (DTC) and
transmits the DTC information across the machine CAN data line to the CAN monitor unit (CMU) to alert the
operator. For complete list of possible codes generated by the EHC, see Diagnostic Trouble Code (DTC) Quick
Reference List—Electrohydraulic Controller (EHC) . (Group 9001-40.)

Go to Section_9015:Group_15

AA95137,000080A-19-20120817

763
 JDLink™ Circuit Theory of Operation—If Equipped

JDLink™ Circuit Theory of Operation—If Equipped

TX1086210-UN: JDLink™ System Circuit Schematic

LEGEND:
A1 - Transmission Control Unit (TCU)
A2 - Engine Control Unit (ECU)
A3 - CAN Monitor Unit (CMU)
A11 - Electrohydraulic Controller (EHC) (IGC option)
A6000 - Modular Telematics Gateway (MTG) Control Unit
A6001 - GPS/Cellular Antenna
A6002 - Satellite (SAT) Control Unit
A6003 - Satellite Antenna
F33 - Main 125-Amp Fuse
F34 - JDLink™ Ground 5-Amp Fuse—If Equipped
F35 - JDLink™ Switched Power 5 Amp Fuse
F36 - JDLink™ Unswitched Power 5 Amp Fuse
G1 - Battery
G2 - Jump Start Terminal
G3 - Alternator
M1 - Starter Motor
S1 - Key Switch
S2 - Battery Disconnect Switch
W2 - Frame Ground At Cab/Canopy Right Front
W6 - Ground Point On Starter Motor
V2 - Starter Solenoid 5-Amp Diode
X1 - TCU Connector
X3 - ECU 30-Pin Connector (L—Y)
X4 - CMU 16-Pin Connector
X18 - Operator's Station Harness-to-Transmission Harness Connector 3

764
 JDLink™ Circuit Theory of Operation—If Equipped
X19 - Engine Harness-to-Transmission Harness Connector
X30 - Operator's Station Harness-to-Transmission Harness Connector 4
X36 - VEC 8-Pin Connector (Green)
X37 - VEC 8-Pin Connector (Brown)
X57 - Not Used
X58 - Not Used
X62 - Not Used
X63 - Operator's Station Harness-to-JDLink™ Harness 12-Pin Connector
X82 - Electrohydraulic Controller (EHC) Connector (IGC option)
X86 - IGC CAN-to-Machine CAN Connector (IGC option)
X95 - IGC Machine Harness-to-IGC Cab Harness Connector (IGC option)
X6001 - Cellular Antenna Connector
X6002 - GPS Antenna Connector
X6005 - Satellite Antenna Connector
X6014 - Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector
X6015 - Satellite (SAT) Module Control Unit 48-Pin Connector
X6016 - Modular Telematics Gateway (MTG) Harness-to-Satellite (SAT) Harness 6-Pin Connector

JDLink™ transmits information via cellular connection from the machine through the modular telematics gateway
(MTG) control unit (A6000) to the JDLink™ server. The optional satellite (SAT) control unit (A6002) allows
wireless data transfer in remote areas where cellular signal is not consistently available. For more information,
see JDLink™ (MTG) Diagnosis and Tests Manual . (TM114519.)

The MTG control unit (A6000) receives unswitched battery power from JDLink™ unswitched power 5-amp fuse
(F36) at terminal M2 of MTG connector (X6014). When the ignition is on, power from JDLink™ switched power 5-
amp fuse (F35) is supplied at terminal L1 of MTG connector (X6014). Constant battery ground is provided from
JDLink™ ground 5-amp fuse (F34) at terminal M1 of MTG connector (X6014). Ground is also provided from
ground at JDLink™ harness ground (W2) at terminal F3 of MTG connector (X6014).

The MTG control unit (A6000) transmits and receives data across the controller area network (CAN) with the
systems controllers. For more information on the CAN network, see Controller Area Network (CAN) Circuit Theory
of Operation . (Group 9015-15.)

Go to Section_9015:Group_15

WS68074,00037DD-19-20110405

765
 Electrical Component Specifications

Electrical Component Specifications

Item Measurement Specification

B1—Decelerator Sensor Calibration Limits 1.25—1.75 V at High Decel
Position
3.25—3.75 V at Low Decel
Position
3.79—3.99 V at Brake Position
B2—Motor Speed Sensor Left Output Signal Voltage (High) 4.0—14.5 V
Output Signal Voltage (Low) 0.0—0.9 V
B3—Motor Speed Sensor Right Output Signal Voltage (High) 4.0—14.5 V
Output Signal Voltage (Low) 0.0—0.9 V
B4—Hydrostatic Charge Pressure Sensor Operating Pressure 0—5171 kPa
(S.N. —173641) 0—51.7 bar
0—750 psi
B5—Right Hydrostatic Pressure Sensor Operating Pressure 0—68 948 kPa
(S.N. —173658) 0—689.5 bar
0—10 000 psi
B6—Left Hydrostatic Pressure Sensor Operating Pressure 0—68 948 kPa
(S.N. —173658) 0—689.5 bar
0—10 000 psi
B7—Pump Pressure Control Pilot (PCP) Resistance 20.7—25.3 ohms
Rear
Amperage 56—80 mA
B8—Pump Pressure Control Pilot (PCP) Resistance 20.7—25.3 ohms
Front
Amperage 56—80 mA
B9—Quick-Drop Pressure Switch Closing pressure 2758—3103 kPa
27.5—31 bar
400—450 psi
Opening pressure 2034—2379 kPa
20.3—23.8 bar
295—345 psi
B10—Fuel Rail Pressure Sensor Operating pressure 0—180 MPa
0—1800 bar
0—26 100 psi
B11—Fuel Temperature Sensor Resistance 90—108 kohms at -40°C (-40°F)
26—31 kohms at -20°C (-4°F)
8.7—10.2 kohms at 0°C (32°F)
3.3—3.8 kohms at 20°C (68°F)
1.4—1.6 kohms at 40°C (104°F)
648—708 ohms at 60°C (140°F)
317—350 ohms at 80°C (176°F)
170—186 ohms at 100°C (212°F)
97—105 ohms at 120°C (248°F)
B12—Engine Coolant Temperature Resistance 120.6—147.4 ohms at 60°C
Sensor (140°F)
46.8—56.3 ohms at 90°C (194°F)
34.6—42.35 ohms at 100°C
(212°F)

766
 Electrical Component Specifications
Item Measurement Specification
B13—Manifold Air Temperature Sensor Resistance 90—108 kohms at -40°C (-40°F)
26—31 kohms at -20°C (-4°F)
8.7—10.2 kohms at 0°C (32°F)
3.3—3.8 kohms at 20°C (68°F)
1.4—1.6 kohms at 40°C (104°F)
648—708 ohms at 60°C (140°F)
317—350 ohms at 80°C (176°F)
170—186 ohms at 100°C (212°F)
97—105 ohms at 120°C (248°F)
B14—Crankshaft Position Sensor Resistance 2.7—3.3 kohms
B15—Camshaft Position Sensor Resistance 2.7—3.3 kohms
B16—Ambient Air Temperature Sensor Resistance 90—108 kohms at -40°C (-40°F)
26—31 kohms at -20°C (-4°F)
8.7—10.2 kohms at 0°C (32°F)
3.3—3.8 kohms at 20°C (68°F)
1.4—1.6 kohms at 40°C (104°F)
648—708 ohms at 60°C (140°F)
17—350 ohms at 80°C (176°F)
170—186 ohms at 100°C (212°F)
97—105 ohms at 120°C (248°F)
B17—Engine Oil Pressure Sensor Operating pressure 0—2660 kPa
0—26.6 bar
0—385 psi
B18—Water-in-Fuel Sensor Resistance 209—231 kohms
B19—Fuel Level Sensor Resistance 168—192 ohms at 100% Fill (Full)
129.5—150.5 ohms at 75% Fill
96—114 ohms at 50% Fill
67.5—82.5 ohms at 25% Fill
4—16 ohms at 0% Fill (Empty)
B20—Hydraulic Oil Temperature Sensor Resistance 90—108 kohms at -40°C (-40°F)
26—31 kohms at -20°C (-4°F)
8.7—10.2 kohms at 0°C (32°F)
3.3—3.8 kohms at 20°C (68°F)
1.4—1.6 kohms at 40°C (104°F)
648—708 ohms at 60°C (140°F)
317—350 ohms at 80°C (176°F)
170—186 ohms at 100°C (212°F)
97—105 ohms at 120°C (248°F)
B21—Transmission Oil Temperature Resistance 90—108 kohms at -40°C (-40°F)
Sensor 26—31 kohms at -20°C (-4°F)
8.7—10.2 kohms at 0°C (32°F)
3.3—3.8 kohms at 20°C (68°F)
1.4—1.6 kohms at 40°C (104°F)
648—708 ohms at 60°C (140°F)
317—350 ohms at 80°C (176°F)
170—186 ohms at 100°C (212°F)
97—105 ohms at 120°C (248°F)
B22—Engine Air Filter Restriction Switch Closing pressure 4.98—7.48 kPa
1.47—2.2 in. of Hg
20—30 in. of H2O
B23—Hydraulic Oil Filter Restriction Closing pressure 248—303 kPa
Switch 2.5—3 bar
36—44 psi

767
 Electrical Component Specifications
Item Measurement Specification
B24—Hydraulic Fan Oil Filter Restriction Opening pressure 248—303 kPa
Switch 2.5—3 bar
36—44 psi
B25—Hydrostatic Charge Oil Filter Opening pressure 248—303 kPa
Restriction Switch 2.5—3 bar
36—44 psi
B27—Air Conditioning Freeze Switch Opening temperature (decreasing) -1.4°C
29.5°F
Closing temperature (increasing) 2.2°C
36°F
B32—TCL Sensor Calibration Limits 2.37—2.63 V at Neutral Position
3.09—3.95 V at Forward Position
1.05—1.91 V at Reverse Position
B33—Steer Sensor Calibration Limits 2.3—2.7 V at Neutral Position
1.52—1.94 V at Right Steer
Position
1.40—1.78 V at Right Counter
Rotate Position
3.06—3.48 V at Left Steer
Position
3.22—3.60 V at Left Counter
Rotate Position
B34—Transmission Speed Control Calibration Limits 0.50—1.22 V w/ Up button
Sensor pressed
2.66—3.50 V w/ Down button
pressed
B35—Brake Pressure Sensor (S.N. — Operating Pressure 0—5171 kPa
173641) 0—51.7 bar
0—750 psi
B41—Hydrostatic Charge Pressure Operating Pressure 0—5171 kPa
Sensor (S.N. 173642— ) 0—51.7 bar
0—750 psi
B42—Brake Pressure Sensor (S.N. Operating Pressure 0—5171 kPa
173642— ) 0—51.7 bar
0—750 psi
B43—Right Hydrostatic Pressure Sensor Operating Pressure 0—68 948 kPa
(S.N. 173659— ) 0—689.5 bar
0—10 000 psi
B44—Left Hydrostatic Pressure Sensor Operating Pressure 0—68 948 kPa
(S.N. 173659— ) 0—689.5 bar
0—10 000 psi
B50—A/C Binary Pressure Switch Opening pressure (high) 2620—2896 kPa (26.2—29 bar)
(380—420 psi)
Closing pressure (high) 1379—2068 kPa (13.8—20.7 bar)
(200—300 psi)
Opening pressure (low) 137.9—227.5 kPa (1.38—2.28
bar) (20—33 psi)
Closing pressure (low) 158.6—255.1 kPa (1.58—2.55
bar) (23—37 psi)
R1—CAN Termination Resistor Resistance 120 ohms
R2—CAN Termination Resistor Resistance 120 ohms

768
 Electrical Component Specifications
Item Measurement Specification
R4—Cab Heater Blower Resistor Low Speed Resistance (X12 pins 2.2—2.7 ohms
2 and 6)
Medium Low Speed Resistance 1.3—1.9 ohms
(X12 pins 3 and 6)
Medium Speed Resistance (X12 0.5—0.9 ohms
pins 5 and 6)
R5—Under-Seat Heater Blower Resistor Low speed resistance (wires A15 1.2 ohms
and A18)
Medium speed resistance (wires 0.6 ohms
A16 and A18)
High speed resistance (wires A17 0.4 ohms
and A18)
R10—Engine Speed Control Resistance between pins A and B 280—420 ohms Minimum Value
4.28—6.42 kohms Maximum
Value
Resistance Between Pins A and C 4—6 kohms
Calibration Limits 2.53—3.59 V (low idle)
0.44—1.07 V (high idle)
S4—Blade Angle Switch Calibration Limits 0.50—1.22 V w/ Right button
pressed
2.66—3.50 V w/ Left button
pressed
S9—Heater Temperature Control Switch Resistance between pins A and B 0 kohms at maximum hot
5 kohms at maximum cold
Resistance Between Pins A and C 5 kohms
Y2—Park Brake Solenoid 1 Resistance 17.3—19.5 ohms at -40°C (-40°F)
19.0—21.5 ohms at -20°C (-4°F)
20.8—23.5 ohms at 0°C (32°F)
22.7—25.6 ohms at 20°C (68°F)
24.4—27.6 ohms at 40°C (104°F)
Y3—Motor Shift Solenoid Left Resistance 21.3 ohms at 20°C (68°F)
Y4—Motor Shift Solenoid Right Resistance 21.3 ohms at 20°C (68°F)
Y5(A)—Hydraulic Fan Proportional Relief Resistance 27—30 ohms at 20°C (68°F)
Solenoid
Y6—Hydraulic Fan Reversing Solenoid Resistance 24.2—27.3 ohms at -40°C (-40°F)
26.7—30.2 ohms at -20°C (-4°F)
29.2—33.0 ohms at 0°C (32°F)
31.8—35.8 ohms at 20°C (68°F)
34.2—38.6 ohms at 40°C (104°F)
Y7—Blade Angle Solenoid Left (Top) Resistance 24.2—27.3 ohms at -40°C (-40°F)
26.7—30.2 ohms at -20°C (-4°F)
29.2—33.0 ohms at 0°C (32°F)
31.8—35.8 ohms at 20°C (68°F)
34.2—38.6 ohms at 40°C (104°F)
Y8—Blade Angle Solenoid Right (Bottom) Resistance 24.2—27.3 ohms at -40°C (-40°F)
26.7—30.2 ohms at -20°C (-4°F)
29.2—33.0 ohms at 0°C (32°F)
31.8—35.8 ohms at 20°C (68°F)
34.2—38.6 ohms at 40°C (104°F)

769
 Electrical Component Specifications
Item Measurement Specification
Y9—Quick-Drop Solenoid Resistance 24.2—27.3 ohms at -40°C (-40°F)
26.7—30.2 ohms at -20°C (-4°F)
29.2—33.0 ohms at 0°C (32°F)
31.8—35.8 ohms at 20°C (68°F)
34.2—38.6 ohms at 40°C (104°F)
Y10—Pilot Control Enable Solenoid Resistance 20.5—23.1 ohms at -40°C (-40°F)
22.6—25.5 ohms at -20°C (-4°F)
24.7—27.8 ohms at 0°C (32°F)
26.8—30.2 ohms at 20°C (68°F)
28.9—32.6 ohms at 40°C (104°F)
Y11—Blade Detent Coil Resistance 110—120 ohms
Y14—Hydrostatic Oil Cooler Bypass Resistance 20.5—23.1 ohms at -40°C (-40°F)
Solenoid 22.6—25.5 ohms at -20°C (-4°F)
24.7—27.8 ohms at 0°C (32°F)
26.8—30.2 ohms at 20°C (68°F)
28.9—32.6 ohms at 40°C (104°F)
Y15—Park Bake Solenoid 2 Resistance 17.3—19.5 ohms at -40°C (-40°F)
19.0—21.5 ohms at -20°C (-4°F)
20.8—23.5 ohms at 0°C (32°F)
22.7—25.6 ohms at 20°C (68°F)
24.4—27.6 ohms at 40°C (104°F)
Y16—Air Conditioning Compressor Resistance 3.5—6 ohms
Clutch Solenoid
Y17—Hydrostatic Oil Reservoir Bypass Resistance 24.2—27.3 ohms at -40°C (-40°F)
Solenoid 26.7—30.2 ohms at -20°C (-4°F)
29.2—33.0 ohms at 0°C (32°F)
31.8—35.8 ohms at 20°C (68°F)
34.2—38.6 ohms at 40°C (104°F)

Go to Section_9015:Group_20

WS68074,000115D-19-20130805

770
 Electrical Component Specifications

Electrical Component Specifications

Item Measurement Specification

B1—Decelerator Sensor Calibration Limits 1.25—1.75 V at High Decel
Position
3.25—3.75 V at Low Decel
Position
3.79—3.99 V at Brake Position
B2—Motor Speed Sensor Left Output Signal Voltage (High) 4.0—14.5 V
Output Signal Voltage (Low) 0.0—0.9 V
B3—Motor Speed Sensor Right Output Signal Voltage (High) 4.0—14.5 V
Output Signal Voltage (Low) 0.0—0.9 V
B4—Hydrostatic Charge Pressure Sensor Operating Pressure 0—5171 kPa
(S.N. —173641) 0—51.7 bar
0—750 psi
B5—Right Hydrostatic Pressure Sensor Operating Pressure 0—68 948 kPa
(S.N. —173658) 0—689.5 bar
0—10 000 psi
B6—Left Hydrostatic Pressure Sensor Operating Pressure 0—68 948 kPa
(S.N. —173658) 0—689.5 bar
0—10 000 psi
B7—Pump Pressure Control Pilot (PCP) Resistance 20.7—25.3 ohms
Rear
Amperage 56—80 mA
B8—Pump Pressure Control Pilot (PCP) Resistance 20.7—25.3 ohms
Front
Amperage 56—80 mA
B9—Quick-Drop Pressure Switch Closing pressure 2758—3103 kPa
27.5—31 bar
400—450 psi
Opening pressure 2034—2379 kPa
20.3—23.8 bar
295—345 psi
B10—Fuel Rail Pressure Sensor Operating pressure 0—180 MPa
0—1800 bar
0—26 100 psi
B11—Fuel Temperature Sensor Resistance 90—108 kohms at -40°C (-40°F)
26—31 kohms at -20°C (-4°F)
8.7—10.2 kohms at 0°C (32°F)
3.3—3.8 kohms at 20°C (68°F)
1.4—1.6 kohms at 40°C (104°F)
648—708 ohms at 60°C (140°F)
317—350 ohms at 80°C (176°F)
170—186 ohms at 100°C (212°F)
97—105 ohms at 120°C (248°F)
B12—Engine Coolant Temperature Resistance 120.6—147.4 ohms at 60°C
Sensor (140°F)
46.8—56.3 ohms at 90°C (194°F)
34.6—42.35 ohms at 100°C
(212°F)

771
 Electrical Component Specifications
Item Measurement Specification
B13—Manifold Air Temperature Sensor Resistance 90—108 kohms at -40°C (-40°F)
26—31 kohms at -20°C (-4°F)
8.7—10.2 kohms at 0°C (32°F)
3.3—3.8 kohms at 20°C (68°F)
1.4—1.6 kohms at 40°C (104°F)
648—708 ohms at 60°C (140°F)
317—350 ohms at 80°C (176°F)
170—186 ohms at 100°C (212°F)
97—105 ohms at 120°C (248°F)
B14—Crankshaft Position Sensor Resistance 2.7—3.3 kohms
B15—Camshaft Position Sensor Resistance 2.7—3.3 kohms
B16—Ambient Air Temperature Sensor Resistance 90—108 kohms at -40°C (-40°F)
26—31 kohms at -20°C (-4°F)
8.7—10.2 kohms at 0°C (32°F)
3.3—3.8 kohms at 20°C (68°F)
1.4—1.6 kohms at 40°C (104°F)
648—708 ohms at 60°C (140°F)
17—350 ohms at 80°C (176°F)
170—186 ohms at 100°C (212°F)
97—105 ohms at 120°C (248°F)
B17—Engine Oil Pressure Sensor Operating pressure 0—2660 kPa
0—26.6 bar
0—385 psi
B18—Water-in-Fuel Sensor Resistance 209—231 kohms
B19—Fuel Level Sensor Resistance 168—192 ohms at 100% Fill (Full)
129.5—150.5 ohms at 75% Fill
96—114 ohms at 50% Fill
67.5—82.5 ohms at 25% Fill
4—16 ohms at 0% Fill (Empty)
B20—Hydraulic Oil Temperature Sensor Resistance 90—108 kohms at -40°C (-40°F)
26—31 kohms at -20°C (-4°F)
8.7—10.2 kohms at 0°C (32°F)
3.3—3.8 kohms at 20°C (68°F)
1.4—1.6 kohms at 40°C (104°F)
648—708 ohms at 60°C (140°F)
317—350 ohms at 80°C (176°F)
170—186 ohms at 100°C (212°F)
97—105 ohms at 120°C (248°F)
B21—Transmission Oil Temperature Resistance 90—108 kohms at -40°C (-40°F)
Sensor 26—31 kohms at -20°C (-4°F)
8.7—10.2 kohms at 0°C (32°F)
3.3—3.8 kohms at 20°C (68°F)
1.4—1.6 kohms at 40°C (104°F)
648—708 ohms at 60°C (140°F)
317—350 ohms at 80°C (176°F)
170—186 ohms at 100°C (212°F)
97—105 ohms at 120°C (248°F)
B22—Engine Air Filter Restriction Switch Closing pressure 4.98—7.48 kPa
1.47—2.2 in. of Hg
20—30 in. of H2O
B23—Hydraulic Oil Filter Restriction Closing pressure 248—303 kPa
Switch 2.5—3 bar
36—44 psi

772
 Electrical Component Specifications
Item Measurement Specification
B24—Hydraulic Fan Oil Filter Restriction Opening pressure 248—303 kPa
Switch 2.5—3 bar
36—44 psi
B25—Hydrostatic Charge Oil Filter Opening pressure 248—303 kPa
Restriction Switch 2.5—3 bar
36—44 psi
B27—Air Conditioning Freeze Switch Opening temperature (decreasing) -1.4°C
29.5°F
Closing temperature (increasing) 2.2°C
36°F
B32—TCL Sensor Calibration Limits 2.37—2.63 V at Neutral Position
3.09—3.95 V at Forward Position
1.05—1.91 V at Reverse Position
B33—Steer Sensor Calibration Limits 2.3—2.7 V at Neutral Position
1.52—1.94 V at Right Steer
Position
1.40—1.78 V at Right Counter
Rotate Position
3.06—3.48 V at Left Steer
Position
3.22—3.60 V at Left Counter
Rotate Position
B34—Transmission Speed Control Calibration Limits 0.50—1.22 V w/ Up button
Sensor pressed
2.66—3.50 V w/ Down button
pressed
B35—Brake Pressure Sensor (S.N. — Operating Pressure 0—5171 kPa
173641) 0—51.7 bar
0—750 psi
B41—Hydrostatic Charge Pressure Operating Pressure 0—5171 kPa
Sensor (S.N. 173642— ) 0—51.7 bar
0—750 psi
B42—Brake Pressure Sensor (S.N. Operating Pressure 0—5171 kPa
173642— ) 0—51.7 bar
0—750 psi
B43—Right Hydrostatic Pressure Sensor Operating Pressure 0—68 948 kPa
(S.N. 173659— ) 0—689.5 bar
0—10 000 psi
B44—Left Hydrostatic Pressure Sensor Operating Pressure 0—68 948 kPa
(S.N. 173659— ) 0—689.5 bar
0—10 000 psi
B50—A/C Binary Pressure Switch Opening pressure (high) 2620—2896 kPa (26.2—29 bar)
(380—420 psi)
Closing pressure (high) 1379—2068 kPa (13.8—20.7 bar)
(200—300 psi)
Opening pressure (low) 137.9—227.5 kPa (1.38—2.28
bar) (20—33 psi)
Closing pressure (low) 158.6—255.1 kPa (1.58—2.55
bar) (23—37 psi)
R1—CAN Termination Resistor Resistance 120 ohms
R2—CAN Termination Resistor Resistance 120 ohms

773
 Electrical Component Specifications
Item Measurement Specification
R4—Cab Heater Blower Resistor Low Speed Resistance (X12 pins 2.2—2.7 ohms
2 and 6)
Medium Low Speed Resistance 1.3—1.9 ohms
(X12 pins 3 and 6)
Medium Speed Resistance (X12 0.5—0.9 ohms
pins 5 and 6)
R5—Under-Seat Heater Blower Resistor Low speed resistance (wires A15 1.2 ohms
and A18)
Medium speed resistance (wires 0.6 ohms
A16 and A18)
High speed resistance (wires A17 0.4 ohms
and A18)
R10—Engine Speed Control Resistance between pins A and B 280—420 ohms Minimum Value
4.28—6.42 kohms Maximum
Value
Resistance Between Pins A and C 4—6 kohms
Calibration Limits 2.53—3.59 V (low idle)
0.44—1.07 V (high idle)
S4—Blade Angle Switch Calibration Limits 0.50—1.22 V w/ Right button
pressed
2.66—3.50 V w/ Left button
pressed
S9—Heater Temperature Control Switch Resistance between pins A and B 0 kohms at maximum hot
5 kohms at maximum cold
Resistance Between Pins A and C 5 kohms
Y2—Park Brake Solenoid 1 Resistance 17.3—19.5 ohms at -40°C (-40°F)
19.0—21.5 ohms at -20°C (-4°F)
20.8—23.5 ohms at 0°C (32°F)
22.7—25.6 ohms at 20°C (68°F)
24.4—27.6 ohms at 40°C (104°F)
Y3—Motor Shift Solenoid Left Resistance 21.3 ohms at 20°C (68°F)
Y4—Motor Shift Solenoid Right Resistance 21.3 ohms at 20°C (68°F)
Y5(A)—Hydraulic Fan Proportional Relief Resistance 27—30 ohms at 20°C (68°F)
Solenoid
Y6—Hydraulic Fan Reversing Solenoid Resistance 24.2—27.3 ohms at -40°C (-40°F)
26.7—30.2 ohms at -20°C (-4°F)
29.2—33.0 ohms at 0°C (32°F)
31.8—35.8 ohms at 20°C (68°F)
34.2—38.6 ohms at 40°C (104°F)
Y7—Blade Angle Solenoid Left (Top) Resistance 24.2—27.3 ohms at -40°C (-40°F)
26.7—30.2 ohms at -20°C (-4°F)
29.2—33.0 ohms at 0°C (32°F)
31.8—35.8 ohms at 20°C (68°F)
34.2—38.6 ohms at 40°C (104°F)
Y8—Blade Angle Solenoid Right (Bottom) Resistance 24.2—27.3 ohms at -40°C (-40°F)
26.7—30.2 ohms at -20°C (-4°F)
29.2—33.0 ohms at 0°C (32°F)
31.8—35.8 ohms at 20°C (68°F)
34.2—38.6 ohms at 40°C (104°F)

774
 Electrical Component Specifications
Item Measurement Specification
Y9—Quick-Drop Solenoid Resistance 24.2—27.3 ohms at -40°C (-40°F)
26.7—30.2 ohms at -20°C (-4°F)
29.2—33.0 ohms at 0°C (32°F)
31.8—35.8 ohms at 20°C (68°F)
34.2—38.6 ohms at 40°C (104°F)
Y10—Pilot Control Enable Solenoid Resistance 20.5—23.1 ohms at -40°C (-40°F)
22.6—25.5 ohms at -20°C (-4°F)
24.7—27.8 ohms at 0°C (32°F)
26.8—30.2 ohms at 20°C (68°F)
28.9—32.6 ohms at 40°C (104°F)
Y11—Blade Detent Coil Resistance 110—120 ohms
Y14—Hydrostatic Oil Cooler Bypass Resistance 20.5—23.1 ohms at -40°C (-40°F)
Solenoid 22.6—25.5 ohms at -20°C (-4°F)
24.7—27.8 ohms at 0°C (32°F)
26.8—30.2 ohms at 20°C (68°F)
28.9—32.6 ohms at 40°C (104°F)
Y15—Park Bake Solenoid 2 Resistance 17.3—19.5 ohms at -40°C (-40°F)
19.0—21.5 ohms at -20°C (-4°F)
20.8—23.5 ohms at 0°C (32°F)
22.7—25.6 ohms at 20°C (68°F)
24.4—27.6 ohms at 40°C (104°F)
Y16—Air Conditioning Compressor Resistance 3.5—6 ohms
Clutch Solenoid
Y17—Hydrostatic Oil Reservoir Bypass Resistance 24.2—27.3 ohms at -40°C (-40°F)
Solenoid 26.7—30.2 ohms at -20°C (-4°F)
29.2—33.0 ohms at 0°C (32°F)
31.8—35.8 ohms at 20°C (68°F)
34.2—38.6 ohms at 40°C (104°F)

Go to Section_9015:Group_20

WS68074,000115D-19-20130805

775
 Diagnostic Trouble Codes (DTC) Quick Reference List

Diagnostic Trouble Codes (DTC) Quick Reference List

The diagnostic trouble code number is indicated by a Suspect Parameter Number (SPN) and a Failure Mode
Indicator (FMI) number. In the example 000096.03 , 96 is the SPN and 03 is the FMI number.

To view diagnostic trouble codes, use one of the following methods:

Service ADVISOR™ system. See Reading Diagnostic Trouble Codes with Service ADVISOR™
Diagnostic Application . (Group 9015-20.)
CAN Monitor Unit (CMU). See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-
20.)

CAN Monitor Unit (CMU) Diagnostic Trouble Codes

NOTE: For in-depth diagnostics on all CMU diagnostic trouble codes, see CAN Monitor Unit (CMU)
Diagnostic Trouble Codes in Group 9001-10.

000096.03— Fuel Level Sensor Open or Short

000096.04— Fuel Level Sensor Short to Ground
000107.03— Engine Air Filter Restriction Indicator Switch Short to Power
000107.04— Engine Air Filter Restricted
000177.03— Transmission Oil Temperature Sensor Short to Power
000177.04— Transmission Oil Temperature Sensor Short to Ground
000609.09— CAN Communication Error, No TCU Message
001638.00— Hydraulic Oil Temperature High
001638.03— Hydraulic Oil Temperature Short to Power
001638.04— Hydraulic Oil Temperature Short to Ground
001713.31— Hydraulic Oil Filter Restricted
002000.09— CAN Communication Error, No ECU Configuration
003156.09— CAN Blade Mode Missing From EHC
003359.31— Transmission Oil Filter Restricted
524227.31— Fan Oil Filter Restricted

Engine Control Unit (ECU) Diagnostic Trouble Codes

NOTE: For in-depth diagnostics on all the ECU diagnostic trouble codes, see Trouble Code Diagnostics
and Tests in CTM502.

000029.03— Throttle #2 Signal Out of Range High

000029.04— Throttle #2 Signal Out of Range Low
000029.14— Throttle Voltage Out of Range
000091.03— Throttle #1 Signal Out of Range High
000091.04— Throttle #1 Signal Out of Range Low
000091.09— CAN Throttle Missing from TCU (Group 9001-20.)
000091.14— Throttle Voltage Out of Range
000097.03— Water-in-Fuel Signal Out of Range High
000097.04— Water In Fuel Short to Gnd
000097.16— Water in Fuel Detected
000100.01— Engine Oil Pressure Signal Extremely Low
000100.03— Eng Oil Press Short to Power (Group 9001-20.)
000100.04— Engine Oil Pressure Signal Out of Range Low
000105.00— Intake Manifold Air Temperature Signal Extremely High
000105.03— Intake Manifold Air Temperature Signal Out of Range High
000105.04— Intake Manifold Air Temperature Signal Out of Range Low
000105.15— Intake Manifold Air Temperature Signal Slightly High
000105.16— Intake Manifold Air Temperature Signal Moderately High
000108.02— Barometric Pressure Signal Invalid
000110.00— Engine Coolant Temperature Signal Extremely High

776
 Diagnostic Trouble Codes (DTC) Quick Reference List
000110.03— Engine Coolant Temperature Signal Out of Range High
000110.04— Engine Coolant Temperature Signal Out of Range Low
000110.15— Engine Coolant Temperature Signal Slightly High
000110.16— Engine Coolant Temperature Signal Moderately High
000111.01— Engine Coolant Level Low
000157.03— Fuel Rail Pressure Signal Out of Range High
000157.04— Fuel Rail Pressure Signal Out of Range Low
000157.10— Fuel Rail Pressure Rate of Change Abnormal
000157.17— Fuel Rail Pressure Not Developed
000158.17— ECU Power Down Error
000171.03— Ambient Air Temp Open or Short (Group 9001-20.)
000171.04— Ambient Air Temp Short to Gnd (Group 9001-20.)
000174.00— Fuel Temperature Signal Extremely High
000174.03— Fuel Temperature Signal Out of Range High
000174.04— Fuel Temperature Signal Out of Range Low
000174.16— Fuel Temperature Signal Moderately High
000189.00— Engine Speed Derate Condition Exists
000190.00— Engine Speed Extremely High
000190.16— Engine Speed Moderately High
000611.03— Injector Shorted to Power
000611.04— Injector Shorted to Ground
000627.01— Injector Current Incorrect (Group 9001-20.)
000629.13— ECU Programming Error
000636.02— Pump Position Sensor Signal Invalid
000636.05— Pump Position Sensor Circuit Has High Resistance
000636.08— Pump Position Sensor Signal Missing
000636.10— Pump Position Signal Rate of Change Abnormal
000637.02— Crank Sensor Signal Invalid
000637.05— Crank Sensor Circuit Has High Resistance
000637.07— Crank and Pump Position Signals Out of Sync
000637.08— Crank Sensor Signal Missing
000637.10— Crank Signal Rate of Change Abnormal
000651.00— Cyl 1 Injector Max Cal (Group 9001-20.)
000651.01— Cyl 1 Injector Min Cal (Group 9001-20.)
000651.02— Injector #1 Part # Data Invalid
000651.05— Injector #1 Circuit Has High Resistance
000651.06— Injector #1 Circuit Has Low Resistance
000651.07— Injector #1 Not Responding
000651.13— Injector #1 Calibration Fault
000652.00— Cyl 2 Injector Max Cal (Group 9001-20.)
000652.01— Cyl 2 Injector Min Cal (Group 9001-20.)
000652.02— Injector #2 Part # Data Invalid
000652.05— Injector #2 Circuit Has High Resistance
000652.06— Injector #2 Circuit Has Low Resistance
000652.07— Injector #2 Not Responding
000652.13— Injector #2 Calibration Fault
000653.00— Cyl 3 Injector Max Cal (Group 9001-20.)
000653.01— Cyl 3 Injector Min Cal (Group 9001-20.)
000653.02— Injector #3 Part # Data Invalid
000653.05— Injector #3 Circuit Has High Resistance
000653.06— Injector #3 Circuit Has Low Resistance
000653.07— Injector #3 Not Responding
000653.13— Injector #3 Calibration Fault
000654.00— Cyl 4 Injector Max Cal (Group 9001-20.)
000654.01— Cyl 4 Injector Min Cal (Group 9001-20.)
000654.02— Injector #4 Part # Data Invalid

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 Diagnostic Trouble Codes (DTC) Quick Reference List
000654.05— Injector #4 Circuit Has High Resistance
000654.06— Injector #4 Circuit Has Low Resistance
000654.07— Injector #4 Not Responding
000654.13— Injector #4 Calibration Fault
000655.00— Cyl 5 Injector Max Cal (Group 9001-20.)
000655.01— Cyl 5 Injector Min Cal (Group 9001-20.)
000655.02— Injector #5 Part # Data Invalid
000655.05— Injector #5 Circuit Has High Resistance
000655.06— Injector #5 Circuit Has Low Resistance
000655.07— Injector #5 Not Responding
000655.13— Injector #5 Calibration Fault
000656.00— Cyl 6 Injector Max Cal (Group 9001-20.)
000656.01— Cyl 6 Injector Min Cal (Group 9001-20.)
000656.02— Injector #6 Part # Data Invalid
000656.05— Injector #6 Circuit Has High Resistance
000656.06— Injector #6 Circuit Has Low Resistance
000656.07— Injector #6 Not Responding
000656.13— Injector #6 Calibration Fault
001136.00— ECU Temperature Signal Extremely High
001136.16— ECU Temperature Signal Moderately High
001347.03— High Pressure Fuel Pump Control Valve Signal Out of Range High
001347.05— High Pressure Fuel Pump Solenoid #1 Circuit Has High Resistance
001347.07— High Pressure Fuel Pump Not Able to Meet Required Rail Pressure
001569.31— Engine in Derate Condition
002000.13— Incorrect ECU for Application
003509.03— Sensor Supply #1 Voltage Out of Range High
003509.04— Sensor Supply #1 Voltage Out of Range Low
003510.03— Sensor Supply #2 Voltage Out of Range High
003510.04— Sensor Supply #2 Voltage Out of Range Low
003511.03— Sensor Supply #3 Voltage Out of Range High
003511.04— Sensor Supply #3 Voltage Out of Range Low

Transmission Control Unit (TCU) Diagnostic Trouble Codes

NOTE: For in-depth diagnostics on all TCU diagnostic trouble codes, see Transmission Control Unit
(TCU) Diagnostic Trouble Codes in Group 9001-30.

000070.00— Park Lock Lever Inputs Both ON

000070.01— Park Lock Lever Inputs Both OFF
000091.00— Throttle Sensor Input Greater Than Maximum Calibration Value
000091.01— Throttle Sensor Input Less Than Minimum Calibration Value
000091.03— Throttle Sensor Short to Power
000091.04— Throttle Sensor Open or Short
000091.15— Throttle Sensor Minimum Calibration Value Too High
000091.16— Throttle Sensor Maximum Calibration Value Too High
000091.17— Throttle Sensor Minimum Calibration Value Too Low
000091.18— Throttle Sensor Maximum Calibration Value Too Low
000116.00— Brake Pressure High
000116.01— Brake Pressure Low
000116.03— Brake Pressure Short to Power
000116.04— Brake Pressure Open or Short
000158.03— TCU System Volts Too High
000158.04— TCU System Volts Too Low
000177.00— Transmission Over Temp
000190.09— CAN Communication Error No Engine Speed
000190.19— CAN Communication Error Invalid Engine Speed
000521.00— Decel Sensor Input Greater Than Maximum Calibration Value

778
 Diagnostic Trouble Codes (DTC) Quick Reference List
000521.01— Decel Sensor Input Less Than Minimum Calibration Value
000521.03— Decel Sensor Short to Power
000521.04— Decel Sensor Open or Short
000521.05— Decel Sensor Brake Calibration Value Too Low
000521.06— Decel Sensor Brake Calibration Value Too High
000521.15— Decel Sensor Minimum Calibration Value Too High
000521.16— Decel Sensor Maximum Calibration Value Too High
000521.17— Decel Sensor Minimum Calibration Value Too Low
000521.18— Decel Sensor Maximum Calibration Value Too Low
000581.00— Speed Buttons Input Greater Than Maximum Calibration Value
000581.01— Speed Buttons Input Less Than Minimum Calibration Value
000581.03— Speed Buttons Short to Power
000581.04— Speed Buttons Open or Short
000581.15— Speed Buttons Minimum Calibration Value Too High
000581.16— Speed Buttons Maximum Calibration Value Too High
000581.17— Speed Buttons Minimum Calibration Value Too Low
000581.18— Speed Buttons Maximum Calibration Value Too Low
000604.03— FNR Neutral Switch Open Circuit
000604.04— FNR Neutral Switch Short Circuit
000604.15— FNR Neutral Switch Minimum Calibration Value Too High
000604.16— FNR Neutral Switch Maximum Calibration Value Too High
000604.17— FNR Neutral Switch Minimum Calibration Value Too Low
000604.18— FNR Neutral Switch Maximum Calibration Value Too Low
000619.05— Brake Solenoid No Response
000620.03— TCU 5V Supply Short to Power
000620.04— TCU 5V Supply Open or Short
000907.03— Left Speed Sensor Short to Power
000907.04— Left Speed Sensor Short
000907.07— Left Speed Sensor No Response
000907.12— Left Speed Sensor Open
000908.03— Right Speed Sensor Short to Power
000908.04— Right Speed Sensor Short
000908.07— Right Speed Sensor No Response
000908.12— Right Speed Sensor Open
000977.05— Fan Reverse Solenoid No Response
001071.05— Fan Drive Solenoid Open Circuit
001071.06— Fan Drive Solenoid Short Circuit
002660.00— Steer Sensor Input Greater Than Maximum Calibration Value
002660.01— Steer Sensor Input Less Than Minimum Calibration Value
002660.03— Steer Sensor Short to Power
002660.04— Steer Sensor Open or Short
002660.15— Steer Sensor Minimum Calibration Value Too High
002660.16— Steer Sensor Maximum Calibration Value Too High
002660.17— Steer Sensor Minimum Calibration Value Too Low
002660.18— Steer Sensor Maximum Calibration Value Too Low
002661.00— FNR Sensor Input Greater Than Maximum Calibration Value
002661.01— FNR Sensor Input Less Than Minimum Calibration Value
002661.03— FNR Sensor Short to Power
002661.04— FNR Sensor Open or Short
002661.15— FNR Sensor Minimum Calibration Value Too High
002661.16— FNR Sensor Maximum Calibration Value Too High
002661.17— FNR Sensor Minimum Calibration Value Too Low
002661.18— FNR Sensor Maximum Calibration Value Too Low
522439.05— Tank Bypass Solenoid Open Circuit
522440.05— Blade Left Solenoid Open Circuit
522440.06— Blade Left Solenoid Short Circuit

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 Diagnostic Trouble Codes (DTC) Quick Reference List
522441.05— Blade Right Solenoid Open Circuit
522441.06— Blade Right Solenoid Short Circuit
522442.00— Blade Buttons Input Greater Than Maximum Calibration Value
522442.01— Blade Buttons Input Less Than Minimum Calibration Value
522442.03— Blade Buttons Short to Power
522442.04— Blade Buttons Open or Short
522442.15— Blade Buttons Minimum Calibration Value Too High
522442.16— Blade Buttons Maximum Calibration Value Too High
522442.17— Blade Buttons Minimum Calibration Value Too Low
522442.18— Blade Buttons Maximum Calibration Value Too Low
522444.00— Charge Pressure High
522444.01— Charge Pressure Low
522444.03— Charge Pressure Short to Power
522444.04— Charge Pressure Open or Short
522445.00— Right System Pressure High
522445.01— Right System Pressure Low
522445.03— Right System Press. Short to Power
522445.04— Right System Press. Open or Short
522446.00— Left System Pressure High
522446.01— Left System Pressure Low
522446.03— Left System Press. Short to Power
522446.04— Left System Press. Open or Short
522447.05— Right Forward Pump Coil Open
522447.06— Right Forward Pump Coil Short
522447.15— Right Forward Pump Threshold Calibration Value Too High
522447.16— Right Forward Pump Max Speed Calibration Value Too High
522447.17— Right Forward Pump Threshold Calibration Value Too Low
522447.18— Right Forward Pump Max Speed Calibration Value Too Low
522448.05— Right Reverse Pump Coil Open
522448.06— Right Reverse Pump Coil Short
522448.15— Right Reverse Pump Threshold Calibration Value Too High
522448.16— Right Reverse Pump Max Speed Calibration Value Too High
522448.17— Right Reverse Pump Thresh Calibration Value Too Low
522448.18— Right Reverse Pump Max Speed Calibration Value Too Low
522449.05— Left Reverse Pump Coil Open
522449.06— Left Reverse Pump Coil Short
522449.15— Left Reverse Pump Threshold Calibration Value Too High
522449.16— Left Reverse Pump Max Speed Calibration Value Too Low
522449.17— Left Reverse Pump Threshold Calibration Value Too Low
522449.18— Left Reverse Pump Max Speed Calibration Value Too Low
522450.05— Left Forward Pump Coil Open
522450.06— Left Forward Pump Coil Short
522450.15— Left Forward Pump Threshold Calibration Value Too High
522450.16— Left Forward Pump Max Speed Calibration Value Too Low
522450.17— Left Forward Pump Threshold Calibration Value Too Low
522450.18— Left Forward Pump Max Speed Calibration Value Too Low
522451.05— Cooler Bypass Solenoid No Response
523108.13— TCU Not Calibrated High Speed Not Done
523108.14— TCU Not Calibrated Sensor/Pump/Motor
523436.07— TCU Watchdog Timer Exceeded
523577.05— Left Motor Solenoid Open Circuit
523577.06— Left Motor Solenoid Short Circuit
523577.16— Left Motor Maximum Calibration Value Too High
523577.18— Left Motor Maximum Calibration Value Too Low
523578.05— Right Motor Solenoid Open Circuit
523578.06— Right Motor Solenoid Short Circuit

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 Diagnostic Trouble Codes (DTC) Quick Reference List
523578.16— Right Motor Maximum Calibration Value Too High
523578.18— Right Motor Maximum Calibration Value Too Low

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

NOTE: For in-depth diagnostics on all EHC diagnostic trouble codes, see Electrohydraulic Controller
(EHC) Diagnostic Trouble Codes in Group 9001-40.

000158.03— EHC System Volts Too High

000158.04— EHC System Volts Too Low
000620.03— Sensor Short to Power
000620.04— Sensor Short to GND
001903.00— Aux 1 PVE Open Circuit
001903.01— Aux 1 PVE Low or Open Circuit
001903.03— Aux 1 PVE Short to Power
001903.04— Aux 1 PVE Short to GND
001903.31— Aux 1 PVE Spool Pos Error
001915.00— Aux 2 PVE Open Circuit
001915.01— Aux 2 PVE Low or Open Circuit
001915.03— Aux 2 PVE Short to Power
001915.04— Aux 2 PVE Short to GND
001915.31— Aux 2 PVE Spool Pos Error
002697.09— CAN Joystick Pos Missing From BCJ
002712.00— Hyd Enable Sw Inputs Both On
002712.01— Hyd Enable Sw Inputs Both Off
003157.03— Incr / Decr Buttons Short to Power
003157.04— Incr / Decr Buttons Open or Short
003157.31— Incr / Decr Buttons Invalid Output
522442.31— Incr / Decr Buttons Invalid Output
523779.00— Blade Rotate Current Above Max
523779.01— Blade Rotate Current Below Min
523780.00— Tilt PVE Open Circuit
523780.01— Tilt PVE Low or Open Circuit
523780.03— Tilt PVE Short to Power
523780.04— Tilt PVE Short to GND
523780.31— Tilt PVE Spool Pos Error
523781.00— Height PVE Open Circuit
523781.01— Height PVE Low or Open Circuit
523781.03— Height PVE Short to Power
523781.04— Height PVE Short to GND
523781.31— Height PVE Spool Pos Error
524059.03— Aux 2 Jstk Sensor 2 Short to Power
524059.04— Aux 2 Jstk Sensor 2 Short to GND
524059.31— Aux 2 Jstk Sensor 2 Invalid Output
524062.03— Aux 1 Jstk Sensor 2 Short to Power
524062.04— Aux 1 Jstk Sensor 2 Short to GND
524062.31— Aux 1 Jstk Sensor 2 Invalid Output
524085.03— Aux 2 Jstk Sensor 1 Short to Power
524085.04— Aux 2 Jstk Sensor 1 Short to GND
524085.14— Aux 2 Jstk Sensor Mismatch
524085.31— Aux 2 Jstk Sensor 1 Invalid Output
524086.03— Aux 1 Jstk Sensor 1 Short to Power
524086.04— Aux 1 Jstk Sensor 1 Short to GND
524086.14— Aux 1 Jstk Sensor Mismatch
524086.31— Aux 1 Jstk Sensor 1 Invalid Output

Blade Control Joystick (BCJ) Diagnostic Trouble Codes

781
 Diagnostic Trouble Codes (DTC) Quick Reference List
NOTE: For in-depth diagnostics on all BCJ diagnostic trouble codes, see Blade Control Joystick (BCJ)
Diagnostic Trouble Codes in Group 9001-50.

002697.03— X-Axis Sensor Out of Range High

002697.04— X-Axis Sensor Out of Range Low
002697.12— X-Axis Joystick Internal Failure
002697.13— X-Axis Joystick Setup Failure
002697.14— X-Axis Joystick Sensor Failure
002698.03— Y-Axis Sensor Out of Range High
002698.04— Y-Axis Sensor Out of Range Low
002698.12— Y-Axis Joystick Internal Failure
002698.13— Y-Axis Joystick Setup Failure
002698.14— Y-Axis Joystick Sensor Failure

Go to Section_9015:Group_20

AA95137,00007C2-19-20131001

782
 Service ADVISOR™ Diagnostic Application

Service ADVISOR™ Diagnostic Application

The Service ADVISOR application is what technicians use to diagnose and troubleshoot equipment. The
application allows technicians to quickly and easily find information and solve equipment problems.

The Service ADVISOR application provides access to manuals, the Dealer Technical Assistance Center (DTAC),
real-time diagnostics, and system readings. The application also allows technicians to perform calibrations, run
tests, and program controllers, when possible.

The Connection - Readings shortcut bar within Service ADVISOR is used to connect to a machine. A connection
allows a technician to take live system readings, create recordings, diagnose problems, calibrate, interactively
test, and program controllers. With a connection established, the Readings menu allows a technician to add or
remove a reading, set a readings baseline, and create and check recording triggers.

With Service ADVISOR connected to a machine, the Diagnostics shortcut bar can be used to read machine
diagnostic trouble codes. The diagnostic codes can then be reviewed by code number for specific details. When a
diagnostic trouble code is opened, code information displays in a window similar to the way a manual would. The
details of a diagnostic trouble code often are in a procedural format with links so the technician can work to
correct the problem with the equipment while following the step-by-step process in the diagnostic trouble code
details.

See Service ADVISOR™ Connection Procedure . (Group 9015-20.)

See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.)

Go to Section_9015:Group_20

LD30992,00002CA-19-20060206

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 Service ADVISOR™ Connection Procedure

Service ADVISOR™ Connection Procedure

NOTE:

For additional information on Service ADVISOR™ , see Service ADVISOR™ Diagnostic

Application and see Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic
Application . (Group 9015-20.)

1.

TX1011710A-UN: EDL and Cables

TX1011712A-UN: PDM and Cables

LEGEND:
1 - USB Cable
2 - Electronic Data Link (EDL)
3 - Diagnostic 9-Pin Connector Cable
4 - Parallel Port Cable
5 - Parallel Port Data Module (PDM)

Connect EDL (2) or PDM (5) to computer.

784
 Service ADVISOR™ Connection Procedure
2.

TX1019581A-UN: Diagnostic 9-Pin Connector and Cover

LEGEND:
6 - Diagnostic 9-Pin Connector

Connect diagnostic 9-pin connector cable (3) to diagnostic 9-pin connector (6) located in the back right
behind the seat.

3.

TX1011711A-UN: EDL LEDs

785
 Service ADVISOR™ Connection Procedure

TX1011713A-UN: PDM LEDs

LEGEND:
8 - CAN Connection LED (red)
9 - Power LED (green)

Turn key switch to ON position. Power LED (9) must come on.

4. The CAN connection LED (8) will come on when computer connects to the CAN data line. The CAN
connection LED may flicker—this is normal. When the CAN connection LED is on, CAN data line is
active and data is being transmitted.

5. If computer cannot connect to the CAN data line and the CAN connection LED does not come on, check
all cable connections to the machine and computer. Make sure the key switch is in the ON position and
the power LED is on.

Go to Section_9015:Group_20

AA95137,00007E3-19-20070222

786
 Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application

Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application

TX1002938A-UN: Service ADVISOR—Diagnostic Trouble Codes

LEGEND:
1 - Diagnostics Shortcut Bar
2 - Connected Diagnostic Trouble Codes Folder
3 - Readings Tab
4 - Connected Diagnostic Trouble Codes Tab

1. Connect service laptop to machine. See Service ADVISOR™ Connection Procedure . (Group 9015-20.)

2. Open Service ADVISOR and display appropriate model information.

3. From the Shortcut bar, click Diagnostics to open the Diagnostics shortcut bar (1).

4. Click the Connected Diagnostic Trouble Codes folder (2).

787
 Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application
5.

TX1002997A-UN: Connection Options Dialog Box

Select the Connect to Model(s) radio button on the Connection Options dialog box, and click OK.

6.

TX1003001A-UN: Select Readings Adapter Dialog Box

LEGEND:
5 - Available Adaptors Drop-Down List
6 - Selected Models List
7 - Change Selected Models Button

On the Select Readings Adapter dialog box, make sure the appropriate adapter is displayed. If not,
select correct adapter from drop-down list (5). Options include:
Electronic Data Link (EDL) Stand-alone USB Device
Electronic Data Link (EDL) Using Bluetooth
Parallel Data Module (PDM)
Parallel Data Module (PDM) With USB Adapter

7. Make sure correct machine to connect to displays in the Selected Models list (6). If not, click the Change
Selected Models button (7).

8. Click OK to connect to machine.

9. After Service ADVISOR connects to machine, both the Readings tab (3) and Connected Diagnostic
Trouble Codes tab (4) display.

788
 Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application
10. Double-click an underlined code on the Connected Diagnostic Trouble Codes tab to display a detailed
description for servicing that diagnostic trouble code.

11. NOTE:

Use the lock topic feature within Service ADVISOR to open multiple windows if machine
is transmitting more than one diagnostic trouble code. Refer to Service ADVISOR
system instructions for using this feature.

Click the Connected Diagnostic Trouble Codes tab (4) to select and view details for additional diagnostic
trouble codes.

Go to Section_9015:Group_20

LD30992,00002CC-19-20060206

789
 JDLink™ System Identification

JDLink™ System Identification

Use the following information to identify which JDLink™ system is equipped. One of the following systems may be
equipped:

GlobalTRACS® Terminal (GTT) and Machine Information Gateway (MIG) JDLink™ System
Modular Telematics Gateway (MTG) and Satellite (SAT) JDLink™ System

NOTE:

If JDLink™ system contains two control units, control units may be installed side by side or
stacked on top of each other.

Locate JDLink™ system. The following are typical system locations according to machine family. JDLink™
system may not be installed at suggested location due to specific machine options or configuration. If necessary,
refer to JDLink™ component location in Electrical—System Diagrams (Group 9015-10.)

-: JDLink™ System Locations

JDLink™ System Locations

Machine Family Location

Loader Backhoe Inside battery box.

Crawler Mounted to bottom of operator station floor or floor plate.

High Speed Dozer Inside load center (outer access door on right side of cab).

4WD Loader Inside load center (outer access door at right rear of cab).

Inside compartment on left side of machine, directly behind cab.

Excavator
Mounted to sheet metal near swing motor.

Articulated Dump Truck (ADT) Inside cab, behind front lower left panel (under load center).

Below main frame sheet metal panel (directly in front of cab).

Motor Grader
Behind rear panel in cab (panel behind seat)

Skidder Below right rear cab console.

Wheeled Feller Inside load center (outer access door on right side of cab).
Buncher/Harvester

Track Feller Below seat in cab.

Buncher/Harvester Mounted to inside of engine enclosure door.

Mounted to bottom of plate covering heating and air conditioning system behind
Knuckleboom Loader
seat in cab.

Forestry Swing Machines Left inner side of boom pivot pin/mounting frame.

GTT and MIG System

790
 JDLink™ System Identification

TX1143631A-UN: GTT (older)

TX1143632A-UN: MIG (if equipped)

TX1143633A-UN: GTT (newer) and MIG (stacked installation)

LEGEND:
1 - GTT (newer)
2 - MIG (if equipped)

GTT is main control unit. MIG control unit is optional.

Key distinguishing characteristics of GTT/MIG:

Single large 70-pin connector on face of control unit, along with antenna connectors.
GTT is black, MIG is silver.

MTG and SAT System

791
 JDLink™ System Identification
MTG is main control unit. SAT control unit is optional.

Key distinguishing characteristics of MTG/SAT:

TX1143680A-UN: MTG

TX1143681A-UN: SAT (if equipped)

Three smaller connectors on side of control unit. All connectors are located on sides of control unit.
Both control units are silver.
Both control units are very similar (SAT has less connectors on one side).

Go to Section_9015:Group_20

AA95137,00000DA-19-20131108

792
 JDLink™ Connection Procedure—If Equipped

JDLink™ Connection Procedure—If Equipped

TX1086498A-UN: Glove Box

TX1086499-UN: Laptop Connector

LEGEND:
1 - Glove Box

793
 JDLink™ Connection Procedure—If Equipped
2 - GTT Config Tool Adapter Connector

Connect to the GlobalTRACS® Terminal (GTT) Controller (S.N. —196449)

1. Locate GlobalTRACS® config tool adapter connector (2) in glove box (1).

2. NOTE:

CV90-J1006 PC Based JDLink™ Config Tool Serial Cable is included in the 65-J1115-
11 PC based JDLink™ Config Tool Kit.

Connect one end of CV90-J1006 PC Based JDLink™ Config Tool Serial Cable to the GTT config tool
adapter connector (2), and connect the other end to a COM port on the computer.

NOTE:

If the computer is not equipped with COM ports, a USB-to-serial adapter cable will be
required to simulate a COM port for use with the GTT Configuration Tool software.

For more information on connecting to the GTT, see Connect PC Laptop to GlobalTRACS® Terminal
(GTT) . (TM114519.)

JDLink™ Connection Procedure (S.N. 196450— )

Connect to JDLink™ via Service ADVISOR™ . See Service ADVISOR™ Connection Procedure . (Group 9015-
20.)

Go to Section_9015:Group_20

WS68074,00037F5-19-20151112

794
 CAN Monitor Unit (CMU) Menu Structure—Service Mode

CAN Monitor Unit (CMU) Menu Structure—Service Mode

NOTE:

The navigation buttons MENU, BACK, NEXT, and SELECT are located at the right side of the
CMU display.

There are two versions of the CAN monitor unit (CMU) main menu structure: Operator Mode and Service Mode.

Operator Mode is used to change user preferences, view operational settings, and view diagnostic trouble codes
(DTCs). To enter Operator Mode, turn key switch to the ON position, then push and immediately release the
MENU button.

Service Mode provides additional items not available in Operator Mode. This feature allows a service technician
to change operational settings and clear DTCs. It also allows the technician to monitor functions for diagnostic
and testing purposes.

To enter Service Mode, turn the key switch to the ON position, then push and hold the MENU button down for
approximately 5 seconds until a beep is heard and Service Mode temporarily appears on the Main Menu.

NOTE:

When Service Mode is accessed, the Main Menu will stay in Service Mode even if the CMU
display is returned to the home screen. As long as the key switch is kept in the ON position, the
MENU button only needs to be pushed once to re-enter Service Mode.

Cycling the key switch to OFF, then back to ON resets the CMU menu mode. Pushing and
releasing the MENU button after the key switch has been cycled, only allows access to the
Operator Mode menus.

To navigate through the menu structure, do the following:

Push the BACK button to go back one screen.

Push the NEXT button to scroll down the menu.
Push the SELECT button to select the highlighted item.

Selecting an item in the main menu will bring up the corresponding submenu. Selecting an item in the submenu
will bring up the next corresponding submenu, if applicable. Continue navigating through the submenus until the
appropriate submenu is obtained, then select the desired screen.

MAIN MENU— When in service mode, the main menu consists of the following submenus:

1. Codes
2. Machine Settings
3. Diagnostics
4. Monitor Settings
5. Calibration (TCU) (service mode only)
6. TCU Diagnostics (service mode only)

1. Codes: The codes menu consists of the following submenus:

1. Active Codes
2. Stored Codes
3. Clear Codes

795
 CAN Monitor Unit (CMU) Menu Structure—Service Mode
1. Active Codes: This menu displays the diagnostic trouble codes (DTCs) that are currently active
on the machine. A detailed description of the code, the source controller (controller reporting
the problem), and the SPN.FMI number.
1. Push NEXT to display the next code or BACK to go back to (1).
2. Push SELECT to view more information about the DTC. The next screen will show
information on what to check to fix the code.
2. Stored Codes: This menu displays the DTCs that are stored in memory. A detailed description
of the code, the source controller (controller reporting the problem), and the SPN.FMI number.
1. Push NEXT to display the next code or BACK to go back to (1).
2. Push SELECT to view more information about the DTC. The next screen will show the
number of occurrences, when the code first and last appeared, and the sensor
reading at that time.
3. Push SELECT to view information on what to check to fix the code.
3. Clear Codes: (service mode only) This menu will clear all stored DTCs on the machine. Push
SELECT to clear the codes or BACK to go back to (1).

2. Machine Settings: The machine settings menu consist of the following submenus:

1. Job Timer
2. Track Information
3. Controller Information
4. Transmission Settings
5. Hydraulic Settings (IGC only)
6. Reversing Fan
7. Auxiliary Cooler (service mode only)
8. Brake Control

1. Job Timer: This menu controls a continually running job timer. Push SELECT to reset the job
timer or push BACK to go back to (2).
2. Track Info: This menu displays track information calculated by the TCU.
Display All—All track information will be displayed.
Forward Distance—The distance the machine has traveled in forward direction is
displayed.
Reverse Distance—The distance the machine has traveled in reverse direction is
displayed.
Forward Hours—The hours the machine has spent traveling in forward direction is
displayed.
Reverse Distance—The hours the machine has spent traveling in reverse direction is
displayed.
3. Controller Info: This menu displays the machine ID, hardware part numbers, and software
version numbers for various devices on the machine.
CMU—Software number and the machine ID number will be displayed.
TCU—Software number and the TCU hardware part number will be displayed.
ECU—Software number and the ECU hardware part number will be displayed.
EHC—Software number and the EHC hardware part number will be displayed.

NOTE:

The electro-hydraulic controller (EHC) is available only on machines equipped

with the integrated grade control (IGC) system.

4. Trans Settings: This menu contains settings that affect transmission function and performance.
Aggressiveness—Transmission aggressiveness can be set to low, medium, or high.
Decelerator Response—Decelerator response can be set to low, medium, or high.
FNR Shift Rate—FNR shift rate can be set to low, medium, or high.

796
 CAN Monitor Unit (CMU) Menu Structure—Service Mode
Steer Rate—Steer rate can be set to low, medium, or high.
Steer Modulation—Steer modulation can be set to low, medium, or high.

NOTE:

Listed track speeds are approximate.

Forward Track Speed (service mode only) —Maximum forward track speed can be
set to low 8.0 km/h (5.0 mph); medium 9.7 km/h (6.0 mph); or high 11 km/h (6.8 mph).
Reverse Track Speed (service mode only) —Maximum reverse track speed can be
set to low 8.0 km/h (5.0 mph); medium 9.7 km/h (6.0 mph); or high 11 km/h (6.8
mph).Reverse track speed can be set to low, medium, or high.
Reverse Ratio—The reverse ratio can be set to 80%, 100%, 115%, or 130%.
Factory Settings (service mode only) —All settings can be returned to factory
settings.
5. Hydraulic Settings: (IGC only) The hydraulic settings for the optional IGC system can be
adjusted using this menu.
Lift—Lift speed can be set to low, medium, or high.
Power Down—Power down speed can be set to low, medium, or high.
Tilt Left—Tilt left speed can be set to low, medium, or high.
Tilt Right—Tilt right speed can be set to low, medium, or high.
Factory Settings (service mode only) —Restores IGC hydraulic settings to factory
settings.
6. Reversing Fan: The interval between reverse cycles for the hydraulic fan can be set in this
menu.
Off—Turns the reversing function off.
0.5 hours—Fan will reverse every half hour when machine is in neutral or reverse.
1.0 hours (default)—Fan will reverse every hour when machine is in neutral or
reverse.
1.5 hours—Fan will reverse every hour and a half when machine is in neutral or
reverse.
7. Auxiliary Cooler: (service mode only) The auxiliary oil cooler option is set here.
Off—Proportional fan speed will not compensate for hydraulic oil temperature.
On—Proportional fan speed will be calculated with hydraulic oil temperature as a
variable.
8. Brake Control: This function controls the park brake solenoids.
Normal—This setting is used for normal operation.
Tow—The park brake will be forced off to allow the machine to be towed. This setting
will reset to normal when the key switch is cycled.
Test (service mode only) —The park brake will be forced on with the park brake lever
in the run position to allow for the transmission to drive against the brakes. This
setting will reset to normal when the key switch is cycled.

3. Diagnostics: The diagnostics menu consists of the following submenus:

1. Live Values
2. Calibrated Values

1. Live Values: This menu displays the live values that the controllers detect.
Temperatures—Displays values for engine, transmission, and hydraulic
temperatures.

-: Live Values—Temperatures

Engine Temp Other Temp

797
 CAN Monitor Unit (CMU) Menu Structure—Service Mode

1-Display All 1-Display All

2-Coolant Temperature 2-Transmission Temperature

3-Fuel Temperature 3-Hydraulic Temperature

4-Manifold Air Temperature

5-Ambient Air Temperature

6-Comp Inlet Temperature

7-EGR Temperature

8-Charge Air Temperature

Pressures—Displays values for transmission and engine pressures.

-: Live Values—Pressures

Trans Press Engine Press

1-Display All 1-Display All

2-Trans Charge Pressure 2-Engine Oil Pressure

3-Left Track System Pres 3-Engine Rail Pressure

4-Right Track System Pres 4-Fuel Pressure

5-Brake Pressure 5-Boost Pressure

Speeds—Displays values for engine, left motor, right motor, crankshaft, and camshaft
speed.

-: Live Values—Speeds

1-Display All 4-Right Motor Speed

2-Engine Speed 5-Crankshaft Speed

3-Left Motor Speed 6-Camshaft Speed

Input Voltages (service mode only) —Displays voltages for all input sensors as well
as system voltages.

-: Live Values—Input Voltages

1-Speed Button 18-Ambient Air

2-Steer 19-Fuel Temp

3-FNR 20-Brake Pressure

4-Decel 21-Blade Angle Button

5-Trans Temp 22-Diag Sensor 1

6-Trans Charge 23-Diag Sensor 2

7-Left Track Pressure 24-Diag Sensor 3

8-Right Track Pressure 25-Diag Sensor 4

9-Hydraulic Temperature 26-Comp Inlet

10-Fuel Level 27-Exhaust Temp

11-Battery 28-CAC Temp

798
 CAN Monitor Unit (CMU) Menu Structure—Service Mode

12-Engine Throttle 29-Rail Pressure

13-ECU Switched 30-Fuel Pressure

14-ECU Unswitched 31-Boost Pressure

15-Oil Pressure 32-Blade Incr/Decr

16-Coolant Temp 33-Aux Joystick Sensor 1

17-Manifold Temp 34-Aux Joystick Sensor 2

Output Info (service mode only) —Displays output currents for solenoids and PCPs,
output states for solenoids and alarms, and resistance of PCPs and solenoids.

-: Live Values—Output Information

1-Left Pump PCP 10-Display Buzzer

2-Right Pump PCP 11-Fan Reverse Solenoid

3-Left Motor 12-Left Pump PCP

4-Right Motor 13-Right Pump PCP

5-Oil Cooler Bypass 14-Backup Alarm

6-Fan Drive 15-Left Motor Solenoid

7-Blade Left 16-Right Motor Solenoid

8-Blade Right 17-Fan Drive Solenoid

9-Brake Solenoid
Switch Status (service mode only) —Displays switch status as interpreted by the
controllers.

-: Live Values—Switch Status

1-Neutral 9-Decouple

2-Park Lock—Lock 10-Water in Fuel

3-Park Lock—Run 11-Fan Reverse

4-Trans Charge Oil Filter 12-Derate Override

5-Fan Oil Filter 13-Hydraulic Enable Switch

6-Engine Air Filter 14-Hydraulic Disable Switch

7-Hydraulic Oil Filter 15-Screen Swap

8-Winch Oil Pressure 16-IGC Switch

Performance (service mode only) —Displays engine, transmission, and IGC (if
equipped) performance variables.

-: Live Values—Performance

1-Trans Speed Set 11-Percent EGR

2-Antistall Percent 12-ACU Connected

3-Tracker Error 13-Lift Spool Command

4-Reverse Ratio 14-Tilt Spool Command

5-Throttle Percent 15-Angle Command CW

799
 CAN Monitor Unit (CMU) Menu Structure—Service Mode

6-Load at RPM 16-Angle Command CCW

7-Fuel Rate 17-Joystick Lift Position

8-Engine Hours 18-Joystick Power Down Pos

9-Fuel Derate 19-Joystick Tilt Left Position

10-Torque ID 20-Joystick Tilt Right Position

2. Calibrated Values: (service mode only) This menu displays the input and output values
recorded during calibration.
Inputs—Displays sensor input voltages recorded during calibration.

-: Live Values—Calibrated Input Values

1-Right Steer 11-Decel Down

2-Left Steer 12-Throttle Low

3-Right Counter 13-Throttle High

4-Left Counter 14-Speed Button UP

5-FNR Forward 15-Speed Button Neutral

6-FNR Forward Switch 16-Speed Button Down

7-FNR Reverse Switch 17-Blade Angle Right

8-FNR Reverse 18-Blade Angle Neutral

9-Decel Up 19-Blade Angle Left

10-Decel Brake Point

Outputs—Displays output current values recorded during calibration.

-: Live Values—Calibrated Output Values

1-Left Forward Threshold 7-Left Reverse Max Pump

2-Right Forward Threshold 8-Right Reverse Max Pump

3-Left Reverse Threshold 9-Left Threshold Motor

4-Right Reverse Threshold 10-Right Threshold Motor

5-Left Forward Max Pump 11-Left Max Motor

6-Right Forward Max Pump 12-Right Max Motor

4. Monitor Settings: The monitor settings menu consist of the following submenus:

1. Units
2. Backlighting
3. LCD Contrast
4. Monitor Configure
5. Language (service mode only)
6. Hide Main Menu (service mode only)

1. Units: This menu sets the units for all functions of the CMU. Push SELECT to select the
desired mode.
English—All units will be English standard units.
Metric—All units will be metric units.
2. Backlighting: This menu sets the amount of backlighting for the CMU. The backlighting has ten
800
 CAN Monitor Unit (CMU) Menu Structure—Service Mode
levels of light intensity. Level 1 provides the lowest amount of light (no light) and level 10
provides the highest amount light.
1. Push BACK to decrement the value or push NEXT to increment the value.
2. Push SELECT to store the current value. Once SELECT is pushed, the CMU will
confirm that the value is stored.
3. Push MENU to return to the main menu.
3. LCD Contrast: This menu sets the amount of contrast for the CMU LCD. The contrast has ten
level settings. Level 1 provides the lightest setting (least contrast) and level 10 provides the
darkest setting (most contrast).
1. Push BACK to decrement the value or push NEXT to increment the value.
2. Push SELECT to store the current value. Once SELECT is pushed, the CMU will
confirm that the value is stored.
3. Push MENU to return to the main menu.
4. Monitor Config: This menu displays the type and performance level of the machine. These
items are populated by the engine control unit (ECU) installed on the machine.
5. Language: (service mode only) This menu sets the language for all functions of the CMU. Push
SELECT to select the desired language.
English—The menu language will be set to English.
Spanish—The menu language will be set to Spanish.
French—The menu language will be set to French.
6. Hide Main Menu: (service mode only) This menu sets the display mode for the main menu.
Push SELECT to select the desired mode.
Hide Main Menu—The main menu will not be available. The service menu will have to
be entered to access any menus.
Show Main Menu—The main menu will be available when the MENU button is
pushed.

5. Calibration (TCU): (service mode only) The TCU calibration performs the transmission calibration
procedure. Push SELECT to start the procedure. The CMU transmits the request across the CAN data
link to the TCU. The TCU will then initiate the procedure. For more information on this procedure, see
Transmission Control Unit (TCU) Calibration . (Group 9020-20.)

6. TCU Diagnostics: (service mode only) The TCU diagnostics menu consists of the following submenus:

1. Settings
2. Procedures

1. Settings: (service mode only)

Tracker Control—This function maintains straight tracking by slowing down the faster
track so both tracks travel at the same speed.

Off—The tracker function will be disabled for troubleshooting. This setting will reset to
normal when the key switch is cycled.

Antistall Control—This function maintains target engine speed by reducing the

transmission demand when there is a high load on the engine to prevent stalling.

Off—The antistall function will be disabled for troubleshooting. This setting will reset
to normal when the key switch is cycled.

Motor Solenoids—This function forces the motor shift solenoids to turn on or off.

On—The right and left motor shift solenoids are turned on for troubleshooting. This
setting will reset to normal when the key switch is cycled.

Off—The right and left motor shift solenoids are turned off for troubleshooting. This

801
 CAN Monitor Unit (CMU) Menu Structure—Service Mode
setting will reset to normal when the key switch is cycled.

Tank Bypass Control—This function controls the hydrostatic oil reservoir bypass
solenoid.

Off—The hydrostatic oil reservoir bypass solenoid is de-energized for

troubleshooting. This setting will reset to normal when the key switch is cycled.

On—The hydrostatic oil reservoir bypass solenoid is energized for troubleshooting.

This setting will reset to normal when the key switch is cycled.

Cool Bypass Control—This function controls the hydrostatic oil cooler bypass
solenoid.

Off—The hydrostatic oil cooler bypass solenoid is de-energized for troubleshooting.

This setting will reset to normal when the key switch is cycled.

On—The hydrostatic oil cooler bypass solenoid is energized for troubleshooting. This
setting will reset to normal when the key switch is cycled.

Fan Valve—This function controls the hydraulic fan proportional relief solenoid.

Maximum—For troubleshooting, the hydraulic fan proportional relief solenoid is

supplied minimum current for maximum fan speed. This setting will reset to normal
when the key switch is cycled.

70%—For troubleshooting, the hydraulic fan proportional relief solenoid is supplied

medium current for 70% fan speed. This setting will reset to normal when the key
switch is cycled.

Minimum—For troubleshooting, the hydraulic fan proportional relief solenoid is

supplied maximum current for minimum fan speed. This setting will reset to normal
when the key switch is cycled.

Fan Reversing (if equipped)—This function controls the hydraulic fan reversing
solenoid.

On—The hydraulic fan is forced in the reverse direction for troubleshooting. This
setting will reset to normal when the key switch is cycled.

Off—The hydraulic fan reverse function is forced off for troubleshooting. This setting
will reset to normal when the key switch is cycled.

2. Procedures: (service mode only) After pushing SELECT, procedures available for the machine
will be listed.
Efficiency and Relief Valve Test—This function displays information required to
perform diagnostic tests. System pressure and pump PCP current supply for the right
and left sides are shown in their respective columns. Charge pressure and pump case
pressure are also shown.

Go to Section_9015:Group_20

AA95137,00007C3-19-20110531

802
 Integrated Grade Control (IGC) Checks—If Equipped
Most problems with the IGC electrical control system will cause a diagnostic trouble code (DTC) to appear on the
CMU or grade control supplier's monitor. Fixing the problem causing the DTC will usually resolve the overall
problem.

Use the following series of checks, in conjunction with the IGC observable symptom diagnostics, to help
determine what part of the IGC system is responsible for the malfunction.

For IGC observable symptoms diagnostics, see Integrated Grade Control (IGC) Diagnose Malfunctions—If
Equipped . (Group 9015-20.)

IGC System Checks

Launch Close Expand List Collapse List

1 Code Check—Machine CAN Monitor Unit (CMU)

Action:

Turn key switch to ON position and check for any active diagnostic trouble codes.

LOOK: Do any active codes appear on the CAN monitor unit (CMU)?

Record of Actual Results:

Result:
YES:
Repair problem causing the code. Clear all active codes and repeat code check until all codes are clear.

For list of all codes, see Diagnostic Trouble Codes (DTC) Quick Reference List . (Group 9015-20.)

To access menu for clearing codes, see CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group
9015-20.)

NO:
Go to Code Check—Grade Control Supplier's Monitor .

2 Code Check—Grade Control Supplier's Monitor

Action:

LOOK: Do any active codes appear on the grade control supplier's monitor?

Record of Actual Results:

Result:
YES:
Refer to documentation of the grade control supplier. If code cannot be cleared, contact the supplier of the
grade control equipment or contact John Deere DTAC.
NO:
Go to Auto Blade Light Check .

3 Auto Blade Light Check

803
 Integrated Grade Control (IGC) Checks—If Equipped

Action:

NOTE:

Before the electrohydraulic controller (EHC) will allow the auto blade light to come on, it first
must detect the appropriate signals from each of the following components:

IGC on/off switch

Pilot control enable switch (ENABLED position)
Blade control joystick (BCJ) (neutral position)
CAN monitor unit (CMU)
Transmission control unit (TCU)
Grade control supplier's controller

Start engine.

Move park lock lever to UNLOCKED (down) position.

Put the pilot control enable switch in the ENABLED position.

Push the IGC on/off switch button to enable blade auto mode.

LOOK: Does the auto blade light come on?

Push the IGC on/off switch button again to disable blade auto mode.

LOOK: Does the auto blade light go off?

Record of Actual Results:

Result:
YES:
If auto blade light is on but blade does not obey commands from the grade control supplier's equipment, see
observable symptom “ All Blade Functions Operate Normally In Manual Mode, But Not In Auto Mode ” in the
Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped procedure. (Group 9015-20.)
NO:
Go to IGC ON/OFF Switch Check .

4 IGC ON/OFF Switch Check

Action:

NOTE:

The switches in the blade control joystick (BCJ) handle can be verified for proper operation
in the CMU menus.

Observe the status of the IGC on/off switch by accessing the Diagnostic / Live Values / Switch State menu to
the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Push and release the IGC on/off switch button several times while observing the switch status in the CMU
menus.

804
 Integrated Grade Control (IGC) Checks—If Equipped
LOOK: Does the status of the IGC on/off switch change when the IGC on/off switch is pushed and released?

Record of Actual Results:

Result:
YES:
Go to Hydraulic Enable Switch Check .
NO:
see Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped . (Group 9015-20.)

5 Hydraulic Enable Switch Check

Action:

Observe the status of the hydraulic enable switch by accessing the Diagnostic / Live Values / Switch State
menu to the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group
9015-20.)

Cycle the hydraulic enable switch several times while observing the switch states.

LOOK: Does the status of switch conditions change when switch is cycled and are they always opposite?

Record of Actual Results:

Result:
YES:
Go to Manual Blade Operation Check .
NO:
See observable symptom “ All Blade Functions Do Not Operate in Manual or Auto Modes ” in the Integrated
Grade Control (IGC) Diagnose Malfunctions—If Equipped procedure. (Group 9015-20.)

6 Manual Blade Operation Check

Action:

NOTE:

The IGC system is in manual mode when the auto blade light on the CMU is off.

Put blade control in manual mode by pushing the IGC on/off switch button.

Operate all blade functions in manual mode.

LOOK: Do the blade controls function properly when in manual mode?

Record of Actual Results:

Result:

805
 Integrated Grade Control (IGC) Checks—If Equipped

YES:
If IGC does not function in auto mode, see observable symptom “ All Blade Functions Operate Normally In
Manual Mode, But Not In Auto Mode ” in the Integrated Grade Control (IGC) Diagnose Malfunctions—If
Equipped procedure. (Group 9015-20.)
NO:
Go to Blade Control Joystick (BCJ) Check—Blade Lift and Tilt .

7 Blade Control Joystick (BCJ) Check—Blade Lift and Tilt

Action:

NOTE:

The four-way axis operation of the blade control joystick can be verified for proper operation
in the CMU menus.

Observe the joystick's 4-way axis movement as a percentage by accessing the Diagnostic / Live Values /
Performance menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service
Mode . (Group 9015-20.)

Slowly move the joystick handle through complete range in all four axes.

LOOK: Do the joystick values in the CMU menu correspond with the joystick movements?

LOOK: From neutral (center) position, does full movement range from 0 to 100 percent at each axis?

LOOK: Does the joystick handle return fully to neutral when released?

NOTE:

The joystick should be replaced if any of the following occurs:

Percentage is inconsistent to corresponding joystick handle movement. (Joystick

can not be calibrated.)
Less than desired percentage of movement is indicated when joystick handle is
moved fully to any one of the four axes. (Joystick can not be calibrated.)
Percentage does NOT go to zero when joystick returns to neutral position.
(Joystick can not be calibrated.)
Joystick movement is loose or sloppy.
Joystick handle does not return fully to neutral position when released.

Record of Actual Results:

Result:
YES:
Go to Blade Angle Switch Check .
NO:
See observable symptom “ All Blade Functions Do Not Operate in Manual or Auto Modes ” and/or “ Blade Lift
and Tilt Operate Normally in Auto Mode, But Not in Manual Mode ” in the Integrated Grade Control (IGC)
Diagnose Malfunctions—If Equipped procedure. (Group 9015-20.)

806
 Integrated Grade Control (IGC) Checks—If Equipped

8 Blade Angle Switch Check

Action:

NOTE:

The blade control joystick switches can be verified for proper operation in the CMU menus.

Observe the voltage input from the blade angle switch by accessing the Diagnostic / Live Values / Input
Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode .
(Group 9015-20.)

Observe blade angle switch voltage reading in the CMU menu with no blade angle buttons pushed.

LOOK: Is the voltage approximately 2.20 volts?

Push and hold the upper button of the blade angle switch while observing the voltage reading in the CMU
menu.

LOOK: Is the voltage approximately 3.00 volts?

Push and hold the lower button of the blade angle switch while observing the voltage reading in the CMU
menu.

LOOK: Is the voltage approximately 0.90 volts?

Record of Actual Results:

Result:
YES:
Check actuator circuit. See observable symptom “ Blade Lift and Tilt Operate Normally, But Blade Angle
Does Not ” in the Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped procedure. (Group
9015-20.)
NO:
See observable symptom “ Blade Lift and Tilt Operate Normally, But Blade Angle Does Not ” in the Integrated
Grade Control (IGC) Diagnose Malfunctions—If Equipped procedure. (Group 9015-20.)

9 Blade Increment/Decrement Switch Check

Action:

NOTE:

The blade control joystick switches can be verified for proper operation in the CMU menus.

Observe the voltage input from the blade increment/decrement switch by accessing the Diagnostic / Live
Values / Input Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—
Service Mode . (Group 9015-20.)

Observe increment/decrement switch voltage reading in the CMU menu with no increment/decrement
buttons pushed.

807
 Integrated Grade Control (IGC) Checks—If Equipped
LOOK: Is the voltage approximately 2.20 volts?

Push and hold the increment (upper) button while observing the voltage reading in the CMU menu.

LOOK: Is the voltage approximately 3.00 volts?

Push and hold the decrement (lower) button while observing the voltage reading in the CMU menu.

LOOK: Is the voltage approximately 0.90 volts?

Record of Actual Results:

Result:
YES:
If both blade lift and blade incr/decr functions do not operate, check blade lift actuator circuit.

If blade lift and angle functions operate normally, but the blade incr/decr function does not, reprogram the
controller.

If reprogramming the controller does not resolve the problem, replace controller.

NO:
Check blade increment/decrement switch circuit. See observable symptom “ Blade Lift and Angle Operate
Normally, But Blade Incr/Decr Does Not ” in the Integrated Grade Control (IGC) Diagnose Malfunctions—If
Equipped procedure. (Group 9015-20.)

Go to Section_9015:Group_20

OUO1010,00009D3-19-20070718

808
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped
Most problems with the IGC electrical control system will cause a diagnostic trouble code (DTC) to appear on the
CMU or grade control supplier's monitor. Fixing the problem causing the DTC will usually resolve the overall
problem.

Use the following diagnostics in conjunction with the IGC checks and general hydraulic symptom diagnostics to
help determine the cause of the malfunction.

For IGC operational checks, see Integrated Grade Control (IGC) Checks—If Equipped . (Group 9015-20.)

For diagnosing general hydraulic symptoms, see Hydraulic System Diagnose Malfunctions—IGC . (Group 9025-
15.)

All Blade Functions Do Not Operate in Manual or Auto Modes

Launch Close Expand List Collapse List

1 Fuse Check

Action:

Check fuses F16 and F103

NOTE:

If no system power is available (all systems are off line), make sure battery disconnect
switch is in the ON position and main 125-amp fuse F33 is good.

Are fuses okay?

Record of Actual Results:

Result:
YES:
Go to Relay K102 Check .
NO:
Replace fuse(s). See Fuse and Relay Specifications . (Group 9015-10.)

2 Relay K102 Check

Action:

Swap relays K101 and K102. See Fuse and Relay Specifications . (Group 9015-10.)

Do blade functions now operate in manual mode?

Record of Actual Results:

Result:
YES:
Replace malfunctioning relay.

809
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped

NO:
Go to Hydraulic Enable Switch Circuit Check .

3 Hydraulic Enable Switch Circuit Check

Action:

NOTE:

For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness
(W22) Wiring Diagram—If Equipped . (Group 9015-10.)

Turn key switch ON.

Check for voltage at pin 2 (wire H22 GRN) of hydraulic enable switch (S8).

Are approximately 5 volts present?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Go to EHC 5-Volt Circuit Check
Action:

Key switch ON.

Put hydraulic enable switch in the DISABLED position.

NOTE:

The hydraulic enable switch (S8) must be connected for this check.

Check for voltage at pin 1 (wire H36 GRN) of hydraulic enable switch (S8).

Are approximately 5 volts present?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check switch. Go to Hydraulic Enable Switch Check .
Action:

810
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped

Key switch ON.

Put hydraulic enable switch in the ENABLED position.

NOTE:

The hydraulic enable switch (S8) must be connected for this check.

Check for voltage at pin 3 (wire H23 GRN) of hydraulic enable switch (S8).

Are approximately 5 volts present?

Record of Actual Results:

Result:
YES:
Check wire H23 GRN for open or short circuit between pin 3 of hydraulic enable switch and pin 18 of EHC
connector X82.

Check wire H36 GRN for open or short circuit between pin 1 of hydraulic enable switch and pin 17 of EHC
connector X82.

IF OK:
If circuits H23 and H36 are good, check wiring between the electrohydraulic controller and all actuators (Y30
—Y32).

If actuator wiring is okay, check hydraulic system. See Hydraulic System Diagnose Malfunctions—IGC .
(Group 9025-15.)

NO:
Check switch. Go to Hydraulic Enable Switch Check .

4 EHC 5-Volt Circuit Check

Action:

NOTE:

For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped . (Group 9015-10.)

Disconnect harness connector X82 from electrohydraulic controller (EHC) (A11).

Turn key switch ON.

NOTE:

EHC connector X83 must be connected when performing this check.

Check for voltage at pin 3 (controller side) of EHC connector X82.

811
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped
Are approximately 5 volts present?

Record of Actual Results:

Result:
YES:
Check wire H22 BRN for open or short circuit between pin 3 of EHC connector X82 and pin 2 of hydraulic
enable switch (S8).
NO:
Go to EHC Supply Voltage Circuit Check .

5 EHC Supply Voltage Circuit Check

Action:

NOTE:

For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped . (Group 9015-10.)

Disconnect harness connector X83 from electrohydraulic controller (EHC) (A11).

Turn key switch ON.

Check for voltage at pins 1 and 18 (wire P58 RED) (harness side) of EHC connector X83.

Is system voltage (approximately 24 volts) present at the designated pins?

Record of Actual Results:

Result:
YES:
Go to EHC Ground Check .
NO:
Go to next step in this check.
Action:

Remove relay (K102) and check for voltage at pins 30 and 85 of the relay socket.

Is system voltage (approximately 24 volts) present at the designated pins?

Record of Actual Results:

Result:
YES:
Go to next step in this check.

812
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped

NO:
If no voltage is present at pin 30, check wire P50 RED for open or short circuit between main fuse (F33) and
pin 30 of relay (K102). Repair as necessary.
NO:
If no voltage is present at pin 85, check wire P14 RED for open or short circuit between fuse (F16) and pin
85 of relay (K102). Repair as necessary.
Action:

Relay (K102) removed.

Check for ground at pin 86 of the relay (K102) socket.

Is ground present?

Record of Actual Results:

Result:
YES:
Check wire P51 RED for open or short circuit between fuse (F103) and pin 87 of relay (K102) socket. Repair
as necessary.
NO:
Check continuity of wire G05 BLK between pin 86 of relay socket and W3 frame ground (located under cab).
Repair as necessary.

6 EHC Ground Check

Action:

NOTE:

For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped . (Group 9015-10.)

Key switch OFF.

Harness connector X83 disconnected from electrohydraulic controller (A11).

Check for ground at pins 6 and 23 (wire G20 BLK) (harness side) of EHC connector X83.

Is ground present at the designated pins?

Record of Actual Results:

Result:
YES:
Reprogram electrohydraulic controller. If problem persists, replace controller.
NO:
If no ground is present at pin 6, check wire G20 BLK for open circuit between pin 6 of EHC connector X83

813
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped
and IGC ground connector X87 [located at battery disconnect switch (S2)]. Repair as necessary.
NO:
If no ground is present at pin 23, check wire G20 BLK for open circuit between pin 23 of EHC connector X83
and IGC ground connector X87 [located at battery disconnect switch (S2)]. Repair as necessary.

7 Hydraulic Enable Switch Check

Action:

Disconnect hydraulic enable switch (S8).

Check hydraulic enable switch terminals for continuity. Refer to continuity table.

-: Continuity Legend

Hydraulic Enable Switch (S8) Continuity Table

Switch Position Terminals Continuity

Hydraulics Disabled 1 and 2 Yes

Hydraulics Disabled 2 and 3 No

Hydraulics Enabled 1 and 2 No

Hydraulics Enabled 2 and 3 Yes

Is continuity between switch terminals as indicated in the continuity table?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Replace switch.

All Blade Functions Operate Normally in Manual Mode, But Not in Auto Mode

NOTE:

This symptom may result from poor reception from satellite or from other guidance equipment.
Consult documentation of supplier's grade control equipment. If problem cannot be resolved,
contact the grade control equipment supplier or John Deere DTAC.

Launch Close Expand List Collapse List

1 Fuse Check

Action:

Check fuses (F101, F104, F105, or F106).

Are fuses okay?

814
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped

Record of Actual Results:

Result:
YES:
Go to Relay K101 Check .
NO:
Replace fuse(s). See Fuse and Relay Specifications . (Group 9015-10.)

2 Relay K101 Check

Action:

Swap relays K101 and K102. See Fuse and Relay Specifications . (Group 9015-10.)

Do blade functions no longer operate in manual mode?

Record of Actual Results:

Result:
YES:
Replace malfunctioning relay.
NO:
Go to IGC Interface Connector (X96) Supply Voltage Circuit Check .

3 IGC Interface Connector (X96) Supply Voltage Circuit Check

Action:

NOTE:

For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped . (Group 9015-10.)

Disconnect IGC interface connector X96.

Key switch OFF.

Check for unswitched voltage at pins T, V, and X (machine side) of IGC interface connector (X96).

Is system voltage (approximately 24 volts) present at the designated pins?

Record of Actual Results:

Result:
YES:
Go next step in this check.
NO:

815
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped
If no voltage exists at pin T, check wire P57 RED for open or short circuit between connector X96 and fuse
(F104). Repair as necessary.

If no voltage exists at pin V, check wire P56 RED for open or short circuit between connector X96 and fuse
(F105). Repair as necessary.

If no voltage exists at pin X, check wire P55 RED for open or short circuit between connector X96 and fuse
(F106). Repair as necessary.

If no voltage is present at all three pins, check wire P50 RED for open or short circuit between main fuse
(F33) and fuses (F104, F105, and F106). Repair as necessary.

Action:

Connector X96 disconnected.

Turn key switch ON.

Check for voltage at pin R (machine side) of IGC interface connector (X96).

Is system voltage (approximately 24 volts) present?

Record of Actual Results:

Result:
YES:
Go to IGC Interface Connector (X96) Ground Circuit Check .
NO:
Go next step in this check.
Action:

Remove fuse (K101) and check for voltage at pin A1 of fuse socket.

Is system voltage (approximately 24 volts) present?

Record of Actual Results:

Result:
YES:
Check wire P60 RED for open or short circuit between pin R of connector X96 and pin AA1 of fuse (F101).
Repair as necessary.
NO:
Go to next step in this check.
Action:

Remove relay (K101) and check for voltage at pins 30 and 85 of the relay socket.

Is system voltage (approximately 24 volts) present at the designated pins?

Record of Actual Results:

816
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped

Result:
YES:
Go to next step in this check.
NO:
If no voltage is present at pin 30, check wire P50 RED for open or short circuit between main fuse (F33) and
pin 30 of relay (K101). Repair as necessary.
NO:
If no voltage is present at pin 85, check wire P14 RED for open or short circuit between fuse (F16) and pin
85 of relay (K101). Repair as necessary.
Action:

Check for ground at pin 86 (wire G05 BLK) of relay (K101) socket.

Is ground present at pin 86?

Record of Actual Results:

Result:
YES:
Check wire P54 RED for open or short circuit between pin A1 of fuse (F101) and pin 87 of relay (K101)
socket. Repair as necessary.
NO:
Check wire G05 BLK for open circuit between relay (K101) and W3 frame ground (located under cab).
Repair as necessary.

4 IGC Interface Connector (X96) Ground Circuit Check

Action:

NOTE:

For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped . (Group 9015-10.)

Key switch OFF.

Connector X96 disconnected.

Check for ground at pins P, S, U, and W (machine side) of IGC interface connector X96.

Is ground present?

Record of Actual Results:

Result:
YES:
Test CAN circuit. Go to CAN Circuit Test . (Group 9015-20.)
817
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped
If problem cannot be resolved, contact the grade control equipment supplier or John Deere DTAC.

NO:
Check wire G20 BLK for open circuit between pins P, S, U, and W of connector X96 and IGC ground
connector X87 [located at the battery disconnect switch (S2)]. Repair as necessary.

All Blade Functions Operate Normally in Auto Mode, But Not in Manual Mode
Launch Close Expand List Collapse List

1 IGC ON/OFF Switch Check

Action:

Turn key switch ON.

Observe the status of the IGC on/off switch by accessing the Diagnostic / Live Values / Switch State menu in
the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Push and release the IGC on/off switch button several times while observing the switch status in the CMU
menu.

Does the status of the IGC on/off switch change when the switch is pushed and released?

Record of Actual Results:

Result:
YES:
Go to Joystick 5-Volt Supply Circuit Check .
NO:
Go to IGC ON/OFF Switch Circuit Check .

2 IGC ON/OFF Switch Circuit Check

Action:

NOTE:

For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness
(W22) Wiring Diagram—If Equipped . (Group 9015-10.)

Check for voltage at pin 21 (wire H33 GRN) of EHC connector X83. Both EHC connectors X82 and X83
must be connected to the electrohydraulic controller (EHC) when performing this check.

Push then release the IGC on/off switch button while observing the voltage reading.

Is the voltage approximately 0.5 volts when switch is pushed and approximately 21.5 volts when switch is
released?

Record of Actual Results:

818
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped

Result:
YES:
Reprogram electrohydraulic controller. If problem persists, replace controller.
NO:
Go to next step in this check.
Action:

Key switch OFF.

Disconnect blade control joystick (BCJ) connector X97 and electrohydraulic controller (EHC) connector X83.

Check wire H33 BLK for open or short circuit between pin 4 of connector X97 and pin 4 of connector X95.

Check wire H33 GRN for open or short circuit between pin 4 of connector X95 and pin 21 of connector X83.

Is an open or short circuit indicated?

Record of Actual Results:

Result:
YES:
Repair as necessary.
NO:
Go to Joystick 5-Volt Supply Circuit Check .

3 Joystick 5-Volt Supply Circuit Check

Action:

NOTE:

For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness
(W22) Wiring Diagram—If Equipped . (Group 9015-10.)

Disconnect electrohydraulic controller (EHC) connector X82. Connector X83 must be connected for this
check.

Turn key switch ON.

At controller side of EHC connector X82, check for voltage across pin 3 (+) and pin 22 (-).

Are approximately 5 volts present?

Record of Actual Results:

Result:

819
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped

YES:
Go to next step in this check.
NO:
Replace electrohydraulic controller.
Action:

Electrohydraulic controller (EHC) connector X82 and blade control joystick (BCJ) connector X97
disconnected.

Key switch OFF.

Check wire H22 BRN for open or short circuit between pin 1 of BCJ connector X97 and pin 3 of EHC
connector X82.

Is an open or short circuit indicated?

Record of Actual Results:

Result:
YES:
Repair wire H22 BRN as necessary.
NO:
Go to Joystick Switch Module Ground Circuit Check .

4 Joystick Switch Module Ground Circuit Check

Action:

NOTE:

For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness
(W22) Wiring Diagram—If Equipped . (Group 9015-10.)

Key switch OFF.

Electrohydraulic controller (EHC) connector X82 and blade control joystick (BCJ) connector X97
disconnected.

Check continuity of wire R41 PNK between pin 6 of BCJ connector X97 and pin 22 of EHC connector X82.

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Replace joystick.
NO:

820
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped
Check circuit R41 for open circuit. Repair as necessary.

Blade Lift and Tilt Operate Normally in Auto Mode, But Not in Manual Mode
Launch Close Expand List Collapse List

1 Joystick 4-Way Axis Check

Action:

Turn key switch ON.

Observe the joystick's 4-way axis movement as a percentage by accessing the Diagnostic / Live Values /
Performance menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service
Mode . (Group 9015-20.)

Slowly move the joystick handle through complete range in all four axes.

Do the joystick values in the CMU menu correspond with the joystick movements?

Record of Actual Results:

Result:
YES:
Reprogram electrohydraulic controller. If problem persists, replace controller.
NO:
Go to Fuse F102 Check .

2 Fuse F102 Check

Action:

Check fuse F102

Is fuse okay?

Record of Actual Results:

Result:
YES:
Go to Relay K102 Check .
NO:
Replace fuse. See Fuse and Relay Specifications . (Group 9015-10.)

3 Relay K102 Check

Action:

Swap relays K101 and K102. See Fuse and Relay Specifications . (Group 9015-10.)

Do blade functions now operate in manual mode?

821
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped

Record of Actual Results:

Result:
YES:
Replace malfunctioning relay.
NO:
Go to Joystick 4-Way Axis Supply Voltage Check .

4 Joystick 4-Way Axis Supply Voltage Check

Action:

NOTE:

For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness
(W22) Wiring Diagram—If Equipped . (Group 9015-10.)

Disconnect blade control joystick (BCJ) connector X98.

Turn key switch ON.

Check for voltage at pin 1 (wire P59 RED) (harness side) of BCJ connector X98.

Is system voltage (approximately 24 volts) present?

Record of Actual Results:

Result:
YES:
Go to Joystick 4-Way Axis Ground Check .
NO:
Go to next step in this check.
Action:

Remove fuse (F102) and check for voltage at pin A2 of fuse socket.

Is system voltage (approximately 24 volts) present?

Record of Actual Results:

Result:
YES:
Check wire P59 RED for open or short circuit between fuse (F102) and BCJ connector X98.
NO:
Check wire P51 RED for open or short circuit between fuse (F102) and pin 87 of relay (K102) socket.

822
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped

5 Joystick 4-Way Axis Ground Circuit Check

Action:

NOTE:

For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness
(W22) Wiring Diagram—If Equipped . (Group 9015-10.)

Blade control joystick (BCJ) connector X98 disconnected.

Key switch OFF.

Check for ground at pin 2 (wire G20 BLK) of BCJ connector X98.

Is ground present?

Record of Actual Results:

Result:
YES:
Test CAN circuit. Go to CAN Circuit Test . (Group 9015-20.)
IF OK:
If CAN circuit is okay, replace joystick.
NO:
Check wire G20 for open circuit between joystick connector X98 and connector X87 [located at battery
disconnect switch (S2)]. Repair as necessary.

Blade Lift and Tilt Operate Normally, But Blade Angle Does Not
Launch Close Expand List Collapse List

1 Blade Angle Switch Check

Action:

Turn key switch ON.

Observe the voltage input for the blade angle switch by accessing the Diagnostic / Live Values / Input
Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode .
(Group 9015-20.)

Observe blade angle switch voltage reading in the CMU menu with no blade angle buttons pushed.

Is the voltage approximately 2.20 volts?

Push and hold the upper button of the blade angle switch while observing the voltage reading in the CMU
menu.

Is the voltage approximately 3.00 volts?

Push and hold the lower button of the blade angle switch while observing the voltage reading in the CMU

823
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped
menu.

Is the voltage approximately 0.90 volts?

Record of Actual Results:

Result:
YES:
Go to Blade Angle Actuator Circuit Check .
NO:
Go to Blade Angle Switch Circuit Check .

2 Blade Angle Switch Circuit Check

Action:

NOTE:

For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness
(W22) Wiring Diagram—If Equipped . (Group 9015-10.)

Key switch ON.

NOTE:

Connector X82 must be connected to the electrohydraulic controller (EHC) to perform this
check.

Check for voltage at pin 20 (wire H25 WHT) of EHC connector X82. Do not push blade angle switch buttons
during this check.

Is approximately 2.20 volts present?

Record of Actual Results:

Result:
YES:
Reprogram electrohydraulic controller. If problem persists, replace controller.
NO:
Go to next step in this check.
Action:

Turn key switch OFF.

Disconnect blade control joystick (BCJ) connector X97 and electrohydraulic controller (EHC) connector X82.

Check wire H25 WHT for open or short circuit between pin 2 of connector X97 and pin 20 of connector X82.

824
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped
Is an open or short circuit indicated?

Record of Actual Results:

Result:
YES:
Repair as necessary.
NO:
Go to Joystick 5-Volt Supply Circuit Check .

3 Joystick 5-Volt Supply Circuit Check

Action:

NOTE:

For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness
(W22) Wiring Diagram—If Equipped . (Group 9015-10.)

Electrohydraulic controller (EHC) connector X82 disconnected. Connector X83 must be connected for this
check.

Turn key switch ON.

At controller side of EHC connector X82, check for voltage across pin 3 (+) and pin 22 (-).

Are approximately 5 volts present?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Replace electrohydraulic controller.
Action:

Electrohydraulic controller (EHC) connector X82 and blade control joystick (BCJ) connector X97
disconnected.

Key switch OFF.

Check wire H22 BRN for open or short circuit between pin 1 of joystick connector X97 and pin 3 of EHC
connector X82.

Is an open or short circuit indicated?

Record of Actual Results:

825
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped

Result:
YES:
Repair as necessary.
NO:
Go to Joystick Switch Module Ground Circuit Check .

4 Joystick Switch Module Ground Circuit Check

Action:

NOTE:

For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness
(W22) Wiring Diagram—If Equipped . (Group 9015-10.)

Key switch OFF.

Electrohydraulic controller (EHC) connector X82 and blade control joystick (BCJ) connector X97
disconnected.

Check continuity of wire R41 PNK between pin 6 of joystick connector X97 and pin 22 of EHC connector
X82.

Is continuity indicated?

Record of Actual Results:

Result:
YES:
Replace joystick.
NO:
Check circuit R41 for open circuit. Repair as necessary.

5 Blade Angle Actuator Circuit Check

Action:

NOTE:

For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped . (Group 9015-10.)

Turn key switch ON.

NOTE:

Blade angle actuator (Y30) must be connected when performing this check.

826
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped

Push and hold upper blade angle button on joystick while checking for voltage at pin 1 (wire H31 RED) of
blade angle actuator (Y30) connector.

Are approximately 5 volts present?

Record of Actual Results:

Result:
YES:
Go to next step in this check.
NO:
Check circuit H31 for open or short circuit between blade angle actuator and pin 12 of EHC connector X83.
Repair as necessary.
Action:

NOTE:

Blade angle actuator (Y30) must be connected when performing this check.

Key switch ON.

Push and hold lower blade angle button on joystick handle while checking for voltage at pin 4 (wire H34 BLK)
of blade angle actuator (Y30) connector.

Are approximately 5 volts present?

Record of Actual Results:

Result:
YES:
Go to Actuator Ground Circuit Check .
NO:
Check circuit H34 for open or short circuit between blade angle actuator and pin 5 of EHC connector X83.

6 Actuator Ground Circuit Check

Action:

NOTE:

For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped . (Group 9015-10.)

Key switch OFF.

Disconnect blade angle actuator (Y30) connector.

Check for ground at pins 2 and 3 (wire G20 BLK) (harness side) of actuator connector.
827
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped

Is ground present?

Record of Actual Results:

Result:
YES:
See Hydraulic System Diagnose Malfunctions—IGC . (Group 9025-15.)

If problem cannot be resolved, contact the grade control equipment supplier or John Deere DTAC.

NO:
Check wire G20 BLK for open circuit between pins 2 and 3 of actuator connector and IGC ground connector
X87 [located at battery disconnect switch (S2)]. Repair as necessary.

Blade Lift and Angle Operate Normally, But Blade Incr/Decr Does Not
Launch Close Expand List Collapse List

1 Blade Increment/Decrement Switch Check

Action:

Turn key switch ON.

Observe the voltage input for the blade increment/decrement switch by accessing the Diagnostic / Live
Values / Input Voltages menu in the CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—
Service Mode . (Group 9015-20.)

Observe increment/decrement switch voltage reading in the CMU menu with no increment/decrement
buttons pushed.

LOOK: Is the voltage approximately 2.20 volts?

Push and hold the increment (upper) button while observing the voltage reading in the CMU menu.

LOOK: Is the voltage approximately 3.00 volts?

Push and hold the decrement (lower) button while observing the voltage reading in the CMU menu.

LOOK: Is the voltage approximately 0.90 volts?

Record of Actual Results:

Result:
YES:
Reprogram electrohydraulic controller. If problem persists, replace controller.
NO:
Go to Blade Increment/Decrement Switch Circuit Check .

2 Blade Increment/Decrement Switch Circuit Check

828
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped

Action:

NOTE:

For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness
(W22) Wiring Diagram—If Equipped . (Group 9015-10.)

Key switch ON.

NOTE:

Connector X83 must be connected to the electrohydraulic controller (EHC) to perform this
check.

Check for voltage at pin 21 (wire H20 GRN) of EHC connector X82. Do not push switch buttons during this
check.

Is approximately 2.20 volts present?

Record of Actual Results:

Result:
YES:
Reprogram electrohydraulic controller. If problem persists, replace controller.
NO:
Go to next step in this check.
Action:

Turn key switch OFF.

Disconnect blade control joystick (BCJ) connector X97 and electrohydraulic controller (EHC) connector X82.

Check wire H20 GRN for open or short circuit between pin 3 of connector X97 and pin 21 of connector X82.

Is an open or short circuit indicated?

Record of Actual Results:

Result:
YES:
Repair as necessary.
NO:
Replace joystick.

Blade Response Is Not Smooth

Launch Close Expand List Collapse List

829
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped

1 Hydraulic Oil Level Check

Action:

Check hydraulic oil level.

Is hydraulic oil level low?

Record of Actual Results:

Result:
YES:
Add oil as necessary. See Transmission and Hydraulic Reservoir Oil . (Operator's Manual.)
NO:
Go to Actuator Circuit Check .

2 Actuator Circuit Check

Action:

NOTE:

A problem with an actuator circuit will most likely cause a diagnostic trouble code to occur.

A flashing red light on the actuator usually indicates a problem with the input signal. A
steady red light on the actuator usually indicates an internal malfunction.

For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped . (Group 9015-10.)

Check wires between affected actuator and electrohydraulic controller (EHC) for intermittent open or short
circuit.

Is an open or short circuit indicated?

Record of Actual Results:

Result:
YES:
Repair wiring of affected actuator circuit as necessary.
NO:
Go to next step in this check.
Action:

Check for ground at pin 3 of affected actuator connector.

Is ground present?

Record of Actual Results:

830
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped

Result:
YES:
Go to CAN Circuit Check .
NO:
Check continuity of wire G20 BLK between pin 3 of affected actuator and connector X87 [located at battery
disconnect switch (S2)]. Repair as necessary.

3 CAN Circuit Check

Action:

NOTE:

A malfunctioning CAN circuit may cause the symptom “Blade Response Is Not Smooth”, but
only in manual mode.

A problem with an CAN circuit will most likely cause a diagnostic trouble code to occur.

For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness
(W22) Wiring Diagram—If Equipped . (Group 9015-10.)

Check if a CAN termination resistor is missing.

Is termination resistor missing?

Record of Actual Results:

Result:
YES:
Install or replace termination resistor.
NO:
Go to nest step in this check.
Action:

Check for intermittent problem in CAN wiring. See CAN Circuit Test . (Group 9015-20.)

Is CAN circuit okay?

Record of Actual Results:

Result:
YES:
Go to Valve Calibration / Valve Offset and Gain Check (Auto Mode Only) .
NO:
If problem cannot be resolved, contact the grade control equipment supplier or John Deere DTAC.

831
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped

4 Valve Calibration / Valve Offset and Gain Check (Auto Mode Only)
Action:

Depending on supplier, perform either the valve calibration procedure or adjust valve offset and gain
procedure per grade control supplier's instructions. Consult documentation provided by the grade control
supplier.

Did performing the valve calibration procedure or valve offset and gain set procedure resolve problem?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Go to Pump Load Sense Pressure Check

5 Pump Load Sense Pressure Check

Action:

Check and adjust pump load sense pressure. See Pump Load Sense Differential and System Pressure Test
and Adjustment—IGC . (Group 9025-25.)

Is pump load sense pressure within specification?

Record of Actual Results:

Result:
YES:
Go to Actuator Valve Check
NO:
If load sensor pressure specification cannot be obtained, inspect pump load sense valve. Check for sticking
load sense spool. Repair if necessary. See Hydraulic Pump Control Valve Disassemble and Assemble .
(Group 3260.)

6 Actuator Valve Check

Action:

Inspect hydraulic actuator valve of affected circuit for sticking spool or sticking control valve load sense relief
valve. See Hydraulic Control Valve Remove and Install and see Hydraulic Control Valve Disassemble and
Assemble—IGC . (Group 3260.)

Does actuator valve pass inspection?

Record of Actual Results:

832
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped

Result:
YES:
If problem cannot be resolved, contact the grade control equipment supplier or John Deere DTAC.
NO:
Repair or replace actuator valve as necessary.

All Blade Functions Are Slow or Sluggish

Launch Close Expand List Collapse List

1 Valve Calibration / Valve Offset and Gain Check (Auto Mode Only)
Action:

Depending on supplier, perform either the valve calibration procedure or adjust valve offset and gain
procedure per grade control supplier's instructions. Consult documentation provided by the grade control
supplier.

Did performing the valve calibration procedure or valve offset and gain set procedure resolve problem?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Go to Pump Load Sense Pressure Check .

2 Pump Load Sense Pressure Check

Action:

Check and adjust pump load sense pressure. See Pump Load Sense Differential and System Pressure Test
and Adjustment—IGC . (Group 9025-25.)

Is pump load sense pressure within specification?

Record of Actual Results:

Result:
YES:
Go to Actuator Valve Check .
NO:
If load sensor pressure specification cannot be obtained, inspect pump load sense valve. Check for sticking
load sense spool. Repair if necessary. See Hydraulic Pump Control Valve Disassemble and Assemble .
(Group 3260.)

3 Actuator Valve Check

Action:
833
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped

Inspect hydraulic actuator valve of affected circuit for sticking spool or sticking control valve load sense relief
valve. See Hydraulic Control Valve Remove and Install and see Hydraulic Control Valve Disassemble and
Assemble—IGC . (Group 3260.)

Does actuator valve pass inspection?

Record of Actual Results:

Result:
YES:
See Hydraulic System Diagnose Malfunctions—IGC . (Group 9025-15.)

If problem cannot be resolved, contact the grade control equipment supplier or John Deere DTAC.

NO:
Repair or replace actuator valve as necessary.

Blade Response Is Too Fast

Launch Close Expand List Collapse List

1 Valve Calibration / Valve Offset and Gain Check (Auto Mode Only)
Action:

Depending on supplier, perform either the valve calibration procedure or adjust valve offset and gain
procedure per grade control supplier's instructions. Consult documentation provided by the grade control
supplier.

Did performing the valve calibration procedure or valve offset and gain set procedure resolve problem?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Go to Pump Load Sense Pressure Check .

2 Pump Load Sense Pressure Check

Action:

Check and adjust pump load sense pressure. See Pump Load Sense Differential and System Pressure Test
and Adjustment—IGC . (Group 9025-25.)

Is pump load sense pressure within specification?

Record of Actual Results:

834
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped

Result:
YES:
Go to Actuator Valve Check .
NO:
If load sensor pressure specification cannot be obtained, inspect pump load sense valve. Check for sticking
load sense spool. Repair if necessary. See Hydraulic Pump Control Valve Disassemble and Assemble .
(Group 3260.)

3 Actuator Valve Check

Action:

Inspect hydraulic actuator valve of affected circuit for sticking spool or sticking control valve load sense relief
valve. See Hydraulic Control Valve Remove and Install and see Hydraulic Control Valve Disassemble and
Assemble—IGC . (Group 3260.)

Does actuator valve pass inspection?

Record of Actual Results:

Result:
YES:
See Hydraulic System Diagnose Malfunctions—IGC . (Group 9025-15.)

If problem cannot be resolved, contact the grade control equipment supplier or John Deere DTAC.

NO:
Repair or replace actuator valve as necessary.

Blade Moves Quickly (Jumps) to One Side, Then Slowly Comes Back on Grade
Launch Close Expand List Collapse List

1 Valve Calibration / Valve Offset and Gain Check (Auto Mode Only)

Action:

Depending on supplier, perform either the valve calibration procedure or adjust valve offset and gain
procedure per grade control supplier's instructions. Consult documentation provided by the grade control
supplier.

Did performing the valve calibration procedure or valve offset and gain set procedure resolve problem?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Go to Actuator Circuit Check .

835
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped

2 Actuator Circuit Check

Action:

NOTE:

A problem with an actuator circuit will most likely cause a diagnostic trouble code to occur.

When the actuator status light flashes red, the input signal is usually the problem. When the
actuator status light is steady red, the problem is usually inside the actuator.

For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped . (Group 9015-10.)

Check wires between affected actuator and electrohydraulic controller (EHC) for intermittent open or short
circuit.

Is an open or short circuit indicated?

Record of Actual Results:

Result:
YES:
Repair wiring of affected actuator circuit as necessary.
NO:
Go to next step in this check.
Action:

Check for ground at pin 3 of affected actuator.

Is ground present?

Record of Actual Results:

Result:
YES:
Go to Actuator Valve Check
NO:
Check continuity of wire G20 BLK between affected actuator and connector X87 [located at battery
disconnect switch (S2)]. Repair as necessary.

3 Actuator Valve Check

Action:

Inspect hydraulic actuator valve of affected circuit for sticking spool or sticking control valve load sense relief
valve. See Hydraulic Control Valve Remove and Install and see Hydraulic Control Valve Disassemble and
Assemble—IGC . (Group 3260.)

Does actuator valve pass inspection?

836
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped

Record of Actual Results:

Result:
YES:
See Hydraulic System Diagnose Malfunctions—IGC . (Group 9025-15.)

If problem cannot be resolved, contact the grade control equipment supplier or John Deere DTAC.

NO:
Repair or replace actuator valve as necessary.

Waves in Graded Surface

NOTE:

When operating in auto mode, this symptom may result from poor reception from satellite or from
other guidance equipment. It may also be caused by malfunctioning grade control supplier's
equipment. Consult documentation of supplier's grade control equipment. If problem cannot be
resolved, contact the grade control equipment supplier or John Deere DTAC.

Launch Close Expand List Collapse List

1 Valve Calibration / Valve Offset and Gain Check (Auto Mode Only)

Action:

Depending on supplier, perform either the valve calibration procedure or adjust valve offset and gain
procedure per grade control supplier's instructions. Consult documentation provided by the grade control
supplier.

Did performing the valve calibration procedure or valve offset and gain set procedure resolve problem?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Go to Actuator Circuit Check .

2 Actuator Circuit Check

Action:

NOTE:

A problem with an actuator circuit will most likely cause a diagnostic trouble code to occur.

When the actuator status light flashes red, the input signal is usually the problem. When the
actuator status light is steady red, the problem is usually inside the actuator.

837
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped
For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness
(W21) Wiring Diagram—If Equipped . (Group 9015-10.)

Check wires between affected actuator and electrohydraulic controller (EHC) for intermittent open or short
circuit.

Is an open or short circuit indicated?

Record of Actual Results:

Result:
YES:
Repair wiring of affected actuator circuit as necessary.
NO:
Go to next step in this check.
Action:

Check for ground at pin 3 affected actuator.

Is ground present?

Record of Actual Results:

Result:
YES:
Go to Actuator Valve Check
NO:
Check continuity of wire G20 BLK between affected actuator and connector X87 [located at battery
disconnect switch (S2)]. Repair as necessary.

3 Actuator Valve Check

Action:

Inspect hydraulic actuator valve of affected circuit for sticking spool or sticking control valve load sense relief
valve. See Hydraulic Control Valve Remove and Install and see Hydraulic Control Valve Disassemble and
Assemble—IGC . (Group 3260.)

Does actuator valve pass inspection?

Record of Actual Results:

Result:
YES:
See Hydraulic System Diagnose Malfunctions—IGC . (Group 9025-15.)

If problem cannot be resolved, contact the grade control equipment supplier or John Deere DTAC.

838
 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped

NO:
Repair or replace actuator valve as necessary.

Go to Section_9015:Group_20

OUO1010,00009D4-19-20120806

839
 Alternator Test

Alternator Test

T7751GM-19: Common Charging Circuit

12 V System

1. With engine running at slow idle, check DC voltage between terminal D+ and ground. Voltage should be
13.5 VDC or greater [Note: For 12 V systems with maintenance free batteries, D+ and B+ voltage
should be 14.1 VDC or greater.] .

2. With engine running at fast idle, check DC voltage between terminal B+ and ground. Voltage should be
13.5 VDC or greater [Note: For 12 V systems with maintenance free batteries, D+ and B+ voltage
should be 14.1 VDC or greater.] .

3. If voltage from previous steps is below 13.5 VDC [ Note: For 12 V systems with maintenance free
batteries, D+ and B+ voltage should be 14.1 VDC or greater.] , check excitation by placing a jumper wire
between terminals D+ and B+ with the engine running. If output at terminals B+ and D+ rise to 13.5 VDC
or greater, check for an open diode, wiring problem or blown fuse in the alternator excitation circuit (wire
to D+ terminal).

4. With engine running, check AC voltage between terminal W (if equipped) and ground. Voltage should be
6—7 VAC .

5. Repeat above steps with lights on to load the alternator.

6. If alternator fails to produce specified voltage after testing, check for worn out brushes in the
regulator/brush assembly. Replace brush/regulator assembly if necessary. See Alternators and Starting
Motors for specific test and repair procedures. (CTM77.) If alternator still fails, replace it. If alternator
tests OK, check indicator light circuit.

24 V System

1. With engine running at slow idle, check DC voltage between terminal D+ and ground. Voltage should be
27.5 VDC or greater [Note: For 24 V systems with maintenance free batteries, D+ and B+ voltage

840
 Alternator Test
should be 28.2 VDC or greater.] .

2. With engine running at fast idle, check DC voltage between terminal B+ and ground. Voltage should be
27.5 VDC or greater [Note: For 24 V systems with maintenance free batteries, D+ and B+ voltage
should be 28.2 VDC or greater.] .

3. If voltage from previous steps is below 27.5 VDC [ Note: For 24 V systems with maintenance free
batteries, D+ and B+ voltage should be 28.2 VDC or greater.] , check excitation by placing a jumper wire
between terminals D+ and B+ with the engine running. If output at terminals B+ and D+ rise to 27.5 VDC
or greater, check for an open diode, wiring problem or blown fuse in the alternator excitation circuit (wire
to D+ terminal).

4. With engine running, check AC voltage between terminal W (if equipped) and ground. Voltage should be
12—14 VAC .

5. Repeat above steps with lights on to load the alternator.

6. If alternator fails to produce specified voltage after testing, check for worn out brushes in the
regulator/brush assembly. Replace brush/regulator assembly if necessary. See Alternators and Starting
Motors for specific test and repair procedures. (CTM77.) If alternator still fails, replace it. If alternator
tests OK, check indicator light circuit.

Go to Section_9015:Group_20

AA95137,00007E0-19-20070212

841
 CAN Circuit Test

CAN Circuit Test

TX1110187-UN: Generic CAN Circuit Schematic

LEGEND:
1 - Controller 1
2 - Controller 2
3 - Service ADVISOR™ Connector
4 - Termination Resistor 1
5 - Termination Resistor 2
6 - CAN High Wire (Yellow)
7 - CAN Low Wire (Green)
8 - Grounded Shield Wire (Black)

NOTE:

For additional information on the controller area network (CAN) circuit, see Controller Area
Network (CAN) Circuit Theory of Operation . (Group 9015-15.)

The diagram and the following diagnostics are for a generic 2-controller network. For networks
with more than two controllers, repeat last step for all controllers if necessary.

Controller Area Network (CAN) Diagnostics

Launch Close Expand List Collapse List

1 System Check
Action:

Connect Service ADVISOR™ application to diagnostic connector. See Service ADVISOR™ Connection
Procedure . (Group 9015-20.)

Turn key switch to the ON position. Establish machine connection using Service ADVISOR™. See Service
842
 CAN Circuit Test
ADVISOR™ Diagnostic Application . (Group 9015-20.)

Do all controllers show up under connected controllers?

Record of Actual Results:

Result:
YES:
Perform CAN Termination Resistor Check . (Group 9015-20.)
NO:
Not all controllers show up. Check fuses for the missing controller(s). For fuse information, see Fuse and
Relay Specifications . (Group 9015-10.) If OK, Perform Controller Check (Group 9015-20.) for missing
controller.
NO:
A connection could not be established. Check fuse for the Service ADVISOR™ connector. For fuse
information, see Fuse and Relay Specifications . (Group 9015-10.) If OK, perform CAN Termination Resistor
Check . (Group 9015-20.)

2 CAN Termination Resistor Check

Action:

Turn key switch to the OFF position. Remove and measure the resistance of each termination resistors (4
and 5).

Is the resistance of each resistor between 110—130 ohm?

Record of Actual Results:

Result:
YES:
Install resistors and perform CAN High Wire Voltage Check . (Group 9015-20.)
NO:
Replace resistor. Install new resistor and perform CAN High Wire Voltage Check . (Group 9015-20.)

3 CAN High Wire Voltage Check

Action:

Turn key switch to the ON position. Using a multimeter, measure the voltage from pin C (CAN high) to pin A
(ground) of Service ADVISOR™ connector (3).

Is voltage between 2.50—3.50 volts?

Record of Actual Results:

Result:
YES:

843
 CAN Circuit Test
Perform CAN Low Wire Voltage Check . (Group 9015-10.)
NO:
System voltage is measured. A short-to-power exists on the CAN high wire. Check CAN high voltage one
controller at a time to locate short circuit. Repair or replace harness as necessary. See Operator's Station
Harness (W7) Wiring Diagram and see Engine Harness (W10) Wiring Diagram . (Group 9015-10.))
NO:
Zero volts are measured. Perform CAN High Wire Circuit Check . (Group 9015-10.)
NO:
Voltage is out of range but greater than 0 and less than system voltage. Remove one controller at a time and
recheck voltage. When voltage is in range, check harness of disconnected controller for short circuits.
Repair or replace harness as necessary. See Operator's Station Harness (W7) Wiring Diagram and see
Engine Harness (W10) Wiring Diagram . (Group 9015-10.)

4 CAN Low Wire Voltage Check

Action:

Using a multimeter, measure voltage from pin D (CAN low) to pin A (ground) of Service ADVISOR™
connector (3).

Is voltage between 1.50—2.50 volts?

Record of Actual Results:

Result:
YES:
Perform CAN High Wire Circuit Check . (Group 9015-10.)
NO:
System voltage is measured. A short-to-power exists on the CAN low wire. Check CAN low voltage one
controller at a time to locate the short circuit. Repair or replace harness as necessary. See Operator's
Station Harness (W7) Wiring Diagram and see Engine Harness (W10) Wiring Diagram . (Group 9015-10.)
NO:
Zero volts are measured. Perform CAN Low Wire Circuit Check . (Group 9015-10.)
NO:
Voltage is out of range but greater than 0 and less than system voltage. Remove one controller at a time and
recheck voltage. When voltage is in range, check harness of disconnected controller for short circuits.
Repair or replace harness as necessary. See Operator's Station Harness (W7) Wiring Diagram and see
Engine Harness (W10) Wiring Diagram . (Group 9015-10.)

5 CAN High Wire Circuit Check

Action:

Using a multimeter, measure continuity between pin C (CAN high) and pin A (ground) of Service
ADVISOR™ connector (3).

Is continuity measured?

Record of Actual Results:

844
 CAN Circuit Test

Result:
YES:
A short-to-ground exists on the CAN high wire. Check CAN high voltage one controller at a time to locate the
short circuit. Repair or replace harness as necessary. See Operator's Station Harness (W7) Wiring Diagram
and see Engine Harness (W10) Wiring Diagram . (Group 9015-10.)
NO:
An open circuit exists on the CAN high wire. Repair or replace harness(es) as necessary. See Operator's
Station Harness (W7) Wiring Diagram and see Engine Harness (W10) Wiring Diagram . (Group 9015-10.)

6 CAN Low Wire Circuit Check

Action:

Using a multimeter, measure continuity between pin D (CAN low) and pin A (ground) of Service ADVISOR™
connector (3).

Is continuity measured?

Record of Actual Results:

Result:
YES:
A short-to-ground exists on the CAN low wire. Check CAN low voltage one controller at a time to locate the
trunk of the harness where the short is located. Repair or replace harness as necessary. See Operator's
Station Harness (W7) Wiring Diagram and see Engine Harness (W10) Wiring Diagram . (Group 9015-10.)
NO:
An open circuit exists on the CAN low wire. Repair or replace harness(es) as necessary. See Operator's
Station Harness (W7) Wiring Diagram and see Engine Harness (W10) Wiring Diagram . (Group 9015-10.)

7 Controller Check

Action:

Turn key switch to the OFF position. Locate the controller and disconnect the appropriate connector to
disconnect the CAN wires. Using a multimeter, measure the resistance between the CAN high and CAN low
wires.

Is resistance between 55—65 ohms?

Record of Actual Results:

Result:
YES:
Connect the controller. Repeat Controller Check for all other controllers.
NO:
An open or short circuit exists in one of the CAN wires. Work from the controller to the harness checking the
CAN high and low wires for open and short circuit. Repair or replace harness as necessary. See Operator's
Station Harness (W7) Wiring Diagram and see Engine Harness (W10) Wiring Diagram . (Group 9015-10.)

845
CAN Circuit Test

Go to Section_9015:Group_20

CS33148,0002293-19-20170328

846
 Transmission Control Unit (TCU) Calibration

Transmission Control Unit (TCU) Calibration

-: Specifications

SPECIFICATIONS

Transmission Oil Temperature 57—66° C

135—150° F

Neutral Charge (minimum) Pressure 2275 kpa

22.75 bar
330 psi

1. IMPORTANT:

Recalibrate whenever transmission components are adjusted or replaced.

A pump null adjustment must be made before calibration following pump repair. See Pump
Displacement Control Valve (PDCV) Neutral (Null) Adjustment . (Group 9026-25.)

Record diagnostic trouble codes and the number of occurrences and clear all stored diagnostic trouble
codes before calibration. See Diagnostic Trouble Code (DTC) Quick Reference List—Transmission
Control Unit (TCU) . (Group 9001-30.)

IMPORTANT:

Prior to running this procedure, clear tracks of excessive mud and verify track tension is within
specification. See Check Track Sag . (Operator's Manual.)

Do this procedure on level ground with enough room to accelerate to full speed for approximately 46—
61 m (150—200 ft.), or with machine off ground supported by 20 ton stands. See Machine Supporting
Procedure . (Group 9026-25.)

If diagnostic trouble code 158.3, 158.4, 620.3 or 620.4 is displayed, do not calibrate. See Diagnostic
Trouble Code (DTC) Quick Reference List—Transmission Control Unit (TCU) . (Group 9001-30.)

2. Verify park lock lever is in the PARK (up) position. Turn engine speed control switch to the slow idle
position. Make sure transmission control lever is in neutral.

3. Start engine.

4. Warm transmission oil to specification. See Transmission Oil Warm-Up Procedure. (Group 9026-25.)
Push the SELECT button on the CAN Monitor Unit (CMU) until charge pressure is displayed.

Item Measurement Specification

Transmission Oil Temperature 57—66° C
135—150° F
Neutral Charge (minimum) Pressure 2275 kpa
22.75 bar
330 psi
If charge pressure is low, see Low Charge Pressure Malfunctions . (Group 9026-25.)

5. Push and hold the MENU button on the CMU for 5 seconds until the monitor alarm beeps and “Service
Mode” is briefly displayed on the screen.

6. Push NEXT until “Calibration” is highlighted and then press SELECT.

847
 Transmission Control Unit (TCU) Calibration
7. Push SELECT again to start the calibration procedure. Follow the commands displayed on the CMU. If
any problems occur during the calibration period and the calibration procedure ends prematurely, check
diagnostic trouble codes. See Diagnostic Trouble Code (DTC) Quick Reference List—Transmission
Control Unit (TCU) . (Group 9001-30.)

8. NOTE:

High speed reverse is not done during calibration. Operator will hear engine lug
momentarily as brakes come on after high speed forward calibration is confirmed.

Calibration will end after high speed forward is calibrated and SELECT is pressed.

Go to Section_9015:Group_20

AA95137,00007C6-19-20100329

848
 Wire Harness Test

Wire Harness Test

IMPORTANT:

When testing wire harnesses, it is necessary to place spare mating terminals into the terminal sockets of the
connectors that are to be tested and apply test leads to those terminals instead of the terminal sockets. Inserting
test leads into terminal sockets of harness connectors can damage the terminal socket and/or connector, causing
unnecessary problems in the electrical system.

T207090A-UN: Proper Wire Harness Test (Deutsch connectors shown)

LEGEND:
1 - Test Lead
2 - Spare Mating Terminal

Go to Section_9015:Group_20

MF82180,000003F-19-20050114

849
 Decelerator/Brake Pedal Adjustment

Decelerator/Brake Pedal Adjustment

-: Specifications

SPECIFICATIONS

High Position Voltage 1.40—1.55 Volts

Low Position Voltage 3.40—3.60 Volts

Brake Position Voltage 3.79—3.99 Volts

-: Essential Tools

ESSENTIAL TOOLS

JT07237-1 Test Harness

JT07329-3 Test Harness

1.

T198884-UN: Decelerator/Brake Pedal Adjustment

LEGEND:
1 - Decelerator Sensor
2 - High Position Stop
3 - Low Position Stop
4 - Brake Position Stop

Disconnect harness from decelerator sensor (B1) (1) and connect JT07329-3 test harness between
sensor and harness. Connect JT07237-1 test harness to the white and black leads of the JT07329-3 test
harness.

2. Turn key switch on measure the sensor DC voltage on a multimeter. Adjust high position stop (2) until
reading is within specification.

Item Measurement Specification

High Position Voltage 1.40—1.55 Volts

3. Press the decel pedal down to the low position stop. Adjust low position stop (3) until reading is within
850
 Decelerator/Brake Pedal Adjustment
3. Press the decel pedal down to the low position stop. Adjust low position stop (3) until reading is within
specification.

Item Measurement Specification

Low Position Voltage 3.40—3.60 Volts

4. Press the decel pedal down to the brake stop. Adjust brake position stop (4) until reading is within
specification.

Item Measurement Specification

Brake Position Voltage 3.79—3.99 Volts

Go to Section_9015:Group_20

MF82180,00001DF-19-20070801

851
 Engine Speed Control Remove and Install

Engine Speed Control Remove and Install

TX1135636A-UN: Engine Speed Control Components

LEGEND:
1 - Knob
2 - Push Nut (2 used)
3 - Stop Tab
4 - Nut (included with engine speed control)
5 - Stop Plate
6 - Plate
7 - Washer (included with engine speed control)
8 - Engine Speed Control

-: Specifications

SPECIFICATIONS

Engine Speed Control Nut Torque 2.7 N·m

24 lb.-in.

1. Remove screws from left console to gain access to engine speed control (8) electrical connector.

2. Disconnect engine speed control electrical connector.

3. NOTE:

Engine speed control assembly on machines (S.N. —231752) used only one push nut
(2). For these machines, order one additional R78035 Push Nut and assemble engine
speed control assembly as shown.

Remove knob (1), push nut (2), stop tab (3), push nut (2), stop plate (5), nut (4), washer (7), plate (6),
and engine speed control (8).

4. Repair or replace parts as necessary.

5. NOTE:

Install switch as shown, knob indicator must align with decal on plate.

852
 Engine Speed Control Remove and Install
Install engine speed control, plate, washer, and nut. Tighten nut to specification.

Item Measurement Specification

Engine Speed Control Nut Torque 2.7 N·m
24 lb.-in.

6. Install stop plate, push nut, stop tab, push nut, and knob.

If engine speed control assembly was assembled with only one push nut, order one additional R78035
Push Nut and assemble engine speed control assembly as shown.

7. Install engine speed control into left console.

Go to Section_9015:Group_20

KK70125,000008F-19-20130429

853
 Rotary Sensor Remove and Install

Rotary Sensor Remove and Install

-: Specifications

SPECIFICATIONS

Rotary Sensor Mounting Cap Screws Torque 5 N·m

48 lb-in.

1.

T199285-UN: Rotary Sensor Remove and Install (Steer Sensor shown)

LEGEND:
1 - Shaft
2 - Sensor
3 - O-Ring

To ease removal and installation, remove the Transmission Control Lever (TCL) or decelerator
assembly. See Transmission Control Lever (TCL) Remove and Install (Group 0315.) or

2. Remove the two cap screws and sensor (2).

3. Install O-ring (3) if needed.

4. Position sensor (2) at about a 4 o'clock position to install sensor on keyed shaft (1).

5. Twist sensor to line up sensor with mounting holes.

6. Install cap screws and tighten to specification.

Item Measurement Specification

Rotary Sensor Mounting Cap Screws Torque 5 N·m
48 lb-in.

7. Install the TCL or decelerator assembly.

854
Rotary Sensor Remove and Install

Go to Section_9015:Group_20

MF82180,00001D5-19-20060928

855
 Transmission Control Lever (TCL) Adjustment

Transmission Control Lever (TCL) Adjustment

-: Specifications

SPECIFICATIONS

Neutral Adjustment

Steer Input—Neutral Voltage 2.39—2.60 V

FNR Input—Neutral Voltage 2.25—2.76 V

Steer Linkage Adjustment

Steer Linkage—Right Voltage 1.52—1.94 V

Steer Linkage—Right Counter-Rotate Voltage 1.40—1.78 V

Steer Linkage—Left Voltage 3.06—3.48 V

Steer Linkage—Left Counter-Rotate Voltage 3.22—3.60 V

TCL Linkage Adjustment

TCL Linkage—Forward Position Voltage 3.13—3.88 V

TCL Linkage—Reverse Position Voltage 1.06—1.80 V

-: Essential Tools

ESSENTIAL TOOLS

JT07237-1 Test Harness

JT07329-3 Test Harness

Neutral Adjustment

This procedure is used to adjust the steer sensor linkage and FNR sensor linkage to provide the correct voltage
for the rotary sensors.

1. Key switch on, engine off and TCL to neutral position.

2. Access service mode by holding MENU button for 5 seconds.

3. Select DIAGNOSTICS .

4. Select LIVE VALUES .

5. Select INPUT VOLTAGES .

6. The steer input voltage must be as specified.

Item Measurement Specification

Neutral Adjustment
Steer Input—Neutral Voltage 2.39—2.60 V

7. Push NEXT button until FNR appears. FNR input voltage in neutral position must be as specified.

856
 Transmission Control Lever (TCL) Adjustment

Item Measurement Specification

Neutral Adjustment
FNR Input—Neutral Voltage 2.25—2.76 V

8. If voltages are not to specification, remove SLC assembly from machine.

Steer Linkage Adjustment

Procedure adjusts the steer linkage.

1.

T118886B-UN: Steer Linkage

LEGEND:
1 - JT07329-3 Test Harness
2 - Steer Sensor
3 - Lock Nut
4 - Rod Assembly
5 - FNR Sensor

Install JT07329-3 test harness (1) to machine harness and to steer sensor (2). Connect JT07237-1 test
harness to the white and black leads of the JT07329-3 test harness.

2. Loosen lock nut (3) from ball joint. Turn rod assembly (4) while monitoring steer voltage on monitor.
Adjust to specification and tighten lock nut.

3. Move steer lever to right steer position. Do not go into counter-rotate. Voltage must be as specified.

857
 Transmission Control Lever (TCL) Adjustment

Item Measurement Specification

Steer Linkage Adjustment
Steer Linkage—Right Voltage 1.52—1.94 V

4. Move steer lever to right counter-rotate position. Voltage must be as specified.

Item Measurement Specification

Steer Linkage Adjustment
Steer Linkage—Right Counter-Rotate Voltage 1.40—1.78 V

5. Move steer lever to left steer position. Do not go into counter-rotate. Voltage must be as specified.

Item Measurement Specification

Steer Linkage Adjustment
Steer Linkage—Left Voltage 3.06—3.48 V

6. Move steer lever to left counter-rotate position. Voltage must be as specified.

Item Measurement Specification

Steer Linkage Adjustment
Steer Linkage—Left Counter-Rotate Voltage 3.22—3.60 V

7. If voltage is not to specification, calibrate machine and recheck voltage. If voltage is still not to
specification, replace sensor.

8. If no voltage can be recorded, see Transmission Control Unit (TCU) Circuit Theory of Operation . (Group
9015-15.)

9. Route all wiring harnesses back to their original location and replace all tie bands that were removed.

NOTE:

Recalibrate whenever control linkages are adjusted or replaced.

TCL Linkage Adjustment

Procedure adjusts the TCL linkage.

858
 Transmission Control Lever (TCL) Adjustment
1.

T118887B-UN: FNR Linkage

LEGEND:
6 - Lock Nut
7 - Nut
8 - Ball Joint

Install JT07329-3 test harness to FNR sensor. Connect JT07237-1 test harness to the white and black
leads of the JT07329-3 test harness.

2. Remove nut (7) and ball joint (8). Loosen lock nut (6) and adjust to specification.

3. Move FNR lever to forward position. Voltage must be as specified.

Item Measurement Specification

TCL Linkage Adjustment
TCL Linkage—Forward Position Voltage 3.13—3.88 V

4. Move FNR lever to reverse position. Voltage must be as specified.

Item Measurement Specification

TCL Linkage Adjustment
TCL Linkage—Reverse Position Voltage 1.06—1.80 V

5. If voltage cannot be adjusted to specification, verify sensor is installed correctly. See Rotary Sensor
Remove and Install . (Group 9015-20.)

6. If no voltage can be recorded, see Transmission Control Unit (TCU) Circuit Theory of Operation . (Group
9015-15.)

7. Route all wiring harnesses back to their original location and replace all tie bands that were removed.

859
 Transmission Control Lever (TCL) Adjustment

NOTE:

Recalibrate whenever control linkages are adjusted or replaced.

Go to Section_9015:Group_20

KV70328,000025C-19-20080220

860
 Bussed Sensor Connectors (X6 and X7) Diagnostics

Bussed Sensor Connectors (X6 and X7) Diagnostics

TX1048454-UN: Bussed Sensor Connectors (X6 and X7) Diagnostics

-: Bussed Sensor 5 V Connector (X6)

Bussed Sensor 5 V Connector (X6)

Pin Sensor () Wire

1 TCU Power T01A

BLU

2 Decelerator Sensor (B1) T02A

BLU

3 Motor Speed Sensor Left (B2) T04A

BLU

4 Motor Speed Sensor Right (B3) T06A

BLU

5 Hydrostatic Charge Pressure Sensor (B4, S.N. —173641) or (B41, S.N. 173642— ) T08A
BLU

6 Hydrostatic Pressure Sensors Right and Left (B5 and B6, S.N. —173658) or (B43 and B44, S.N. T10A
173659— ) BLU

7 Brake Pressure Sensor (B35, S.N. —173641) or (B42, S.N. 173642— ) T12A
BLU

8 Blade Angle Switch (S4) T14A

BLU

9 Engine Speed Control (R10) T15A

BLU

10 FNR Sensor (B32) T28A

BLU

861
 Bussed Sensor Connectors (X6 and X7) Diagnostics

Bussed Sensor 5 V Connector (X6)

Pin Sensor () Wire

11 Steer Sensor (B33) T29A

BLU

12 Transmission Speed Control Switch (B34) T30A

BLU

-: Bussed Sensor Ground Connector (X7)

Bussed Sensor Ground Connector (X7)

Pin Sensor () Wire

1 TCU Ground R01A

BLU

2 Decelerator Sensor (B1) R02A

BLK

3 Motor Speed Sensor Left (B2) R03B

BLK

4 Motor Speed Sensor Right (B3) R04B

BLK

5 Hydrostatic Charge Pressure Sensor (B4, S.N. —173641) or (B41, S.N. 173642— ) R05B
BLK

6 Hydrostatic Pressure Sensors Right and Left (B5 and B6, S.N. —173658) or (B43 and B44, S.N. R06B
173659— ) BLK

7 Brake Pressure Sensor (B35, S.N. —173641) or (B42, S.N. 173642— ) R07B
BLK

8 Engine Speed Control (R10) R08A

BLK

9 Blade Angle Switch (S4) R09A

BLK

10 Transmission Speed Control Switch (B34) R21A

BLK

11 FNR Sensor (B32) R22A

BLK

12 Steer Sensor (B33) R23A

BLK

Use these procedures to check the sensor circuits connected to the bussed sensor connectors (X6 and X7).

Resistance Check

Use this procedure for diagnostic trouble code (DTC) 620.04—TCU 5V Supply Open or Short.

1. Disconnect bussed connectors from X6 (blue wires) and X7 (black wires).

2. NOTE:

When checking, use the multimeter positive

862 red lead with X6 (blue wires) and the black
 Bussed Sensor Connectors (X6 and X7) Diagnostics
When checking, use the multimeter positive red lead with X6 (blue wires) and the black
ground lead with X7 (black wires). If reversed, checks will show open if there is a diode
in the circuit.

Set multimeter to check resistance and check each circuit between the X6 and X7 connectors for a
short. See tables for correct pins to check.

3. NOTE:

Resistance will vary depending on length of wire and type of sensor used.

There should be resistance on all the circuits. A shorted circuit will be below 1 ohm resistance.

4. If low resistance is found, unplug the sensor for that circuit.

5. Install bussed connector for X6 (blue wires) and start the machine.

6. Check for diagnostic trouble codes (DTCs).

7. If DTC for sensor voltage 620.04 is no longer active, sensor for that circuit is shorted.

8. If DTC for sensor voltage 620.04 is still active, check wiring to sensor for a shorted circuit.

Voltage Check

Use this procedure for diagnostic trouble code (DTC) 620.03—TCU 5V Supply Short to Power.

1. Disconnect bussed connectors from X6 (blue wires) and X7 (black wires).

2. Turn key switch to ON position.

3. NOTE:

When checking, use the multimeter positive red lead with X6 (blue wires) and the black
ground lead with X7 (black wires).

Set multimeter to check voltage and check each circuit between the X6 and X7 connectors for a short to
power. See tables for correct pins to check.

4. A circuit shorted to power will have voltage.

5. If a circuit is found to have voltage, determine location of short to power and repair or replace wire
harness to correct.

Go to Section_9015:Group_20

JW40272,00004ED-19-20091023

863
 Replace WEATHER PACK™ Connector

Replace WEATHER PACK™ Connector

TS0128-UN: Terminal Contact

IMPORTANT:

Identify wire color locations with connector terminal letters.

1. Open connector body.

2. Insert JDG364 Extraction Tool over terminal contact in connector body.

3. Hold extractor tool fully seated and pull wire from connector body.

NOTE:

If terminal cannot be removed, insert wire or nail through extractor tool handle and push
terminal contact from connector.

4. IMPORTANT:

TS0130-UN: Connector Body

Carefully spread contact lances to assure good seating on connector body.

NOTE:

Connector bodies are "keyed" for proper contact mating. Be sure contacts are in proper
alignment.

Push contact into new connector body until fully seated.

5. Pull on wire slightly to be certain contact is locked in place.

6. Transfer remaining wires to correct terminal in new connector.

7. Close connector body.

864
Replace WEATHER PACK™ Connector

Go to Section_9015:Group_20

DX,ECONN,O-19-19941103

865
 Install Weather Pack™ Contact

Install Weather Pack™ Contact

TS0136-UN: Weather Pack™ Contact

TS1623-UN: Strip Insulation

NOTE:

Cable seals are color coded for three sizes of wire:

Green - 18 to 20 gauge wire

Gray - 14 to 16 gauge wire
Blue - 10 to 12 gauge wire

1. Slip correct size cable seal on wire.

2. Strip insulation from wire to expose 6 mm (1/4 in.) and align cable seal with edge of insulation.

3. NOTE:

Contacts have numbered identification for two sizes of wire: a) #15 for 14 to 16 gauge
wire b) #19 for 18 to 20 gauge wire

Put proper size contact on wire and crimp in place with a "W" type crimp, using JDG783 Crimping Tool.

4. IMPORTANT:

866
 Install Weather Pack™ Contact

TS0139-UN: Contact Installation

LEGEND:
A - Sleeve
B - Pin

Proper contact installation for sleeve (A) and pin” (B) is shown.

Secure cable seal to contact as shown, using JDG783 Crimping Tool.

Go to Section_9015:Group_20

DX,ECONN,AA-19-20180129

867
 Replace DEUTSCH™ Connectors

Replace DEUTSCH™ Connectors

TS0124-UN: Extractor Tool

TS120-UN: Slide Extractor Tool

1. Select correct size extractor tool for size of wire to be removed:

JDG361 Extractor Tool for 12 to 14 gauge wire.

JDG362 Extractor Tool for 16 to 18 gauge wire.
JDG363 Extractor Tool for 20 gauge wire.

2. Start correct size extractor tool over wire at handle (A).

3. Slide extractor tool rearward along wire until tool tip snaps onto wire.

4. IMPORTANT:

Do NOT twist tool when inserting in connector.

Slide extractor tool along wire into connector body until it is positioned over terminal contact.

5. Pull wire out of connector body, using extractor tool.

6. IMPORTANT:

Install contact in proper location using correct size grommet.

868
 Replace DEUTSCH™ Connectors
TS122-UN: Push Contact
Push contact straight into connector body until positive stop is felt.

7. Pull on wire slightly to be certain contact is locked in place.

8. Transfer remaining wires to correct terminal in new connector.

Go to Section_9015:Group_20

DX,ECONN,J-19-19941103

869
 Replace DEUTSCH™ Rectangular or Triangular Connectors

Replace DEUTSCH™ Rectangular or Triangular Connectors

1. NOTE:

Connector shown is the female half or a 4-pin square connector. Other similar styles of
Deutsch connectors can be serviced using the same procedure.

T130688B-UN: Removing Locking Wedge

LEGEND:
1 - Connector
2 - Locking Wedge

Pull connector (1) apart. Inspect and clean connector seal and contacts.

2. Remove locking wedge (2) from connector using hook on JDG1383 service tool.

3.

T130689B-UN: Releasing Primary Latch

870
 Replace DEUTSCH™ Rectangular or Triangular Connectors

T130690B-UN: Removing Wire

LEGEND:
3 - Primary Locking Latches

Release primary locking latch (3) next to the pin to be removed using screwdriver on JDG1383 service
tool.

4. Gently pull wire out from back of connector.

5. Replace connector contact as necessary.

6. Install wire terminal back into connector until it clicks into place.

7. NOTE:

Locking wedge in 2-pin connector is not symmetrical. Position latch shoulder next to
terminals.

Install locking wedge until it snaps into place.

Go to Section_9015:Group_20

LW86157,00003B9-19-20080205

871
 Install DEUTSCH™ Contact

Install DEUTSCH™ Contact

TS117-UN: Crimper

1. Strip 6 mm (1/4 in.) insulation from wire.

2. Adjust selector (A) on JDG360 Crimper for correct wire size.

3. Loosen lock nut (B) and turn adjusting screw (C) in until it stops.

4. IMPORTANT:

Select proper size contact "sleeve" or "pin" to fit connector body.

TS0134-UN: Adjusting Screw

Insert contact (A) and turn adjusting screw (D) until contact is flush with cover (B).

5. Tighten lock nut (C).

6. IMPORTANT:

Contact must remain centered between indentors while crimping.

TS118-UN: Crimp
Insert wire in contact and crimp until handle touches stop.
872
 Install DEUTSCH™ Contact
7. Release handle and remove contact.

8. IMPORTANT:

If all wire strands are not crimped into contact, cut off wire at contact and repeat contact installation
procedures.

NOTE:

Readjust crimping tool for each crimping procedure.

TS0135-UN: Inspect Contact

Inspect contact to be certain all wires are in crimped barrel.

Go to Section_9015:Group_20

DX,ECONN,W-19-19900604

873
 Repair 32 and 48 Way CINCH™ Connectors

Repair 32 and 48 Way CINCH™ Connectors

1.

RXA0070459-UN: CINCH™ Connector

RXA0070462-UN: CINCH Cover Lock Tabs

RXA0070463-UN: CINCH Cover

LEGEND:
A - Tab
B - Locking Cam
C - Cover Locks
D - Cover

Push tab (A) and rotate locking cam (B) 90° to disconnect connector from flexbox.

2. Move cover locks (C) slightly outward with a small screwdriver.

3. Remove cover (D) away from wires.

874
 Repair 32 and 48 Way CINCH™ Connectors
4.

RXA0070464-UN: Terminal Lock

LEGEND:
A - Terminal Lock

Pull terminal lock (A) out until it stops. Do not force its removal.

5. NOTE:

JDG1725 terminal extractor tool has two different sizes of pins: 0.6 for smaller 20 gauge
holes (A) and 1.5 for larger 16 and 18 gauge holes (B).

RXA0070471-UN: Connector Holes

RXA0070472-UN: CINCH Connector Terminal Holes

875
 Repair 32 and 48 Way CINCH™ Connectors

RXA0070473-UN: CINCH Terminal Extraction Tool

LEGEND:
A - 20 Gauge Holes
B - 16 and 18 Gauge Holes
C - Holes
D - Terminal Hole
E - Terminal

Insert JDG1725 Terminal Extractor Toolinto holes (C) next to terminal opening (D) to unlock terminal.

6. Pull wire and terminal (E) from connector body.

7.

RXA0070479-UN: Crimp Terminal

RXA0070480-UN: CINCH Terminal Crimping Tool

876
 Repair 32 and 48 Way CINCH™ Connectors

RXA0070481-UN: Terminal Crimping Tool

LEGEND:
A - CINCH Terminal Crimping Tool
B - Terminal Receptacle
C - Terminal
D - Wire

Remove old terminal and strip 4.85 mm (0.191 in.) of insulation from wire.

8. Firmly grip JDG1727 terminal crimping tool (A). Squeeze ratcheting mechanism until it bottoms out, then
allow it to open completely.

9. With tool in ready position (open handle), open terminal receptacle (B).

10. Insert terminal (C) into correct wire gauge window so crimp wings are facing up.

11. Close terminal receptacle (B).

12. Squeeze handle until two clicks are heard.

13. Insert stripped wire (D) into terminal.

14. Hold wire stationary and squeeze tool together until ratchet releases.

15. Remove terminated wire from tool.

16. Push terminal into connector body until fully seated. Pull on wire slightly to ensure terminal is locked in
position.

17. Push terminal lock closed.

18. Install cover.

19. Install connector to controller and close connector body locking cam.

Go to Section_9015:Group_20

OUO1010,00009D5-19-20070209

877
 Replace (Pull Type) Metri-Pack™ Connectors

Replace (Pull Type) Metri-Pack™ Connectors

RW16933-UN: Connector

RW16934-UN: Socket

RW16935-UN: Terminals
LEGEND:
A - Connector
B - “T” Pin
C - Body Socket
D - Locking Tab
E - Push Terminal

Disconnect the Metri-Pack [Metri-Pack is a trademark of Packard Electric] connector (A). Remove tie bands and
tape.

Insert a “T” pin (B) 6.4 mm (1/4 in.) into connector body socket (C).

NOTE:

Use JDG777 [Included in JT07195A Electrical Repair Kit] Terminal Extraction Tool or “T” pin to
remove terminals.

Angle “T” pin so pin tip slides close to the plastic socket edge pushing terminal locking tab (D) inward.

Remove “T” pin and push terminal (E) out of socket.

878
 Replace (Pull Type) Metri-Pack™ Connectors
Remove terminal, cut strip and crimp wire through connector.

Check to make sure locking tab on new terminal is in outward position, then pull on wire until terminal locks in
connector body socket.

NOTE:

Terminal will seat only one way. If terminal does not pull into the connector body socket, check to
make sure terminal is aligned correctly.

Go to Section_9015:Group_20

LW86157,00003B5-19-20080208

879
 Replace (Push Type) Metri-Pack™ Connectors

Replace (Push Type) Metri-Pack™ Connectors

RW21325-UN: Push Type Connector

LEGEND:
A - Connector Lock
B - Extraction Tool JDG777
C - Connector Body Socket
D - Terminal
E - Locking Tab

Disconnect the Metri-Pack [Metri-Pack is a trademark of Packard Electric] connector. Remove the tie bands and
tape.

Remove the connector lock (A), and mark wire colors for identification.

Identify wire color locations with connector terminal letters.

Insert JDG776 or JDG777 [Included in JT07195A Electrical Repair Kit] Terminal Extraction Tool (B) into connector
body socket (C) pushing the terminal locking tab inward.

NOTE:

Use JDG776 Extraction Tool with 56, 280 and 630 series METRI-PACK terminals. Use JDG777
Extraction Tool with 150 series METRI-PACK terminals.

Remove extraction tool and pull terminal (D) out of the socket.

Replace terminal. Make sure locking tab (E) on the new terminal is in the outward position.

Push terminal into connector body socket until terminal locks.

Go to Section_9015:Group_20

LW86157,00003B6-19-20080208

880
 Table of Contents

Section 9025: Hydraulics

Group 05: Theory

Hydraulic System Operation

Hydraulic Pump Operation

Hydraulic Control Valve Operation

Hydraulic Control Valve Operation—IGC

Load Sense Circuit Operation

Load Sense Isolator Operation

Circuit Relief Valve with Anticavitation Operation

Hydraulic System Relief Valve Operation

Hydraulic Oil Filter Manifold Operation

Blade Angle Operation

Ripper Operation

Ripper Operation—IGC

Hydraulic Cylinder Operation

Quick-Drop Valve Operation

Group 15: Diagnostic Information

Hydraulic System Schematic

Hydraulic System Schematic—IGC

Main Hydraulic Component Location

Ripper Ready Hydraulic Component Location

Winch Ready Hydraulic Component Location

Main Hydraulic Component Location—IGC

Ripper Hydraulic Component Location—IGC

Hydraulic System Diagnose Malfunctions

Hydraulic System Diagnose Malfunctions—IGC

Group 25: Tests

JT02156A Digital Pressure/Temperature Analyzer Installation

Ultra Clean® Hand Launcher

Hydraulic Oil Cleanup Procedure

Hydraulic System Relief Valve Test

Hydraulic System Relief Valve Test—IGC

881
 Table of Contents
Circuit Relief Valve Test

Circuit Relief Valve Test—IGC

Pump Load Sense Differential and System Pressure (Pump Cut-Off) Test and Adjustment

Pump Load Sense Differential and System Pressure Test and Adjustment—IGC

Lift and Tilt Cylinder Function Drift Test

Cylinder Leakage Test

Pressure Reducing Valve Pressure Test and Adjustment

Blade Down Accumulator Hydraulic Discharge

Blade Down Accumulator Precharge Test

Hydraulic Pump Flow Test

Hydraulic Pump Case Drain Test

882
 Hydraulic System Operation

Hydraulic System Operation

NOTE:

See Hydraulic System Schematic . (Group 9025-15.)

All hydraulic functions are incorporated into one system utilizing a single axial piston pump.

This machine has a closed-center, load sensing hydraulic system. A variable displacement, axial piston pump
supplies oil to hydraulic functions.

Upon initial startup, the hydraulic pump reaches low standby pressure until a function is activated. Standby
pressure oil is equally supplied to the control valve inlet section and the pressure reducing valve. Standby
pressure oil is converted to load sense (LS) pressure oil when a function is activated and valve spool shifted.

Pump will go into stroke and deliver highest workport pressure required from an activated function when LS signal
is received from that function. Total pump pressure will be equal to the highest work port pressure sensed in the
system plus the load sense differential pressure.

The entire hydraulic system is protected from pressure spikes by the system relief valve, located in the inlet
section of the control valve. On Power Angle Tilt (PAT) machines, circuit relief valves protect the blade angle
circuit. On Outside Dozers (OSD), a circuit relief valve protects the blade lift circuit.

Return oil flows through the return line into the filter to the reservoir. The return filter has a bypass valve and a
filter restriction indicator switch.

The load sensing hydraulic system on this machine improves fuel economy and reduces heat buildup by not
wasting horsepower on unused excessive pump output.

Go to Section_9025:Group_05

BR81691,0000064-19-20040910

883
 Hydraulic System Operation

Hydraulic System Operation

NOTE:

See Hydraulic System Schematic . (Group 9025-15.)

All hydraulic functions are incorporated into one system utilizing a single axial piston pump.

This machine has a closed-center, load sensing hydraulic system. A variable displacement, axial piston pump
supplies oil to hydraulic functions.

Upon initial startup, the hydraulic pump reaches low standby pressure until a function is activated. Standby
pressure oil is equally supplied to the control valve inlet section and the pressure reducing valve. Standby
pressure oil is converted to load sense (LS) pressure oil when a function is activated and valve spool shifted.

Pump will go into stroke and deliver highest workport pressure required from an activated function when LS signal
is received from that function. Total pump pressure will be equal to the highest work port pressure sensed in the
system plus the load sense differential pressure.

The entire hydraulic system is protected from pressure spikes by the system relief valve, located in the inlet
section of the control valve. On Power Angle Tilt (PAT) machines, circuit relief valves protect the blade angle
circuit. On Outside Dozers (OSD), a circuit relief valve protects the blade lift circuit.

Return oil flows through the return line into the filter to the reservoir. The return filter has a bypass valve and a
filter restriction indicator switch.

The load sensing hydraulic system on this machine improves fuel economy and reduces heat buildup by not
wasting horsepower on unused excessive pump output.

Go to Section_9025:Group_05

BR81691,0000064-19-20040910

884
 Hydraulic Pump Operation

Hydraulic Pump Operation

T202385-UN: Hydraulic Pump Component Location

LEGEND:
104 - Hydraulic Pump
109 - Pressure Reducing Valve
129 - Control Valve-to-Pressure Reducing Valve Hose
130 - Hydraulic Reservoir-to-Hydraulic Pump Inlet Hose
131 - Load Sense Hose
132 - Hydraulic Pump-to-Control Valve Inlet Hose
199 - Hydraulic Pump Case Drain Hose
200 - Control Valve-to-Hydraulic Filter Hose
201 - Pressure Reducing Valve-to-Hydraulic Reservoir Return Hose

885
 Hydraulic Pump Operation

T204409-UN: Hydraulic Pump Cross Section

LEGEND:
104 - Hydraulic Pump
131 - Load Sense Isolator-to-Hydraulic Pump
132 - Hydraulic Pump-to-Control Valve Inlet
169 - Pump Drive Shaft
170 - Rotating Group
171 - Bias Piston
172 - Bias Piston Spring
173 - Displacement Piston
174 - Swash Plate
175 - Roller Bearing
176 - Cut-off Spring
177 - High Pressure Cut-Off Adjustment Screw
178 - Load Sense Differential Pressure Adjustment Screw
179 - Load Sense Spring
180 - Load Sense Spool
181 - High Pressure Cut-Off Spool

886
 Hydraulic Pump Operation

T210372-UN: Hydraulic Pump Schematic

LEGEND:
104 - Hydraulic Pump
131 - Load Sense Isolator-to-Hydraulic Pump
132 - Hydraulic Pump-to-Control Valve Inlet
169 - Pump Drive Shaft
170 - Rotating Group
171 - Bias Piston
172 - Bias Piston Spring
173 - Displacement Piston
174 - Swash Plate
175 - Roller Bearing
176 - Cut-off Spring
177 - High Pressure Cut-Off Adjustment Screw
178 - Load Sense Differential Pressure Adjustment Screw
179 - Load Sense Spring
180 - Load Sense Spool
181 - High Pressure Cut-Off Spool

The hydraulic pump is an axial piston variable displacement pump. The pump is mounted to and driven by the
rear hydrostatic pump. The hydraulic system is a closed-center load sensing system. Load sense (LS) pressure is
always equal to the highest work port pressure created by an activated function.

When a function is activated, an LS signal is sent to the pump control valve. This pressure in addition to spring

887
 Hydraulic Pump Operation
force cause LS spool (180) to shift making a connection between the displacement piston and case return. This
connection vents displacement piston oil to return allowing the displacement piston to shift as the bias spring and
piston force the pump onto stroke. The pump will come onto stroke until demanded pressure settings are
achieved.

The pump has two pistons: bias piston (171) and displacement piston (173). With engine off, spring force acting
on bias piston holds the pump at maximum displacement. As the engine is started, transmission begins to rotate
turning pump drive shaft (169). Pump outlet pressure acts against the head end of load sense spool (180) and
high pressure cut-off spool (181). When pump outlet pressure is great enough to overcome the LS spring (179)
and cut-off spring (176) pressure, the spools shift making a connection to the displacement piston (173) and
allowing oil into displacement piston (173). The displacement piston then shifts to rotate swash plate (174) to
minimum displacement, allowing a small amount of displacement for internal leakage. This condition is known as
low pressure standby.

Go to Section_9025:Group_05

BR81691,0000009-19-20050106

888
 Hydraulic Control Valve Operation

Hydraulic Control Valve Operation

TX1036390-UN: Hydraulic Control Valve (optional auxiliary section shown)

LEGEND:
1 - Outlet Section
2 - Blade Angle Section
3 - Blade Tilt Section
4 - Blade Lift Section
5 - Auxiliary Section (Optional)
6 - Inlet Section
7 - System Relief Valve
8 - Blade Angle Circuit Relief Valve (2 used)

The control valve inlet section (6) contains the system relief valve (7). See Hydraulic System Relief Valve
Operation . (Group 9025-05.) The blade lift section (4) is a four-position, five-way, spool-type valve containing a
load check valve. The valve spool is returned to neutral by a centering spring in the spool end cap. When a
function is activated, oil flows from the parallel passage, past the load check, spool, and out the workport to the
cylinders. Return oil from the cylinders flows into the other workport, past the spool, into the return passage, and
out of the outlet section (1) of the control valve to the hydraulic reservoir. When the spool is moved to the blade
float position, both workports are open to the return passage, allowing oil to flow in and out both ends of the
cylinders. The blade float function uses an electromagnetic detent. When the hydraulic control lever is moved
forward to the float position, a plate connected to the control lever is held downward by the electromagnet with
enough force to hold the control lever in the float position, but it can be manually disengaged by pulling back on
the hydraulic control lever. When the hydraulic control lever is in float position , it sends full pilot pressure to the lift
spool.

The blade tilt section (3) is a three-position, five-way valve. The blade angle section (2) is a three-position, five-

889
 Hydraulic Control Valve Operation
way valve that contains two circuit relief valves (8) with anticavitation check valves. See Circuit Relief Valve with
Anticavitation Operation . (Group 9025-05.) Both the blade tilt and blade angle sections contain a load check
valve. The valve spools are returned to neutral by a centering spring in the spool end cap. When a function is
activated, oil flows from the parallel passage, past the load check, spool, and out the workport to the cylinder.
Return oil from the cylinder flows into the other workport, past the spool, into the return oil passage, and out the
control valve to the hydraulic reservoir. The spools have grooves that meter oil through the valve to allow for
smooth starts and stops.

See Main Hydraulic Component Location—IGC (Group 9025-15.) for hydraulic control valve location.

Go to Section_9025:Group_05

TX,9025,BS429-19-20120425

890
 Hydraulic Control Valve Operation—IGC

Hydraulic Control Valve Operation—IGC

TX1036418-UN: Hydraulic Control Valve—IGC

LEGEND:
213 - Auxiliary Section Actuator
214 - Blade Angle Section Actuator
215 - Blade Tilt Section Actuator
216 - Blade Lift Section Actuator
222 - End Section
223 - Blade Lift Section
224 - Blade Tilt Section
225 - Blade Angle Section
227 - Auxiliary Section
228 - Inlet/Outlet Section

The hydraulic control valve is designed to be used with the optional Integrated Grade Control (IGC). See
Hydraulic System Schematic—IGC and see Main Hydraulic Component Location—IGC and see Integrated Grade
Control (IGC) Theory of Operation—If Equipped (Group 9015-15).

The control valve is a closed-center, load sense proportional type valve with electrical actuation. The control valve
is sectionalized and is composed of the inlet/outlet section (228), auxiliary section (227), blade lift section (223),
blade tilt section (224), blade angle section (225), and end section (222).

Supply oil from the pump enters the control valve port P. The internal passage P routes supply oil to each function
spool, the system relief valve, the pressure reducing valve, and the function actuators. The pressure reducing
valve regulates the pressure of the supply oil to the actuators.

891
 Hydraulic Control Valve Operation—IGC
When a function is actuated, oil flows through the function spool and is routed to the end of the compensator
valve. The oil pressure shifts the spool, allowing supply oil to flow through the LS shuttle valve to the LS signal
circuit. At the same time, supply oil is routed back through the function spool to the work port, where it is routed to
the cylinder.

Return oil from the cylinder is routed back through the function spool and out of the control valve port T, where it is
routed through the hydraulic oil filter and then to the reservoir.

The LS signal circuit controls pump flow by sending an LS signal to the pump regulator. The pump will only supply
the amount of oil required by a work port or a combination of work port functions.

The electrohydraulic blade function actuators are controlled by a signal from the EHC. See Integrated Grade
Control (IGC) Theory of Operation—If Equipped . (Group 9015-15.) The actuators control the function spools by
varying the flow of oil to and from the ends of the spool. In this way precise placement of the spool is
accomplished.

Inlet/Outlet Section— contains the valve inlet port P, the valve outlet port T, and the outlet port TO, which routes
oil to the end section port LX to be used as makeup oil for the load sense (LS) circuit, with the remainder of the oil
going to the reservoir.

TX1036859-UN: Blade Lift Section—Blade Lower

LEGEND:
155 - Supply Oil
156 - Load Sense Oil
157 - Regulated Supply Oil
159 - Return Oil
216 - Blade Lift Actuator
217 - Anticavitation Valve
223 - Blade Lift Section
226 - Compensator Valve

Blade Lift Section— contains a four position valve spool with a blade float position, an LS shuttle valve (not
shown), a compensator valve (226), a blade lower anticavitation valve (217), and a proportional PVEH blade lift
actuator (216).
892
 Hydraulic Control Valve Operation—IGC

TX1011018-UN: Blade Tilt Section—Blade Tilt Right

LEGEND:
155 - Supply Oil
156 - Load Sense Oil
157 - Regulated Supply Oil
159 - Return Oil
215 - Blade Tilt Actuator
224 - Blade Tilt Section
226 - Compensator Valve

Blade Tilt Section— contains a three position valve spool, an LS shuttle valve (not shown), a compensator valve
(226), and a proportional PVEH blade tilt actuator (215).

893
 Hydraulic Control Valve Operation—IGC

TX1036858-UN: Blade Angle Section

LEGEND:
155 - Supply Oil
156 - Load Sense Oil
157 - Regulated Supply Oil
159 - Return Oil
214 - Blade Angle Actuator
217 - Anticavitation Valve (2 used)
218 - Circuit Relief Valve (2 used)
225 - Blade Angle Section
226 - Compensator Valve

Blade Angle Section— contain a three position valve spool, an LS shuttle valve (not shown), a compensator
valve (226), two circuit relief valves (218), two anticavitation valves (217), and an on/off PVEO blade angle
actuator (214).

TX1036857-UN: Auxiliary Section

LEGEND:
155 - Supply Oil
156 - Load Sense Oil
157 - Regulated Supply Oil
159 - Return Oil
213 - Auxiliary Actuator
217 - Anticavitation Valve (2 used)
218 - Auxiliary Circuit Relief Valve (2 used)
227 - Auxiliary Section
226 - Compensator Valve

Auxiliary Section— contains a three position valve spool, an LS shuttle valve (not shown), a compensator valve
(226), two circuit relief valves (218), two anti-cavitation valves (217), and a proportional PVEH actuator (213).

894
 Hydraulic Control Valve Operation—IGC

TX1011021-UN: End Section

LEGEND:
155 - Supply Oil
156 - Load Sense Oil
157 - Regulated Supply Oil
159 - Return Oil
219 - Load Sense Relief Valve
220 - Pressure Reducing Valve
221 - System Relief Valve
222 - End Section

End Section— contains a system relief valve (221), a pressure reducing valve (220), and an adjustable LS relief
valve (219).

Go to Section_9025:Group_05

OUO1020,000158A-19-20080214

895
 Load Sense Circuit Operation

Load Sense Circuit Operation

Load Sense (LS) hydraulic systems provide flow on demand. When the valve spools are all in neutral positions,
then the hydraulic pump is in neutral as well. When the hydraulic pump is in neutral, it outputs differential standby
pressure. See Pump Load Sense Differential and System Pressure (Pump Cut-Off) Test and Adjustment . (Group
9025-25.)

Each hydraulic function has an LS shuttle check valve. The purpose of the LS shuttle is to compare LS signals
from each function and direct the highest work port pressure to the LS isolator valve, located in the outlet section
of the control valve, to the hydraulic pump. See Load Sense Isolator Operation . (Group 9025-05.) When the
hydraulic pump senses work port pressure, it goes onto stroke producing the highest work port pressure needed
plus differential standby pressure.

The LS circuit port is located on the outlet section of the control valve. This port allows additional hydraulic
functions, such as a winch, to be added into the LS circuit. This is accomplished by adding a LS shuttle valve in
the LS circuit. See Hydraulic System Schematic . (Group 9025-15.)

Go to Section_9025:Group_05

AA95132,0000385-19-20100621

896
 Load Sense Isolator Operation

Load Sense Isolator Operation

TX1021609-UN: Load Sense Isolator

LEGEND:
155 - Low Pressure Oil
156 - Load Sense Pressure Oil
159 - Return Oil
160 - Input from Valve Load Sensing Network
161 - Supply from Pump
162 - Load Sense Output (to compensators and pump load sense input)
163 - Return Passage
164 - Damping Orifice
165 - Pilot Passage
166 - Orifice
167 - Spring
168 - Spool

The load sense (LS) isolator senses the control valve’s highest bridge pressure which indicates the greatest load
at a work port. The isolator then shifts to allow an equal pressure to flow to the pump load sense control valve.
When all control valve spools are in neutral, the highest work port pressure at isolator input (160) is equal to
return pressure. Pump output pressure is transmitted to LS isolator through port (161) and out through port (162).
The pump provides its own constant source of oil through the isolator to keep the hose between the load sense
output port of the control valve and the port on the load sense control valve filled with oil. When load sense
pressure changes, the new pressure is transmitted to the load sense port without the need to first fill the hose with
oil, and performance lag is eliminated.

Go to Section_9025:Group_05

TX,9025,RR7541-19-20070712

897
 Circuit Relief Valve with Anticavitation Operation

Circuit Relief Valve with Anticavitation Operation

T204503-UN: Circuit Relief with Anitcavitation

LEGEND:
156 - Pressure Oil
159 - Return Oil
188 - Piston
189 - Main Poppet
190 - Anticavitation Poppet
191 - Anticavitation Spring
192 - Main Spring
193 - Pilot Poppet
194 - Pilot Spring
195 - Orifice
196 - Cavity
197 - Relief Body

The relief valve is used in the blade angle, lift, and ripper lift circuits. The relief is a pilot operated, screw
adjustable, with anticavitation operation.

The relief valve setting is controlled by the pilot spring (194) holding the pilot poppet (193) on its seat. The setting
is adjustable. Loosening lock nut and screwing adjustment cap in will increase pressure setting.

In normal operation, pressure oil less than relief valve setting flows though orifice (195) in piston (188) into cavity
(196) behind the anticavitation poppet (190) and main relief valve poppet (189). This oil pressure and the springs
hold the main poppet (189) and anticavitation poppet (190) closed because the effective areas of the poppets on
the cavity side is greater than the work port side.

In relief operation, pressure oil overcomes the pilot poppet (193) and oil flows from the pressurized port through
orifice (195) into cavity (196) past pilot poppet (193) to tank through a path between relief body (197) and
anticavitation poppet (190). The pressure drop through orifice (195) causes a pressure difference across piston
(188) and it moves against main spring (192) until it rests on pilot poppet (193). This movement shuts off orifice
(195) and further reduces the pressure in cavity (196). When the pressure difference is large enough to overcome
the differential area effect holding the main poppet (189) on its seat and oil is allowed to flow from the work port to
the return port.

898
 Circuit Relief Valve with Anticavitation Operation
During anticavitation operation, the pressure in the work port and cavity (196) is less than the pressure in the
return port. This pressure difference overcomes the differential area effect holding the anticavitation poppet (190)
on it’s seat and oil is allowed to flow from return port to work port to prevent cavitation.

Go to Section_9025:Group_05

TX03768,0000B03-19-20051025

899
 Hydraulic System Relief Valve Operation

Hydraulic System Relief Valve Operation

T204514-UN: System Relief Valve Operation

LEGEND:
156 - Pressure Oil
159 - Return Oil
198 - Main Poppet

This metal-to-metal seal relief is used on the inlet of the load sensing control valve.

This relief valve is direct acting, screw adjustable, and does not have anticavitation operation.

The pressure set point is adjustable by turning the adjustment screw at the end of the relief. Turning the screw in
increases the pressure setting.

In relief operation, pressure oil overcomes main poppet (198) and oil flows from the pressurized port to tank.

Go to Section_9025:Group_05

BT40170,0000040-19-20041027

900
 Hydraulic Oil Filter Manifold Operation

Hydraulic Oil Filter Manifold Operation

T202635-UN: Hydraulic Oil Filter Manifold Operation

LEGEND:
106 - Oil Filter Element
107 - Oil Filter Head
114 - Hydraulic Reservoir
134 - Control Valve-to-Filter Head Inlet Hose

901
 Hydraulic Oil Filter Manifold Operation

T203022-UN: Hydraulic Oil Filter

LEGEND:
106 - Oil Filter Element
141 - Oil Filter Restriction Indicator Switch
142 - Diagnostic Port
143 - Inlet Port
144 - Outlet Port
145 - Hydraulic Oil Filter Bypass Valve

The hydraulic oil filter manifold contains the hydraulic oil filter element (106), hydraulic oil filter restriction indicator
switch (141) and hydraulic oil filter bypass valve (145). Hydraulic oil enters through the inlet port (143) elbow
fitting. Oil is directed into the head assembly toward the filter bypass valve where it flows into the spin-on filter
assembly. Oil continues to flow through the filter element from an outside-to-inside path. Oil then flows back into
the filter head and through the outlet port fitting (144) to the reservoir.

Diagnostic port (142) can be used to collect oil samples or to obtain pressure readings on the upstream side of
the filter element.

Filter bypass valve (145) function is used to protect the filter element from excessive pressure drop and from
pressure differential between the clean side and dirty side of the filter element. High pressure drop can cause the
filter element to have a structural failure. High pressure drop conditions can occur from cold start high viscosity
oil, contamination build up in the filter element, or high flow surge conditions. The bypass valve will open under
these conditions allowing some fluid to bypass the filter element. Fluid flowing through the bypass is not filtered.

There is a filter restriction indicator switch (141) that monitors pressure drop across the filter element. If the
pressure drop attains the setting of the electrical indicator it will activate a light on the monitor warning the
machine operator that the spin-on filter needs to be serviced. The filter restriction indicator switch is set at a point
just lower than the bypass valve setting allowing the operator time to change the spin-on filter prior to the bypass
valve opening due to contamination build up in the filter element.

Go to Section_9025:Group_05

BR81691,0000066-19-20041027

902
 Blade Angle Operation

Blade Angle Operation

T202384-UN: Blade Angle Operation

LEGEND:
102 - Angle Cylinder (2 used)
104 - Hydraulic Pump
105 - Hydraulic Control Valve
108 - Angle Solenoid Valve
109 - Pressure Reducing Valve
117 - Hydraulic Control Lever
118 - Blade Angle Switch
121 - Control Valve-to-Rod End of Right Angle Cylinder and Head End of Left Angle Cylinder Hose
122 - Control Valve-to-Head End of Right Angle Cylinder and Rod End of Left Angle Cylinder Hose

The blade angle circuit contains two proportional solenoid valves (108), a valve section, two circuit relief valves,
and two cylinders (102).

Pilot oil is sent from the pressure reducing valve (109), to the blade angle solenoid valves. The solenoid valves
are controlled by the blade angle switch (118) located on the hydraulic control lever. When the blade angle switch
is pressed, a signal is sent to the transmission control unit (TCU), where it is interpreted and sent to the blade
angle solenoid valves. The blade angle solenoid valves will shift allowing pilot oil to the blade angle valve section
shifting the spool.

903
 Blade Angle Operation

T203015-UN: Blade Angle Solenoid Valve

LEGEND:
135 - Solenoid Coil 1
136 - Solenoid Coil 2
137 - Port 1
138 - Port 2
139 - Port 3
140 - Port 4

The blade angle solenoid valve is a three way, three position, spool type, screw-in hydraulic cartridge valve. When
de-energized, the cartridge blocks flow to port 3 (139), while allowing flow from port 2 (138) to port 1 (137), and
from port 4 (140) to port 1 (137). When coil 1 (135) is energized, flow is allowed from port 3 (139) to port 4 (140),
and from port 2 (138) to port 1 (137). When coil 2 (136) is energized, flow is allowed from port 3 (139) to port 2
(138) and from port 4 (140) to port 1 (137).

904
 Blade Angle Operation

TX1074971-UN: Blade Angle Section Schematic

LEGEND:
102 - Angle Cylinder (2 used)
108 - Angle Solenoid Valve
120 - Circuit Relief (2 used)
149 - Blade Angle Section
155 - Low Pressure Oil
156 - Load Pressure Sense Oil
157 - Regulated Pressure Oil
158 - Trapped Oil
159 - Return Oil

The blade angle valve section is a three-position, four-way, spool type valve containing a load check. Pilot oil
shifts the valve spool sending pressure oil to the blade angle cylinders. The valve spool is returned to neutral by
centering springs in the spool end caps. There is one circuit relief for each angle direction, protecting the system
from excessive pressure.

Go to Section_9025:Group_05

BR81691,0000065-19-20120821

905
 Ripper Operation

Ripper Operation

T215999-UN: Ripper Operation

LEGEND:
105 - Hydraulic Control Valve
107 - Ripper Cylinder (2 Used)
119 - Auxiliary Pilot Controller

The ripper circuit contains a valve section, one circuit relief valve, and two cylinders (107).

When the auxiliary pilot controller (119) is pushed or pulled, pilot oil is sent from the auxiliary pilot controller, to the
hydraulic control valve (105) allowing pilot oil to the ripper lift valve section shifting the spool.

906
 Ripper Operation

TX1074975-UN: Ripper Section Schematic

LEGEND:
107 - Ripper Cylinders (2 used)
119 - Circuit Relief
146 - Ripper Section
154 - Anticavitation Valve
155 - Low Pressure Oil
156 - Load Pressure Sense Oil
157 - Regulated Pressure Oil
158 - Trapped Oil
159 - Return Oil

The ripper valve section (146) is a three-position, four-way, spool type valve containing a load check. Pilot oil
907
 Ripper Operation
shifts the valve spool sending pressure oil to the ripper cylinders (107). The valve spool is returned to neutral by
centering springs in the spool end caps. There is one circuit relief (119) used on the rod end side of the ripper
cylinders, protecting the system from excessive pressure.

Go to Section_9025:Group_05

MS12501,0000011-19-20120821

908
 Ripper Operation—IGC

Ripper Operation—IGC

TX1018326-UN: Auxiliary/Ripper Valve Schematic

LEGEND:
107 - Ripper Cylinder (2 used)
119 - Circuit Relief Valve (2 used)
146 - Auxiliary Valve Section
154 - Anticavitation Valve (2 used)
155 - Low Pressure Oil
156 - Load Sense Pressure Oil
157 - Pilot Pressure Oil
158 - Trapped Oil

909
 Ripper Operation—IGC
159 - Return Oil
226 - Compensator Valve
231 - Auxiliary Valve Actuator

The Integrated Grade Control (IGC) ripper circuit contains the auxiliary joystick, the electrohydraulic controller
(EHC), the IGC hydraulic control valve, and two ripper cylinders.

When the auxiliary joystick is pushed or pulled, a signal is sent from the joystick to the EHC. The EHC processes
the signal and sends a command to the proportional PVEH auxiliary valve actuator (231). The actuator then sends
pilot pressure oil (157) to the ends of the auxiliary valve spool to precisely position the spool.

For complete auxiliary valve information, see Hydraulic Control Valve Operation—IGC . (Group 9025-05.)

Go to Section_9025:Group_05

OUO1020,000161C-19-20120821

910
 Hydraulic Cylinder Operation

Hydraulic Cylinder Operation

TX1210801-UN: Outside Dozer (OSD) Lift Cylinder Component Location

LEGEND:
1 - Piston
2 - Check Valve Ball (4 used)
3 - Check Valve Spring (2 used)
127 - Piston Bypass Valve (2 used)

The hydraulic cylinders transfer the hydraulic power from the main hydraulic pump as mechanical power to the
blade or optional ripper. The power demand (pressure build up in the hydraulic system) depends on the
resistance that the attachment encounters.

For outside dozer (OSD) machines, the two lift cylinders use pistons equipped with piston bypass valves (127).
Under pressure, the pressure side check valve balls (2) of the piston bypass valves open. However, oil flow is
blocked by the second set of check valve balls, which act in the opposite direction. If the pistons in the lift
cylinders reach an end position, then the second set of check valves, which had been blocked, are mechanically
opened. Pressurized oil flows via the piston bypass valves to the opposite side and system pressure no longer
increases.

Go to Section_9025:Group_05

KK70125,000010F-19-20160212

911
 Quick-Drop Valve Operation

Quick-Drop Valve Operation

T203418-UN: Quick-Drop Valve

LEGEND:
103 - Lift Cylinder (2 used)
104 - Hydraulic Pump
105 - Control Valve
115 - Quick-Drop Valve

The quick-drop valve (115) allows the operator to lower the blade to the ground very quickly. The high speed
blade drop allows for shedding of material from the mold board. The quick-drop valve also serves as an
anticavitation device. In quick-drop mode, return oil from the rod end of the lift cylinders is allowed to fill the head
end of the lift cylinders instead of returning to the reservoir. The cylinder velocity when the blade is falling is much
faster than the pump can provide flow for, so the head end of the cylinder will cavitate. Dumping rod end oil into
the head end helps eliminate this void.

The quick-drop valve is connected to the system between the blade lift cylinders and the hydraulic control valve.
The quick-drop valve operation is controlled by an electric switch activated by the position of the valve spool in the
hydraulic control valve.

During normal lift and lower operation of the dozer blade, the quick-drop solenoid actuation switch in the hydraulic
control valve is not activated and the quick-drop spool is in its normal spring biased position. In this mode the
quick-drop valve is nothing more than a tee fitting, connected to the hydraulic control valve, that splits the flow to
the two lift cylinders.

When raising the blade, oil is directed from the blade lift section of the control valve to the quick-drop valve. From
the quick-drop valve oil is directed to the rod end of both lift cylinders.

During blade float, oil is directed from the control valve through the quick-drop valve to the head end of both lift
cylinders. The solenoid valve shifts, blocking pilot oil to the pilot valve. Oil from the rod end of both lift cylinders is
directed to the quick-drop valve where oil applied pressure to the top of the pilot valve which overcomes the spring
force, shifting the spool. With the spool shifted, oil flows through the pilot valve and back out of the quick-drop
valve to the head end of the lift cylinders.

912
 Quick-Drop Valve Operation
For more information on lift cylinder and piston bypass valve operation, see Hydraulic Cylinder Operation . (Group
9025-05.)

Go to Section_9025:Group_05

TX,9025,BS442-19-20160212

913
 Hydraulic System Schematic

Hydraulic System Schematic

Hydraulic Schematic Power Angle Tilt (PAT)

TX1122076-UN: Hydraulic Schematic Power Angle Tilt (PAT)—Neutral

LEGEND:
101 - Tilt Cylinder
102 - Angle Cylinder (2 used)
103 - Lift Cylinder (2 used)
104 - Hydraulic Pump
105 - Control Valve
106 - Hydraulic Filter
108 - Angle Solenoid Valve
109 - Pressure Reducing Valve
114 - Hydraulic Reservoir
116 - Load Sense Isolator
117 - Pilot Controller
120 - Blade Angle Circuit Relief Valve (2 used)
146 - Inlet Valve Section
147 - Blade Lift Valve Section
148 - Blade Tilt Valve Section
149 - Blade Angle Valve Section
150 - Outlet Valve Section
151 - Hydraulic System Relief Valve
152 - Load Sense (LS) Shuttle Valve (3 used)
202 - Load Sense Remote Test Port
203 - Pump Remote Test Port
211 - Valve LS Circuit Port
602 - Low Pressure Oil
604 - Return Oil
606 - Trapped Oil

914
 Hydraulic System Schematic
609 - Pilot Pressure Oil
614 - Load Sense Pressure Oil
B23 - Hydraulic Oil Filter Restriction Switch
Y7 - Blade Angle Solenoid Left (top)
Y8 - Blade Angle Solenoid Right (bottom)
Y10 - Pilot Control Enable Solenoid

Hydraulic Schematic Outside Dozer (OSD)

TX1210802-UN: Hydraulic Schematic Outside Dozer (OSD)—Neutral

LEGEND:
101 - Tilt Cylinder
103 - Lift Cylinder (2 used)
104 - Hydraulic Pump
105 - Control Valve
106 - Hydraulic Filter
109 - Pressure Reducing Valve
114 - Hydraulic Reservoir
115 - Quick-Drop Valve
116 - Load Sense Isolator
117 - Pilot Controller
120 - Blade Lift Circuit Relief Valve (2 used)
127 - Piston Bypass Valve (4 used)
146 - Inlet Valve Section
147 - Blade Lift Valve Section
148 - Blade Tilt Valve Section
150 - Outlet Valve Section
151 - Hydraulic System Relief Valve
152 - Load Sense (LS) Shuttle Valve (2 used)
202 - Load Sense Remote Test Port
203 - Pump Remote Test Port

915
 Hydraulic System Schematic
211 - Valve LS Circuit Port
602 - Low Pressure Oil
604 - Return Oil
606 - Trapped Oil
609 - Pilot Pressure Oil
614 - Load Sense Pressure Oil
B9 - Quick-Drop Pressure Switch
B23 - Hydraulic Oil Filter Restriction Switch
Y9 - Quick-Drop Solenoid
Y10 - Pilot Control Enable Solenoid

Hydraulic Schematic Power Angle Tilt (PAT) With Winch (S.N. —208865)

TX1178685-UN: Hydraulic Schematic Power Angle Tilt (PAT) With Winch—Neutral (S.N. —208865)
LEGEND:
101 - Tilt Cylinder
102 - Angle Cylinder (2 used)
103 - Lift Cylinder (2 used)
104 - Hydraulic Pump
105 - Control Valve
106 - Hydraulic Filter
108 - Angle Solenoid Valve
109 - Pressure Reducing Valve
114 - Hydraulic Reservoir
116 - Load Sense Isolator
117 - Pilot Controller
120 - Blade Angle Circuit Relief Valve (2 used)
146 - Inlet Valve Section
147 - Blade Lift Valve Section
148 - Blade Tilt Valve Section
149 - Blade Angle Valve Section
150 - Outlet Valve Section
151 - Hydraulic System Relief Valve
152 - Load Sense (LS) Shuttle Valve (4 used)
153 - LS Circuit Port
202 - Load Sense Remote Test Port
203 - Pump Remote Test Port

916
 Hydraulic System Schematic
207 - Bypass Valve
208 - Hydraulic Oil Cooler
209 - Winch Connections
210 - Auxiliary Pilot Controller
211 - Valve LS Circuit Port
602 - Low Pressure Oil
604 - Return Oil
606 - Trapped Oil
609 - Pilot Pressure Oil
614 - Load Sense Pressure Oil
B23 - Hydraulic Oil Filter Restriction Switch
Y7 - Blade Angle Solenoid Left (top)
Y8 - Blade Angle Solenoid Right (bottom)
Y10 - Pilot Control Enable Solenoid

Hydraulic Schematic Power Angle Tilt (PAT) With Winch (S.N. 208866— )

TX1178686-UN: Hydraulic Schematic Power Angle Tilt (PAT) With Winch—Neutral (S.N. 208866— )
LEGEND:
101 - Tilt Cylinder
102 - Angle Cylinder (2 used)
103 - Lift Cylinder (2 used)
104 - Hydraulic Pump
105 - Control Valve
106 - Hydraulic Filter
108 - Angle Solenoid Valve
109 - Pressure Reducing Valve
114 - Hydraulic Reservoir
116 - Load Sense Isolator
117 - Pilot Controller
120 - Blade Angle Circuit Relief Valve (2 used)
146 - Inlet Valve Section
147 - Blade Lift Valve Section
148 - Blade Tilt Valve Section
149 - Blade Angle Valve Section
150 - Outlet Valve Section
151 - Hydraulic System Relief Valve

917
 Hydraulic System Schematic
152 - Load Sense (LS) Shuttle Valve (4 used)
153 - LS Circuit Port
202 - Load Sense Remote Test Port
203 - Pump Remote Test Port
207 - Bypass Valve
208 - Hydraulic Oil Cooler
209 - Winch Connections
210 - Auxiliary Pilot Controller
211 - Valve LS Circuit Port
602 - Low Pressure Oil
604 - Return Oil
606 - Trapped Oil
609 - Pilot Pressure Oil
614 - Load Sense Pressure Oil
B23 - Hydraulic Oil Filter Restriction Switch
Y7 - Blade Angle Solenoid Left (top)
Y8 - Blade Angle Solenoid Right (bottom)
Y10 - Pilot Control Enable Solenoid

Hydraulic Schematic Outside Dozer (OSD) With Winch (S.N. —208865)

TX1210804-UN: Hydraulic Schematic Outside Dozer (OSD) With Winch—Neutral (S.N. —208865)
LEGEND:
101 - Tilt Cylinder
103 - Lift Cylinder (2 used)
104 - Hydraulic Pump
105 - Control Valve
106 - Hydraulic Filter
109 - Pressure Reducing Valve
114 - Hydraulic Reservoir
115 - Quick-Drop Valve
116 - Load Sense Isolator
117 - Pilot Controller
120 - Blade Lift Circuit Relief Valve (2 used)
127 - Piston Bypass Valve (4 used)
146 - Inlet Valve Section
147 - Blade Lift Valve Section

918
 Hydraulic System Schematic
148 - Blade Tilt Valve Section
150 - Outlet Valve Section
151 - Hydraulic System Relief Valve
152 - Load Sense (LS) Shuttle Valve (3 used)
202 - Load Sense Remote Test Port
203 - Pump Remote Test Port
207 - Bypass Valve
208 - Hydraulic Oil Cooler
209 - Winch Connections
210 - Auxiliary Pilot Controller
211 - Valve LS Circuit Port
602 - Low Pressure Oil
604 - Return Oil
606 - Trapped Oil
609 - Pilot Pressure Oil
614 - Load Sense Pressure Oil
B9 - Quick-Drop Pressure Switch
B23 - Hydraulic Oil Filter Restriction Switch
Y9 - Quick-Drop Solenoid
Y10 - Pilot Control Enable Solenoid

Hydraulic Schematic Outside Dozer (OSD) With Winch (S.N. 208866— )

TX1210805-UN: Hydraulic Schematic Outside Dozer (OSD) With Winch—Neutral (S.N. 208866— )
LEGEND:
101 - Tilt Cylinder
103 - Lift Cylinder (2 used)
104 - Hydraulic Pump
105 - Control Valve
106 - Hydraulic Filter
109 - Pressure Reducing Valve
114 - Hydraulic Reservoir
115 - Quick-Drop Valve
116 - Load Sense Isolator
117 - Pilot Controller
120 - Blade Lift Circuit Relief Valve (2 used)
127 - Piston Bypass Valve (4 used)

919
 Hydraulic System Schematic
146 - Inlet Valve Section
147 - Blade Lift Valve Section
148 - Blade Tilt Valve Section
150 - Outlet Valve Section
151 - Hydraulic System Relief Valve
152 - Load Sense (LS) Shuttle Valve (3 used)
202 - Load Sense Remote Test Port
203 - Pump Remote Test Port
207 - Bypass Valve
208 - Hydraulic Oil Cooler
209 - Winch Connections
210 - Auxiliary Pilot Controller
211 - Valve LS Circuit Port
602 - Low Pressure Oil
604 - Return Oil
606 - Trapped Oil
609 - Pilot Pressure Oil
614 - Load Sense Pressure Oil
B9 - Quick-Drop Pressure Switch
B23 - Hydraulic Oil Filter Restriction Switch
Y9 - Quick-Drop Solenoid
Y10 - Pilot Control Enable Solenoid

Hydraulic Schematic Power Angle Tilt (PAT) With Ripper

TX1122078-UN: Hydraulic Schematic Power Angle Tilt (PAT) With Ripper—Neutral

LEGEND:
101 - Tilt Cylinder
102 - Angle Cylinder (2 used)
103 - Lift Cylinder (2 used)
104 - Hydraulic Pump

920
 Hydraulic System Schematic
105 - Control Valve
106 - Hydraulic Filter
107 - Ripper Lift Cylinders (2 used)
108 - Angle Solenoid Valve
109 - Pressure Reducing Valve
114 - Hydraulic Reservoir
116 - Load Sense Isolator
117 - Pilot Controller
119 - Ripper Lift Circuit Relief Valve
120 - Blade Angle Circuit Relief Valve (2 used)
145 - Inlet Valve Section
146 - Ripper Lift Valve Section
147 - Blade Lift Valve Section
148 - Blade Tilt Valve Section
149 - Blade Angle Valve Section
150 - Outlet Valve Section
151 - Hydraulic System Relief Valve
152 - Load Sense (LS) Shuttle Valve (4 used)
202 - Load Sense Remote Test Port
203 - Pump Remote Test Port
211 - Valve LS Circuit Port
602 - Low Pressure Oil
604 - Return Oil
606 - Trapped Oil
609 - Pilot Pressure Oil
614 - Load Sense Pressure Oil
B23 - Hydraulic Oil Filter Restriction Switch
Y7 - Blade Angle Solenoid Left (top)
Y8 - Blade Angle Solenoid Right (bottom)
Y10 - Pilot Control Enable Solenoid

Hydraulic Schematic Outside Dozer (OSD) With Ripper

921
 Hydraulic System Schematic

TX1210803-UN: Hydraulic Schematic Outside Dozer (OSD) With Ripper—Neutral

LEGEND:
101 - Tilt Cylinder
103 - Lift Cylinder (2 used)
104 - Hydraulic Pump
105 - Control Valve
106 - Hydraulic Filter
107 - Ripper Lift Cylinders (2 used)
109 - Pressure Reducing Valve
114 - Hydraulic Reservoir
115 - Quick-Drop Valve
116 - Load Sense Isolator
117 - Pilot Controller
119 - Ripper Lift Circuit Relief Valve
120 - Blade Lift Circuit Relief Valve (2 used)
127 - Piston Bypass Valve (4 used)
145 - Inlet Valve Section
146 - Ripper Lift Valve Section
147 - Blade Lift Valve Section
148 - Blade Tilt Valve Section
150 - Outlet Valve Section
151 - Hydraulic System Relief Valve
152 - Load Sense (LS) Shuttle Valve (3 used)
202 - Load Sense Remote Test Port
203 - Pump Remote Test Port
211 - Valve LS Circuit Port
602 - Low Pressure Oil
604 - Return Oil
606 - Trapped Oil
609 - Pilot Pressure Oil
922
 Hydraulic System Schematic

614 - Load Sense Pressure Oil

B9 - Quick-Drop Pressure Switch
B23 - Hydraulic Oil Filter Restriction Switch
Y9 - Quick-Drop Solenoid
Y10 - Pilot Control Enable Solenoid

Go to Section_9025:Group_15

OUO1020,000161E-19-20160215

923
 Hydraulic System Schematic

Hydraulic System Schematic

Hydraulic Schematic Power Angle Tilt (PAT)

TX1122076-UN: Hydraulic Schematic Power Angle Tilt (PAT)—Neutral

LEGEND:
101 - Tilt Cylinder
102 - Angle Cylinder (2 used)
103 - Lift Cylinder (2 used)
104 - Hydraulic Pump
105 - Control Valve
106 - Hydraulic Filter
108 - Angle Solenoid Valve
109 - Pressure Reducing Valve
114 - Hydraulic Reservoir
116 - Load Sense Isolator
117 - Pilot Controller
120 - Blade Angle Circuit Relief Valve (2 used)
146 - Inlet Valve Section
147 - Blade Lift Valve Section
148 - Blade Tilt Valve Section
149 - Blade Angle Valve Section
150 - Outlet Valve Section
151 - Hydraulic System Relief Valve
152 - Load Sense (LS) Shuttle Valve (3 used)
202 - Load Sense Remote Test Port
203 - Pump Remote Test Port
211 - Valve LS Circuit Port
602 - Low Pressure Oil
604 - Return Oil
606 - Trapped Oil

924
 Hydraulic System Schematic
609 - Pilot Pressure Oil
614 - Load Sense Pressure Oil
B23 - Hydraulic Oil Filter Restriction Switch
Y7 - Blade Angle Solenoid Left (top)
Y8 - Blade Angle Solenoid Right (bottom)
Y10 - Pilot Control Enable Solenoid

Hydraulic Schematic Outside Dozer (OSD)

TX1210802-UN: Hydraulic Schematic Outside Dozer (OSD)—Neutral

LEGEND:
101 - Tilt Cylinder
103 - Lift Cylinder (2 used)
104 - Hydraulic Pump
105 - Control Valve
106 - Hydraulic Filter
109 - Pressure Reducing Valve
114 - Hydraulic Reservoir
115 - Quick-Drop Valve
116 - Load Sense Isolator
117 - Pilot Controller
120 - Blade Lift Circuit Relief Valve (2 used)
127 - Piston Bypass Valve (4 used)
146 - Inlet Valve Section
147 - Blade Lift Valve Section
148 - Blade Tilt Valve Section
150 - Outlet Valve Section
151 - Hydraulic System Relief Valve
152 - Load Sense (LS) Shuttle Valve (2 used)
202 - Load Sense Remote Test Port
203 - Pump Remote Test Port

925
 Hydraulic System Schematic
211 - Valve LS Circuit Port
602 - Low Pressure Oil
604 - Return Oil
606 - Trapped Oil
609 - Pilot Pressure Oil
614 - Load Sense Pressure Oil
B9 - Quick-Drop Pressure Switch
B23 - Hydraulic Oil Filter Restriction Switch
Y9 - Quick-Drop Solenoid
Y10 - Pilot Control Enable Solenoid

Hydraulic Schematic Power Angle Tilt (PAT) With Winch (S.N. —208865)

TX1178685-UN: Hydraulic Schematic Power Angle Tilt (PAT) With Winch—Neutral (S.N. —208865)
LEGEND:
101 - Tilt Cylinder
102 - Angle Cylinder (2 used)
103 - Lift Cylinder (2 used)
104 - Hydraulic Pump
105 - Control Valve
106 - Hydraulic Filter
108 - Angle Solenoid Valve
109 - Pressure Reducing Valve
114 - Hydraulic Reservoir
116 - Load Sense Isolator
117 - Pilot Controller
120 - Blade Angle Circuit Relief Valve (2 used)
146 - Inlet Valve Section
147 - Blade Lift Valve Section
148 - Blade Tilt Valve Section
149 - Blade Angle Valve Section
150 - Outlet Valve Section
151 - Hydraulic System Relief Valve
152 - Load Sense (LS) Shuttle Valve (4 used)
153 - LS Circuit Port
202 - Load Sense Remote Test Port
203 - Pump Remote Test Port

926
 Hydraulic System Schematic
207 - Bypass Valve
208 - Hydraulic Oil Cooler
209 - Winch Connections
210 - Auxiliary Pilot Controller
211 - Valve LS Circuit Port
602 - Low Pressure Oil
604 - Return Oil
606 - Trapped Oil
609 - Pilot Pressure Oil
614 - Load Sense Pressure Oil
B23 - Hydraulic Oil Filter Restriction Switch
Y7 - Blade Angle Solenoid Left (top)
Y8 - Blade Angle Solenoid Right (bottom)
Y10 - Pilot Control Enable Solenoid

Hydraulic Schematic Power Angle Tilt (PAT) With Winch (S.N. 208866— )

TX1178686-UN: Hydraulic Schematic Power Angle Tilt (PAT) With Winch—Neutral (S.N. 208866— )
LEGEND:
101 - Tilt Cylinder
102 - Angle Cylinder (2 used)
103 - Lift Cylinder (2 used)
104 - Hydraulic Pump
105 - Control Valve
106 - Hydraulic Filter
108 - Angle Solenoid Valve
109 - Pressure Reducing Valve
114 - Hydraulic Reservoir
116 - Load Sense Isolator
117 - Pilot Controller
120 - Blade Angle Circuit Relief Valve (2 used)
146 - Inlet Valve Section
147 - Blade Lift Valve Section
148 - Blade Tilt Valve Section
149 - Blade Angle Valve Section
150 - Outlet Valve Section
151 - Hydraulic System Relief Valve

927
 Hydraulic System Schematic
152 - Load Sense (LS) Shuttle Valve (4 used)
153 - LS Circuit Port
202 - Load Sense Remote Test Port
203 - Pump Remote Test Port
207 - Bypass Valve
208 - Hydraulic Oil Cooler
209 - Winch Connections
210 - Auxiliary Pilot Controller
211 - Valve LS Circuit Port
602 - Low Pressure Oil
604 - Return Oil
606 - Trapped Oil
609 - Pilot Pressure Oil
614 - Load Sense Pressure Oil
B23 - Hydraulic Oil Filter Restriction Switch
Y7 - Blade Angle Solenoid Left (top)
Y8 - Blade Angle Solenoid Right (bottom)
Y10 - Pilot Control Enable Solenoid

Hydraulic Schematic Outside Dozer (OSD) With Winch (S.N. —208865)

TX1210804-UN: Hydraulic Schematic Outside Dozer (OSD) With Winch—Neutral (S.N. —208865)
LEGEND:
101 - Tilt Cylinder
103 - Lift Cylinder (2 used)
104 - Hydraulic Pump
105 - Control Valve
106 - Hydraulic Filter
109 - Pressure Reducing Valve
114 - Hydraulic Reservoir
115 - Quick-Drop Valve
116 - Load Sense Isolator
117 - Pilot Controller
120 - Blade Lift Circuit Relief Valve (2 used)
127 - Piston Bypass Valve (4 used)
146 - Inlet Valve Section
147 - Blade Lift Valve Section

928
 Hydraulic System Schematic
148 - Blade Tilt Valve Section
150 - Outlet Valve Section
151 - Hydraulic System Relief Valve
152 - Load Sense (LS) Shuttle Valve (3 used)
202 - Load Sense Remote Test Port
203 - Pump Remote Test Port
207 - Bypass Valve
208 - Hydraulic Oil Cooler
209 - Winch Connections
210 - Auxiliary Pilot Controller
211 - Valve LS Circuit Port
602 - Low Pressure Oil
604 - Return Oil
606 - Trapped Oil
609 - Pilot Pressure Oil
614 - Load Sense Pressure Oil
B9 - Quick-Drop Pressure Switch
B23 - Hydraulic Oil Filter Restriction Switch
Y9 - Quick-Drop Solenoid
Y10 - Pilot Control Enable Solenoid

Hydraulic Schematic Outside Dozer (OSD) With Winch (S.N. 208866— )

TX1210805-UN: Hydraulic Schematic Outside Dozer (OSD) With Winch—Neutral (S.N. 208866— )
LEGEND:
101 - Tilt Cylinder
103 - Lift Cylinder (2 used)
104 - Hydraulic Pump
105 - Control Valve
106 - Hydraulic Filter
109 - Pressure Reducing Valve
114 - Hydraulic Reservoir
115 - Quick-Drop Valve
116 - Load Sense Isolator
117 - Pilot Controller
120 - Blade Lift Circuit Relief Valve (2 used)
127 - Piston Bypass Valve (4 used)

929
 Hydraulic System Schematic
146 - Inlet Valve Section
147 - Blade Lift Valve Section
148 - Blade Tilt Valve Section
150 - Outlet Valve Section
151 - Hydraulic System Relief Valve
152 - Load Sense (LS) Shuttle Valve (3 used)
202 - Load Sense Remote Test Port
203 - Pump Remote Test Port
207 - Bypass Valve
208 - Hydraulic Oil Cooler
209 - Winch Connections
210 - Auxiliary Pilot Controller
211 - Valve LS Circuit Port
602 - Low Pressure Oil
604 - Return Oil
606 - Trapped Oil
609 - Pilot Pressure Oil
614 - Load Sense Pressure Oil
B9 - Quick-Drop Pressure Switch
B23 - Hydraulic Oil Filter Restriction Switch
Y9 - Quick-Drop Solenoid
Y10 - Pilot Control Enable Solenoid

Hydraulic Schematic Power Angle Tilt (PAT) With Ripper

TX1122078-UN: Hydraulic Schematic Power Angle Tilt (PAT) With Ripper—Neutral

LEGEND:
101 - Tilt Cylinder
102 - Angle Cylinder (2 used)
103 - Lift Cylinder (2 used)
104 - Hydraulic Pump

930
 Hydraulic System Schematic
105 - Control Valve
106 - Hydraulic Filter
107 - Ripper Lift Cylinders (2 used)
108 - Angle Solenoid Valve
109 - Pressure Reducing Valve
114 - Hydraulic Reservoir
116 - Load Sense Isolator
117 - Pilot Controller
119 - Ripper Lift Circuit Relief Valve
120 - Blade Angle Circuit Relief Valve (2 used)
145 - Inlet Valve Section
146 - Ripper Lift Valve Section
147 - Blade Lift Valve Section
148 - Blade Tilt Valve Section
149 - Blade Angle Valve Section
150 - Outlet Valve Section
151 - Hydraulic System Relief Valve
152 - Load Sense (LS) Shuttle Valve (4 used)
202 - Load Sense Remote Test Port
203 - Pump Remote Test Port
211 - Valve LS Circuit Port
602 - Low Pressure Oil
604 - Return Oil
606 - Trapped Oil
609 - Pilot Pressure Oil
614 - Load Sense Pressure Oil
B23 - Hydraulic Oil Filter Restriction Switch
Y7 - Blade Angle Solenoid Left (top)
Y8 - Blade Angle Solenoid Right (bottom)
Y10 - Pilot Control Enable Solenoid

Hydraulic Schematic Outside Dozer (OSD) With Ripper

931
 Hydraulic System Schematic

TX1210803-UN: Hydraulic Schematic Outside Dozer (OSD) With Ripper—Neutral

LEGEND:
101 - Tilt Cylinder
103 - Lift Cylinder (2 used)
104 - Hydraulic Pump
105 - Control Valve
106 - Hydraulic Filter
107 - Ripper Lift Cylinders (2 used)
109 - Pressure Reducing Valve
114 - Hydraulic Reservoir
115 - Quick-Drop Valve
116 - Load Sense Isolator
117 - Pilot Controller
119 - Ripper Lift Circuit Relief Valve
120 - Blade Lift Circuit Relief Valve (2 used)
127 - Piston Bypass Valve (4 used)
145 - Inlet Valve Section
146 - Ripper Lift Valve Section
147 - Blade Lift Valve Section
148 - Blade Tilt Valve Section
150 - Outlet Valve Section
151 - Hydraulic System Relief Valve
152 - Load Sense (LS) Shuttle Valve (3 used)
202 - Load Sense Remote Test Port
203 - Pump Remote Test Port
211 - Valve LS Circuit Port
602 - Low Pressure Oil
604 - Return Oil
606 - Trapped Oil
609 - Pilot Pressure Oil
932
 Hydraulic System Schematic

614 - Load Sense Pressure Oil

B9 - Quick-Drop Pressure Switch
B23 - Hydraulic Oil Filter Restriction Switch
Y9 - Quick-Drop Solenoid
Y10 - Pilot Control Enable Solenoid

Go to Section_9025:Group_15

OUO1020,000161E-19-20160215

933
 Hydraulic System Schematic—IGC

Hydraulic System Schematic—IGC

TX1075009-UN: Hydraulic System Schematic with Integrated Grade Control (IGC)—Neutral

LEGEND:
101 - Tilt Cylinder
102 - Angle Cylinder (2 used)
103 - Lift Cylinder (2 used)
104 - Hydraulic Pump
106 - Hydraulic Oil Filter
107 - Ripper Cylinder (2 used)
114 - Hydraulic Reservoir
145 - Hydraulic Oil Filter Bypass Valve
155 - Low Pressure Oil
156 - Load Sense Oil
157 - Regulated Pressure Oil
158 - Trapped Oil
159 - Return Oil
212 - Inlet/Outlet Section
213 - Control Valve—IGC
214 - Blade Lift Actuator
215 - Blade Tilt Actuator
216 - Blade Angle Actuator
217 - Blade Angle Anticavitation Valve (2 used)
218 - Blade Angle Circuit Relief Valve (2 used)
219 - Load Sense Relief Valve
220 - Pressure Reducing Valve
221 - System Relief Valve
222 - End Section
223 - Blade Angle Section
224 - Blade Tilt Section
225 - Blade Lift Section
226 - Compensator Valve (4 used)
229 - Load Sense Shuttle Valve (4 used)
230 - Test Port P
231 - Auxiliary Actuator
233 - Auxiliary Anticavitation Valve (2 used)
934
 Hydraulic System Schematic—IGC
234 - Auxiliary Circuit Relief Valve (2 used)
235 - Auxiliary Section

NOTE:

Integrated grade control (IGC) is available as an option.

Go to Section_9025:Group_15

OUO1020,000161F-19-20100329

935
 Main Hydraulic Component Location

Main Hydraulic Component Location

T202636-UN: Main Hydraulic Component Location

LEGEND:
101 - Tilt Cylinder
102 - Angle Cylinder (2 used)
103 - Lift Cylinder (2 used)
104 - Hydraulic Pump
105 - Hydraulic Control Valve
106 - Hydraulic Filter
108 - Angle Solenoid Valve
109 - Pressure Reducing Valve
114 - Hydraulic Reservoir
117 - Hydraulic Control Lever
118 - Blade Angle Switch

Go to Section_9025:Group_15

BR81691,0000068-19-20041008

936
 Ripper Ready Hydraulic Component Location

Ripper Ready Hydraulic Component Location

T215999-UN: Ripper Ready Hydraulic Component Location

LEGEND:
105 - Hydraulic Control Valve
107 - Ripper Cylinder (2 Used)
119 - Auxiliary Pilot Controller

Go to Section_9025:Group_15

MS12501,000000C-19-20070807

937
 Winch Ready Hydraulic Component Location

Winch Ready Hydraulic Component Location

TX1021588-UN: Winch Ready Hydraulic Component Location

LEGEND:
105 - Control Valve
106 - Hydraulic Filter
109 - Pressure Reducing Valve
207 - Bypass Valve
208 - Hydraulic Oil Cooler
210 - Auxiliary Pilot Controller
236 - Jumper Hose

Go to Section_9025:Group_15

BR81691,0000010-19-20070605

938
 Main Hydraulic Component Location—IGC

Main Hydraulic Component Location—IGC

TX1009149-UN: Hydraulic System with Integrated Grade Control (IGC) Component Location
LEGEND:
101 - Tilt Cylinder
102 - Angle Cylinder (2 used)
103 - Lift Cylinder (2 used)
104 - Hydraulic Pump
106 - Hydraulic Oil Filter
114 - Hydraulic Reservoir
213 - Control Valve—IGC

NOTE:

Integrated Grade Control (IGC) is available as an option on the 750J.

Go to Section_9025:Group_15

OUO1020,0001620-19-20070208

939
 Ripper Hydraulic Component Location—IGC

Ripper Hydraulic Component Location—IGC

TX1019288-UN: Ripper Hydraulic Component Location—IGC

LEGEND:
107 - Ripper Cylinder (2 used)
213 - Integrated Grade Control (IGC) Hydraulic Control Valve
250 - Auxiliary Joystick
251 - Electrohydraulic Controller (EHC)

Go to Section_9025:Group_15

OUO1020,000161D-19-20070221

940
 Hydraulic System Diagnose Malfunctions

No Hydraulic Functions Diagnostic Procedure

Launch Close Expand List Collapse List

1 Hydraulic Enable Switch in Off Position

Action:

Check position of hydraulic enable switch.

Is switch in off position?

Record of Actual Results:

Result:
YES:
Move switch to on position.
NO:
Go to Hydraulic Enable Switch Malfunction .

2 Hydraulic Enable Switch Malfunction

Action:

Perform hydraulic control enable circuit check. See Operational Checkout . (Group 9005-10.)

Check hydraulic control enable switch and circuit. See System Functional Schematic and Section Legend .
(Group 9015-10.)

Are switch and circuit working correctly?

Record of Actual Results:

Result:
YES:
Go to Hydraulic System Relief Valve Stuck Open .
NO:
Repair or replace hydraulic enable switch and circuit.

3 Hydraulic System Relief Valve Stuck Open

Action:

Check hydraulic system pressure. Perform Hydraulic System Relief Valve Test . (Group 9025-25.)

Is relief valve adjusted to specification?

Record of Actual Results:

941
 Hydraulic System Diagnose Malfunctions

Result:
YES:
Go to Pilot Control Pressure Low .
NO:
Replace relief valve.

4 Pilot Control Pressure Low

Action:

Check pilot control pressure. Perform Pressure Reducing Valve Pressure Test and Adjustment . (Group
9025-25.)

Is pressure reducing valve adjusted to specification?

Record of Actual Results:

Result:
YES:
Go to Pump Load Sense Differential and System Pressure Low .
NO:
Replace pressure reducing valve.

5 Pump Load Sense Differential and System Pressure Low

Action:

Check pump load sense differential and system pressure. Perform Pump Load Sense Differential and
System Pressure (Pump Cut-Off) Test and Adjustment . (Group 9025-25.)

Is pump control valve adjusted to specification?

Record of Actual Results:

Result:
YES:
Checks complete.
NO:
Replace pump control valve.

Hydraulic Functions Slow Diagnostic Procedure

Launch Close Expand List Collapse List

1 Hydraulic Oil Cold

Action:

Check hydraulic oil temperature.

942
 Hydraulic System Diagnose Malfunctions
Is hydraulic oil at normal operating temperature?

Record of Actual Results:

Result:
YES:
Go to Engine Speed Slow .
NO:
Warm-up hydraulic oil.

2 Engine Speed Slow

Action:

Check engine speed. See  E 6.8 L (6068) John Deere Engine . (Group 9010-15.)

Is engine speed to specification?

Record of Actual Results:

Result:
YES:
Go to Pump Suction Line Air Leak .
NO:
Follow engine diagnostic procedure.

3 Pump Suction Line Air Leak

Action:

Check for foamy hydraulic oil. See Check Hydraulic Oil Level . (Operator's Manual.)

Is hydraulic oil foamy?

Record of Actual Results:

Result:
YES:
Repair pump suction line leak.
NO:
Go to Hydraulic Oil Level Low .

4 Hydraulic Oil Level Low

Action:

Check hydraulic oil level. See Check Hydraulic Oil Level . (Operator's Manual.)

943
 Hydraulic System Diagnose Malfunctions
IMPORTANT:

If machine is equipped with winch, check oil level in winch. A malfunction of winch hydraulic components can
transfer hydraulic oil to winch and reduce the hydraulic oil level of machine.

Is hydraulic oil level to specification?

Record of Actual Results:

Result:
YES:
Go to Oil Viscosity Wrong .
NO:
Add recommended oil. See Transmission and Hydraulic Reservoir Oil . (Operator's Manual.)

5 Oil Viscosity Wrong

Action:

Check reservoir oil. See Transmission and Hydraulic Reservoir Oil . (Operator's Manual.)

Is correct oil used?

Record of Actual Results:

Result:
YES:
Go to Hydraulic Lines Blocked or Damaged .
NO:
Replace reservoir oil with recommended oil.

6 Hydraulic Lines Blocked or Damaged

Action:

Inspect hydraulic lines. See Main Hydraulic Component Location . (Group 9025-15.)

Are any hydraulic lines blocked or damaged?

Record of Actual Results:

Result:
YES:
Repair or replace damaged lines.
NO:
Go to Hydraulic Cylinders Leaking Internally .

7 Hydraulic Cylinders Leaking Internally

944
 Hydraulic System Diagnose Malfunctions

Action:

Check cylinders for leakage. Perform Lift and Tilt Cylinder Function Drift Test . (Group 9025-25.)

Are any cylinders leaking?

Record of Actual Results:

Result:
YES:
Repair or replace leaking cylinders.
NO:
Go to Hydraulic System Relief Valve Stuck Open .

8 Hydraulic System Relief Valve Stuck Open

Action:

Check hydraulic system pressure. Perform Hydraulic System Relief Valve Test . (Group 9025-25.)

Is relief valve adjusted to specification?

Record of Actual Results:

Result:
YES:
Go to Pilot Control Pressure Low .
NO:
Replace relief valve.

9 Pilot Control Pressure Low

Action:

Check pilot control pressure. Perform Pressure Reducing Valve Pressure Test and Adjustment . (Group
9025-25.)

Is pressure reducing valve adjusted to specification?

Record of Actual Results:

Result:
YES:
Go to Pump Load Sense Differential and System Pressure Low .
NO:
Replace pressure reducing valve.

945
 Hydraulic System Diagnose Malfunctions

10 Pump Load Sense Differential and System Pressure Low

Action:

Check pump load sense differential and system pressure. Perform Pump Load Sense Differential and
System Pressure (Pump Cut-Off) Test and Adjustment . (Group 9025-25.)

Is pump control valve adjusted to specification?

Record of Actual Results:

Result:
YES:
Go to Hydraulic Control Valve Spool Binding .
NO:
Replace pump control valve.

11 Hydraulic Control Valve Spool Binding

Action:

Inspect and repair control valve. See Hydraulic Control Valve Disassemble and Assemble . (Group 3260.)

Is control valve spool binding?

Record of Actual Results:

Result:
YES:
Repair or replace control valve.
NO:
Go to Hydraulic Pump Worn or Damaged .

12 Hydraulic Pump Worn or Damaged

Action:

Check pump Flow. Perform Hydraulic Pump Flow Test . (Group 9025-25.)

Is pump flow to specification?

Record of Actual Results:

Result:
YES:
Checks complete.
NO:
Repair or replace pump as necessary.
946
 Hydraulic System Diagnose Malfunctions

Hydraulic Pump Noisy Diagnostic Procedure

Launch Close Expand List Collapse List

1 Pump Suction Line Air Leak

Action:

Check for foamy hydraulic oil. See Check Hydraulic Oil Level . (Operator's Manual.)

Is hydraulic oil foamy?

Record of Actual Results:

Result:
YES:
Repair pump suction line leak.
NO:
Go to Hydraulic Oil Level Low .

2 Hydraulic Oil Level Low

Action:

Check hydraulic oil level. See Check Hydraulic Oil Level . (Operator's Manual.)

IMPORTANT:

If machine is equipped with winch, check oil level in winch. A malfunction of winch hydraulic components can
transfer hydraulic oil to winch and reduce the hydraulic oil level of machine.

Is hydraulic oil level to specification?

Record of Actual Results:

Result:
YES:
Go to Oil Viscosity Wrong .
NO:
Add recommended oil. See Transmission and Hydraulic Reservoir Oil . (Operator's Manual.)

3 Oil Viscosity Wrong

Action:

Check reservoir oil. See Transmission and Hydraulic Reservoir Oil . (Operator's Manual.)

Is correct oil used?

Record of Actual Results:

947
 Hydraulic System Diagnose Malfunctions

Result:
YES:
Go to Hydraulic Lines in Contact with Frame .
NO:
Replace reservoir oil with recommended oil.

4 Hydraulic Lines in Contact with Frame

Action:

Inspect line routing.

Are any lines against frame?

Record of Actual Results:

Result:
YES:
Adjust lines as necessary.
NO:
Go to Hydraulic Pump Worn or Damaged .

5 Hydraulic Pump Worn or Damaged

Action:

Check pump flow. Perform Hydraulic Pump Flow Test . (Group 9025-25.)

Is pump flow to specification?

Record of Actual Results:

Result:
YES:
Checks complete.
NO:
Repair or replace pump as necessary.

Blade Float Does Not Work Diagnostic Procedure

Launch Close Expand List Collapse List

1 Pilot Control Pressure Low

Action:

Check pilot control pressure. Perform Pressure Reducing Valve Pressure Test and Adjustment . (Group
9025-25.)
948
 Hydraulic System Diagnose Malfunctions

Is pressure reducing valve adjusted to specification?

Record of Actual Results:

Result:
YES:
Go to Pilot Controller Detent Malfunction .
NO:
Replace pressure reducing valve.

2 Pilot Controller Detent Malfunction

Action:

Inspect pilot controller. See Hydraulic System Schematic . (Group 9025-15.)

Is pilot controller worn or damaged?

Record of Actual Results:

Result:
YES:
Repair or replace pilot controller.
NO:
Go to Hydraulic Control Valve Spool Binding .

3 Hydraulic Control Valve Spool Binding

Action:

Inspect and repair control valve. See Hydraulic Control Valve Disassemble and Assemble . (Group 3260.)

Is control valve spool binding?

Record of Actual Results:

Result:
YES:
Repair or replace control valve.
NO:
Checks complete.

One Hydraulic Function Does Not Work Diagnostic Procedure

Launch Close Expand List Collapse List

1 Pilot Control Pressure Low

949
 Hydraulic System Diagnose Malfunctions

Action:

Check pilot control pressure. Perform Pressure Reducing Valve Pressure Test and Adjustment . (Group
9025-25.)

Is pressure reducing valve adjusted to specification?

Record of Actual Results:

Result:
YES:
Go to Circuit Relief Valve Stuck Open .
NO:
Replace pressure reducing valve.

2 Circuit Relief Valve Stuck Open

Action:

Check circuit relief valves. See Hydraulic Control Valve Disassemble and Assemble . (Group 3260.)

Is circuit relief valve worn or damaged?

Record of Actual Results:

Result:
YES:
Repair or replace circuit relief valve.
NO:
Go to Anticavitation Valve Stuck Open .

3 Anticavitation Valve Stuck Open

Action:

Check anticavitation valves. See Hydraulic Control Valve Disassemble and Assemble . (Group 3260.)

Is anticavitation valve worn or damaged?

Record of Actual Results:

Result:
YES:
Repair or replace anticavitation valve.
NO:
Go to Hydraulic Lines Blocked or Damaged .

950
 Hydraulic System Diagnose Malfunctions

4 Hydraulic Lines Blocked or Damaged

Action:

Inspect hydraulic lines. See Main Hydraulic Component Location . (Group 9025-15.)

Are any hydraulic lines blocked or damaged?

Record of Actual Results:

Result:
YES:
Repair or replace damaged lines.
NO:
Go to Hydraulic Cylinders Leaking Internally .

5 Hydraulic Cylinders Leaking Internally

Action:

Check cylinders for leakage. Perform Lift and Tilt Cylinder Function Drift Test . (Group 9025-25.)

Are any cylinders leaking?

Record of Actual Results:

Result:
YES:
Repair or replace leaking cylinders.
NO:
Go to Hydraulic Control Valve Spool Binding .

6 Hydraulic Control Valve Spool Binding

Action:

Inspect and repair control valve. See Hydraulic Control Valve Disassemble and Assemble . (Group 3260.)

Is control valve spool binding?

Record of Actual Results:

Result:
YES:
Repair or replace control valve.
NO:
Checks complete.

951
 Hydraulic System Diagnose Malfunctions

Function Drifts Down Diagnostic Procedure

Launch Close Expand List Collapse List

1 Hydraulic Cylinders Leaking Internally

Action:

Check cylinders for leakage. Perform Lift and Tilt Cylinder Function Drift Test . (Group 9025-25.)

Are any cylinders leaking?

Record of Actual Results:

Result:
YES:
Repair or replace leaking cylinders.
NO:
Go to Circuit Relief Valve Stuck Open or Leaking .

2 Circuit Relief Valve Stuck Open or Leaking

Action:

Check circuit relief valves. See Hydraulic Control Valve Disassemble and Assemble . (Group 3260.)

Is circuit relief valve worn or damaged?

Record of Actual Results:

Result:
YES:
Repair or replace circuit relief valve.
NO:
Go to Anticavitation Valve Stuck Open or Leaking .

3 Anticavitation Valve Stuck Open or Leaking

Action:

Check anticavitation valves. See Hydraulic Control Valve Disassemble and Assemble . (Group 3260.)

Is anticavitation valve worn or damaged?

Record of Actual Results:

Result:
YES:
Repair or replace anticavitation valve.

952
 Hydraulic System Diagnose Malfunctions

NO:
Go to Hydraulic Control Valve Spool Leaking .

4 Hydraulic Control Valve Spool Leaking

Action:

Inspect and repair control valve. See Hydraulic Control Valve Disassemble and Assemble . (Group 3260.)

Is control valve spool worn or damaged?

Record of Actual Results:

Result:
YES:
Replace control valve.
NO:
Checks complete.

Oil Overheats Diagnostic Procedure

Launch Close Expand List Collapse List

1 Oil Viscosity Wrong

Action:

Check reservoir oil. See Transmission and Hydraulic Reservoir Oil . (Operator's Manual.)

Is correct oil used?

Record of Actual Results:

Result:
YES:
Go to Hydraulic System Relief Valve Stuck Open or Leaking .
NO:
Replace reservoir oil with recommended oil.

2 Hydraulic System Relief Valve Stuck Open or Leaking

Action:

Check hydraulic system pressure. Perform Hydraulic System Relief Valve Test . (Group 9025-25.)

Is relief valve adjusted to specification?

Record of Actual Results:

953
 Hydraulic System Diagnose Malfunctions

Result:
YES:
Go to Circuit Relief Valve Stuck Open or Leaking .
NO:
Replace relief valve.

3 Circuit Relief Valve Stuck Open or Leaking

Action:

Check circuit relief valves. See Hydraulic Control Valve Disassemble and Assemble . (Group 3260.)

Is circuit relief valve worn or damaged?

Record of Actual Results:

Result:
YES:
Repair or replace circuit relief valve.
NO:
Go to Anticavitation Valve Stuck Open or Leaking .

4 Anticavitation Valve Stuck Open or Leaking

Action:

Check anticavitation valves. See Hydraulic Control Valve Disassemble and Assemble . (Group 3260.)

Is anticavitation valve worn or damaged?

Record of Actual Results:

Result:
YES:
Repair or replace anticavitation valve.
NO:
Go to Hydraulic Lines Blocked or Damaged .

5 Hydraulic Lines Blocked or Damaged

Action:

Inspect hydraulic lines. See Main Hydraulic Component Location . (Group 9025-15.)

Are any hydraulic lines blocked or damaged?

Record of Actual Results:

954
 Hydraulic System Diagnose Malfunctions

Result:
YES:
Repair or replace damaged lines.
NO:
Go to Hydraulic Cylinders Leaking Internally .

6 Hydraulic Cylinders Leaking Internally

Action:

Check cylinders for leakage. Perform Lift and Tilt Cylinder Function Drift Test . (Group 9025-25.)

Are any cylinders leaking?

Record of Actual Results:

Result:
YES:
Repair or replace leaking cylinders.
NO:
Go to Hydraulic Pump Worn or Damaged .

7 Hydraulic Pump Worn or Damaged

Action:

Check pump Flow. Perform Hydraulic Pump Flow Test . (Group 9025-25.)

Is pump flow to specification?

Record of Actual Results:

Result:
YES:
Checks complete.
NO:
Repair or replace pump as necessary.

Go to Section_9025:Group_15

OUO1020,0001609-19-20100621

955
 Hydraulic System Diagnose Malfunctions—IGC

No Hydraulic Functions Diagnostic Procedure—IGC

Launch Close Expand List Collapse List

1 Hydraulic Enable Switch in Off Position

Action:

Check position of hydraulic enable switch.

Is switch in off position?

Record of Actual Results:

Result:
YES:
Move switch to on position.
NO:
Go to Hydraulic Enable Switch Malfunction .

2 Hydraulic Enable Switch Malfunction

Action:

Perform hydraulic control enable circuit check.

Check hydraulic control enable switch (S8), pilot control enable solenoid (Y10), and circuit. See Integrated
Grade Control (IGC) Diagnose Malfunctions—If Equipped . (Group 9015-20.)

See Transmission Harness (W11) Wiring Diagram and see Transmission Harness (W11) Component
Location . (Group 9015-10.)

Are switch and circuit working correctly?

Record of Actual Results:

Result:
YES:
Go to Hydraulic System Relief Valve Stuck Open .
NO:
Repair or replace hydraulic enable switch and circuit.

3 Hydraulic System Relief Valve Stuck Open

Action:

Check hydraulic system relief valve. See Hydraulic Control Valve Disassemble and Assemble—IGC . (Group
3260.)

Is relief valve worn or damaged?

956
 Hydraulic System Diagnose Malfunctions—IGC

Record of Actual Results:

Result:
YES:
Replace relief valve.
NO:
Go to Pilot Control Pressure Low .

4 Pilot Control Pressure Low

Action:

Check pressure reducing valve. See Hydraulic Control Valve Disassemble and Assemble—IGC . (Group
3260.)

Is pressure reducing valve worn or damaged?

Record of Actual Results:

Result:
YES:
Replace pressure reducing valve.
NO:
Go to Pump Load Sense Differential and System Pressure Low .

5 Pump Load Sense Differential and System Pressure Low

Action:

Check pump load sense differential and system pressure. Perform Pump Load Sense Differential and
System Pressure Test and Adjustment—IGC . (Group 9025-25.)

Is pump control valve adjusted to specification?

Record of Actual Results:

Result:
YES:
Go to Electrical Malfunction .
NO:
Replace pump control valve.

6 Electrical Malfunction

Action:

Check electrical system malfunctions. See Integrated Grade Control (IGC) Diagnose Malfunctions—If

957
 Hydraulic System Diagnose Malfunctions—IGC
Equipped . (Group 9015-20.)

Is an electrical malfunction found?

Record of Actual Results:

Result:
YES:
Repair or replace electrical components as necessary.
NO:
Checks complete.

Hydraulic Functions Slow Diagnostic Procedure—IGC

Launch Close Expand List Collapse List

1 Hydraulic Oil Cold

Action:

Check hydraulic oil temperature.

Is hydraulic oil at normal operating temperature?

Record of Actual Results:

Result:
YES:
Go to Engine Speed Slow .
NO:
Warm-up hydraulic oil.

2 Engine Speed Slow

Action:

Check engine speed. See  E 6.8 L (6068) John Deere Engine . (Group 9010-15.)

Is engine speed to specification?

Record of Actual Results:

Result:
YES:
Go to Pump Suction Line Air Leak .
NO:
Follow engine diagnostic procedure.

958
 Hydraulic System Diagnose Malfunctions—IGC

3 Pump Suction Line Air Leak

Action:

Check for foamy hydraulic oil. See Check Hydraulic Oil Level . (Operator's Manual.)

Is hydraulic oil foamy?

Record of Actual Results:

Result:
YES:
Repair pump suction line leak.
NO:
Go to Hydraulic Oil Level Low .

4 Hydraulic Oil Level Low

Action:

Check hydraulic oil level. See Check Hydraulic Oil Level . (Operator's Manual.)

IMPORTANT:

If machine is equipped with winch, check oil level in winch. A malfunction of winch hydraulic components can
transfer hydraulic oil to winch and reduce the hydraulic oil level of machine.

Is hydraulic oil level to specification?

Record of Actual Results:

Result:
YES:
Go to Oil Viscosity Wrong .
NO:
Add recommended oil. See Transmission and Hydraulic Reservoir Oil . (Operator's Manual.)

5 Oil Viscosity Wrong

Action:

Check reservoir oil. See Transmission and Hydraulic Reservoir Oil . (Operator's Manual.)

Is correct oil used?

Record of Actual Results:

Result:
YES:
959
 Hydraulic System Diagnose Malfunctions—IGC
Go to Hydraulic Lines Blocked or Damaged .
NO:
Replace reservoir oil with recommended oil.

6 Hydraulic Lines Blocked or Damaged

Action:

Inspect hydraulic lines. See Main Hydraulic Component Location . (Group 9025-15.)

Are any hydraulic lines blocked or damaged?

Record of Actual Results:

Result:
YES:
Repair or replace damaged lines.
NO:
Go to Hydraulic Cylinders Leaking Internally .

7 Hydraulic Cylinders Leaking Internally

Action:

Check cylinders for leakage. Perform Lift and Tilt Cylinder Function Drift Test . (Group 9025-25.)

Are any cylinders leaking?

Record of Actual Results:

Result:
YES:
Repair or replace leaking cylinders.
NO:
Go to Hydraulic System Relief Valve Stuck Open .

8 Hydraulic System Relief Valve Stuck Open

Action:

Check hydraulic system pressure. Perform Hydraulic System Relief Valve Test . (Group 9025-25.)

Is relief valve adjusted to specification?

Record of Actual Results:

Result:
YES:

960
 Hydraulic System Diagnose Malfunctions—IGC
Go to Pilot Control Pressure Low .
NO:
Replace relief valve.

9 Pilot Control Pressure Low

Action:

Check pilot control pressure. Perform Pressure Reducing Valve Pressure Test and Adjustment . (Group
9025-25.)

Is pressure reducing valve adjusted to specification?

Record of Actual Results:

Result:
YES:
Go to Pump Load Sense Differential and System Pressure Low .
NO:
Replace pressure reducing valve.

10 Pump Load Sense Differential and System Pressure Low

Action:

Check pump load sense differential and system pressure. Pump Load Sense Differential and System
Pressure Test and Adjustment—IGC . (Group 9025-25.)

Is pump control valve adjusted to specification?

Record of Actual Results:

Result:
YES:
Go to Hydraulic Control Valve Spool Binding .
NO:
Replace pump control valve.

11 Hydraulic Control Valve Spool Binding

Action:

Inspect and repair control valve. See Hydraulic Control Valve Disassemble and Assemble—IGC . (Group
3260.)

Is control valve spool binding?

Record of Actual Results:

961
 Hydraulic System Diagnose Malfunctions—IGC

Result:
YES:
Repair or replace control valve.
NO:
Go to Electrohydraulic Actuator Malfunction .

12 Electrohydraulic Actuator Malfunction

Action:

Check electrohydraulic actuator. See Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped .
(Group 9015-20.)

Is actuator malfunctioning?

Record of Actual Results:

Result:
YES:
Replace actuator.
NO:
Go to Joystick Malfunction .

13 Joystick Malfunction
Action:

Check joystick. See Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped . (Group 9015-20.)

Is joystick malfunctioning?

Record of Actual Results:

Result:
YES:
Repair or replace joystick as necessary.
NO:
Go to Hydraulic Pump Worn or Damaged .

14 Hydraulic Pump Worn or Damaged

Action:

Check pump flow. Perform Hydraulic Pump Flow Test . (Group 9025-25.)

Is pump flow to specification?

Record of Actual Results:

962
 Hydraulic System Diagnose Malfunctions—IGC

Result:
YES:
Checks complete.
NO:
Repair or replace pump as necessary.

Blade Float Does Not Work Diagnostic Procedure—IGC

Launch Close Expand List Collapse List

1 Pilot Control Pressure Low

Action:

Check pilot control pressure. Perform Pressure Reducing Valve Pressure Test and Adjustment . (Group
9025-25.)

Is pressure reducing valve adjusted to specification?

Record of Actual Results:

Result:
YES:
Go to Joystick Malfunction .
NO:
Replace pressure reducing valve.

2 Joystick Malfunction
Action:

Check joystick. See Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped . (Group 9015-20.)

Is joystick malfunctioning?

Record of Actual Results:

Result:
YES:
Repair or replace joystick as necessary.
NO:
Go to Electrohydraulic Actuator Malfunction .

3 Electrohydraulic Actuator Malfunction

Action:

Check electrohydraulic actuator. See Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped .
963
 Hydraulic System Diagnose Malfunctions—IGC
(Group 9015-20.)

Is actuator malfunctioning?

Record of Actual Results:

Result:
YES:
Replace actuator.
NO:
Go to Hydraulic Control Valve Spool Binding .

4 Hydraulic Control Valve Spool Binding

Action:

Inspect and repair control valve. See Hydraulic Control Valve Disassemble and Assemble—IGC . (Group
3260.)

Is control valve spool binding?

Record of Actual Results:

Result:
YES:
Repair or replace control valve.
NO:
Checks complete.

One Hydraulic Function Does Not Work Diagnostic Procedure—IGC

Launch Close Expand List Collapse List

1 Circuit Relief Valve Stuck Open

Action:

Check circuit relief valves. See Hydraulic Control Valve Disassemble and Assemble—IGC . (Group 3260.)

Is circuit relief valve worn or damaged?

Record of Actual Results:

Result:
YES:
Repair or replace circuit relief valve.
NO:
Go to Anticavitation Valve Stuck Open .

964
 Hydraulic System Diagnose Malfunctions—IGC

2 Anticavitation Valve Stuck Open

Action:

Check anticavitation valves. See Hydraulic Control Valve Disassemble and Assemble—IGC . (Group 3260.)

Is anticavitation valve worn or damaged?

Record of Actual Results:

Result:
YES:
Repair or replace anticavitation valve.
NO:
Go to Hydraulic Lines Blocked or Damaged .

3 Hydraulic Lines Blocked or Damaged

Action:

Inspect hydraulic lines. See Main Hydraulic Component Location—IGC . (Group 9025-15.)

Are any hydraulic lines blocked or damaged?

Record of Actual Results:

Result:
YES:
Repair or replace damaged lines.
NO:
Go to Hydraulic Cylinders Leaking Internally .

4 Hydraulic Cylinders Leaking Internally

Action:

Check cylinders for leakage. Perform Lift and Tilt Cylinder Function Drift Test . (Group 9025-25.)

Are any cylinders leaking?

Record of Actual Results:

Result:
YES:
Repair or replace leaking cylinders.
NO:
Go to Electrohydraulic Actuator Malfunction .

965
 Hydraulic System Diagnose Malfunctions—IGC

5 Electrohydraulic Actuator Malfunction

Action:

Check electrohydraulic actuator. See Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped .
(Group 9015-20.)

Is actuator malfunctioning?

Record of Actual Results:

Result:
YES:
Replace actuator.
NO:
Go to Hydraulic Control Valve Spool Binding .

6 Hydraulic Control Valve Spool Binding

Action:

Inspect and repair control valve. See Hydraulic Control Valve Disassemble and Assemble—IGC . (Group
3260.)

Is control valve spool binding?

Record of Actual Results:

Result:
YES:
Repair or replace control valve.
NO:
Checks complete.

Hydraulic Power Low Diagnostic Procedure—IGC

Launch Close Expand List Collapse List

1 Pump Load Sense Differential and System Pressure Low

Action:

Check pump load sense differential and system pressure. Perform Pump Load Sense Differential and
System Pressure Test and Adjustment—IGC . (Group 9025-25.)

Is pump control valve adjusted to specification?

Record of Actual Results:

Result:
966
 Hydraulic System Diagnose Malfunctions—IGC

YES:
Go to next check.
NO:
Replace pump control valve.

2 Circuit Relief Valve Pressure Low

Action:

Check circuit relief valve pressure. See Circuit Relief Valve Test—IGC . (Group 9025-25.)

Is circuit relief valve adjusted to specification?

Record of Actual Results:

Result:
YES:
Go to Pilot Control Pressure Low .
NO:
Replace circuit relief valve. See Hydraulic Control Valve Disassemble and Assemble—IGC . (Group 3260.)

3 Pilot Control Pressure Low

Action:

Check pressure reducing valve. See Hydraulic Control Valve Disassemble and Assemble—IGC . (Group
3260.)

Is pressure reducing valve worn or damaged?

Record of Actual Results:

Result:
YES:
Replace pressure reducing valve.
NO:
Go to Circuit Relief Valve Stuck Open .

4 Circuit Relief Valve Stuck Open

Action:

Check circuit relief valves. See Hydraulic Control Valve Disassemble and Assemble—IGC . (Group 3260.)

Is circuit relief valve worn or damaged?

Record of Actual Results:

967
 Hydraulic System Diagnose Malfunctions—IGC

Result:
YES:
Repair or replace circuit relief valve.
NO:
Go to Anticavitation Valve Stuck Open .

5 Anticavitation Valve Stuck Open

Action:

Check anticavitation valves. See Hydraulic Control Valve Disassemble and Assemble—IGC . (Group 3260.)

Is anticavitation valve worn or damaged?

Record of Actual Results:

Result:
YES:
Repair or replace anticavitation valve.
NO:
Go to Hydraulic Pump Worn or Damaged .

6 Hydraulic Pump Worn or Damaged

Action:

Check pump flow. Perform Hydraulic Pump Flow Test . (Group 9025-25.)

Is pump flow to specification?

Record of Actual Results:

Result:
YES:
Checks complete.
NO:
Repair or replace pump as necessary.

Function Drifts Down Diagnostic Procedure—IGC

Launch Close Expand List Collapse List

1 Hydraulic Cylinders Leaking Internally

Action:

Check cylinders for leakage. Perform Lift and Tilt Cylinder Function Drift Test . (Group 9025-25.)

Are any cylinders leaking?

968
 Hydraulic System Diagnose Malfunctions—IGC

Record of Actual Results:

Result:
YES:
Repair or replace leaking cylinders.
NO:
Go to Circuit Relief Valve Stuck Open .

2 Circuit Relief Valve Stuck Open

Action:

Check circuit relief valves. See Hydraulic Control Valve Disassemble and Assemble—IGC . (Group 3260.)

Is circuit relief valve worn or damaged?

Record of Actual Results:

Result:
YES:
Repair or replace circuit relief valve.
NO:
Go to Anticavitation Valve Stuck Open .

3 Anticavitation Valve Stuck Open

Action:

Check anticavitation valves. See Hydraulic Control Valve Disassemble and Assemble—IGC . (Group 3260.)

Is anticavitation valve worn or damaged?

Record of Actual Results:

Result:
YES:
Repair or replace anticavitation valve.
NO:
Go to Hydraulic Control Valve Spool Leaking .

4 Hydraulic Control Valve Spool Leaking

Action:

Inspect and repair control valve. See Hydraulic Control Valve Disassemble and Assemble—IGC . (Group
3260.)

969
 Hydraulic System Diagnose Malfunctions—IGC
Is control valve spool worn or damaged?

Record of Actual Results:

Result:
YES:
Repair or replace control valve.
NO:
Checks complete.

Oil Overheats Diagnostic Procedure—IGC

Launch Close Expand List Collapse List

1 Oil Viscosity Wrong

Action:

Check reservoir oil. See Transmission and Hydraulic Reservoir Oil . (Operator's Manual.)

Is correct oil used?

Record of Actual Results:

Result:
YES:
Go to Hydraulic System Relief Valve Stuck Open or Leaking .
NO:
Replace reservoir oil with recommended oil.

2 Hydraulic System Relief Valve Stuck Open or Leaking

Action:

Check hydraulic system relief valve. See Hydraulic Control Valve Disassemble and Assemble . (Group
3260.)

Is relief valve worn or damaged?

Record of Actual Results:

Result:
YES:
Repair or replace relief valve.
NO:
Go to Circuit Relief Valve Stuck Open or Leaking .

3 Circuit Relief Valve Stuck Open or Leaking

970
 Hydraulic System Diagnose Malfunctions—IGC

Action:

Check circuit relief valves. See Hydraulic Control Valve Disassemble and Assemble . (Group 3260.)

Is circuit relief valve worn or damaged?

Record of Actual Results:

Result:
YES:
Repair or replace circuit relief valve.
NO:
Go to Anticavitation Valve Stuck Open or Leaking .

4 Anticavitation Valve Stuck Open or Leaking

Action:

Check anticavitation valves. See Hydraulic Control Valve Disassemble and Assemble . (Group 3260.)

Is anticavitation valve worn or damaged?

Record of Actual Results:

Result:
YES:
Repair or replace anticavitation valve.
NO:
Go to Hydraulic Lines Blocked or Damaged .

5 Hydraulic Lines Blocked or Damaged

Action:

Inspect hydraulic lines. See Main Hydraulic Component Location . (Group 9025-15.)

Are any hydraulic lines blocked or damaged?

Record of Actual Results:

Result:
YES:
Repair or replace damaged lines.
NO:
Go to Hydraulic Cylinders Leaking Internally .

6 Hydraulic Cylinders Leaking Internally

971
 Hydraulic System Diagnose Malfunctions—IGC

Action:

Check cylinders for leakage. Perform Lift and Tilt Cylinder Function Drift Test . (Group 9025-25.)

Are any cylinders leaking?

Record of Actual Results:

Result:
YES:
Repair or replace leaking cylinders.
NO:
Go to Hydraulic Pump Worn or Damaged .

7 Hydraulic Pump Worn or Damaged

Action:

Check pump Flow. Perform Hydraulic Pump Flow Test . (Group 9025-25.)

Is pump flow to specification?

Record of Actual Results:

Result:
YES:
Checks complete.
NO:
Repair or replace pump as necessary.

Blade Response Not Smooth Diagnostic Procedure—IGC

Launch Close Expand List Collapse List

1 Electrical Connection to Spool Actuators Intermittent

Action:

Check harness and connections to control valve actuators. See Integrated Grade Control (IGC) Machine
Harness (W21) Wiring Diagram—If Equipped . (Group 9015-10.)

Are harness or connectors worn or damaged?

Record of Actual Results:

Result:
YES:
Repair or replace harness or connectors as necessary.

972
 Hydraulic System Diagnose Malfunctions—IGC

NO:
Go to Solenoid Malfunction (DTC) .

2 Solenoid Malfunction (DTC)

Action:

Check solenoid. See Diagnostic Trouble Code (DTC) Quick Reference List—Electrohydraulic Controller
(EHC) . (Group 9001-40.)

Is solenoid malfunctioning?

Record of Actual Results:

Result:
YES:
Repair or replace solenoid as necessary.
NO:
Go to Pump Load Sense Differential and System Pressure Low .

3 Pump Load Sense Differential and System Pressure Low

Action:

Check pump load sense differential and system pressure. Perform Pump Load Sense Differential and
System Pressure Test and Adjustment—IGC . (Group 9025-25.)

Is pump control valve adjusted to specification?

Record of Actual Results:

Result:
YES:
Go to Pump Load Sense Control Spool Binding .
NO:
Replace pump control valve.

4 Pump Load Sense Control Spool Binding

Action:

Inspect and repair pump control. See Hydraulic Pump Control Valve Disassemble and Assemble . (Group
3260.)

Is pump control valve spool binding?

Record of Actual Results:

973
 Hydraulic System Diagnose Malfunctions—IGC

Result:
YES:
Repair or replace pump control valve.
NO:
Go to Hydraulic Control Valve Spool Binding .

5 Hydraulic Control Valve Spool Binding

Action:

Inspect and repair control valve. See Hydraulic Control Valve Disassemble and Assemble—IGC . (Group
3260.)

Is control valve spool binding?

Record of Actual Results:

Result:
YES:
Repair or replace control valve.
NO:
Go to Electrohydraulic Malfunction .

6 Electrohydraulic Malfunction
Action:

Check electrohydraulic circuit. See Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped .
(Group 9015-20.)

Is electrohydraulic circuit malfunctioning?

Record of Actual Results:

Result:
YES:
Replace or replace as necessary.
NO:
Checks complete.

Go to Section_9025:Group_15

OUO1020,0001615-19-20120613

974
 JT02156A Digital Pressure/Temperature Analyzer Installation

JT02156A Digital Pressure/Temperature Analyzer Installation

T8543AI-UN: JT02156A Digital Pressure/Temperature Analyzer

LEGEND:
A - Digital Pressure/Temperature Analyzer
B - 3400 kPa (35 bar) (500 psi) Transducer
34 000 kPa (350 bar) (5000 psi) Transducer
70 000 kPa (700 bar) (10 000 psi) Transducer

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JT02156A Digital Pressure/Temperature Analyzer

JT02159 20 ft. Cable with Couplers

JT02161 500 psi Transducer

JT02162 5000 psi Transducer

JT05969 Thermo-Coupler

312883 Carry Case

JT02160 10 000 psi Transducer (optional, order separately)

JT07148-2 Flow Block

Use the digital pressure/temperature analyzer (A), and transducers (B) in place of analog gauges and a separate
temperature reader.

Transducers are temperature sensitive. Allow transducer to warm to system temperature. After transducer is
warmed and no pressure applied, push sensor zero button for one second to set the true zero point.

When using for different pressures, turn selector to OFF for two seconds and then to the pressure range.
Readings are inaccurate if proper range for transducer is not used.

Go to Section_9025:Group_25

MF82180,0000047-19-20050128

975
 JT02156A Digital Pressure/Temperature Analyzer Installation

JT02156A Digital Pressure/Temperature Analyzer Installation

T8543AI-UN: JT02156A Digital Pressure/Temperature Analyzer

LEGEND:
A - Digital Pressure/Temperature Analyzer
B - 3400 kPa (35 bar) (500 psi) Transducer
34 000 kPa (350 bar) (5000 psi) Transducer
70 000 kPa (700 bar) (10 000 psi) Transducer

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JT02156A Digital Pressure/Temperature Analyzer

JT02159 20 ft. Cable with Couplers

JT02161 500 psi Transducer

JT02162 5000 psi Transducer

JT05969 Thermo-Coupler

312883 Carry Case

JT02160 10 000 psi Transducer (optional, order separately)

JT07148-2 Flow Block

Use the digital pressure/temperature analyzer (A), and transducers (B) in place of analog gauges and a separate
temperature reader.

Transducers are temperature sensitive. Allow transducer to warm to system temperature. After transducer is
warmed and no pressure applied, push sensor zero button for one second to set the true zero point.

When using for different pressures, turn selector to OFF for two seconds and then to the pressure range.
Readings are inaccurate if proper range for transducer is not used.

Go to Section_9025:Group_25

MF82180,0000047-19-20050128

976
 Ultra Clean® Hand Launcher

Ultra Clean® Hand Launcher

Use the Ultra Clean® Hand Launcher Kit to help eliminate contamination in hydraulic systems. All newly installed
hose and tube assemblies should be cleaned using this tool.

Go to Section_9025:Group_25

BR81691,000000E-19-20160229

977
 Hydraulic Oil Cleanup Procedure

Hydraulic Oil Cleanup Procedure

A hydraulic oil cleanup procedure must be done prior to starting machine after a component has been repaired or
replaced. The use of attachments increases the need to monitor and filter oil to a safe contamination level. See
750J and 850J Crawler Dozer General Oil Cleanup Procedure . (CTM310—Super Caddy Oil Cleanup Procedure.)

Go to Section_9025:Group_25

TE14778,0000087-19-20050125

978
 Hydraulic System Relief Valve Test

Hydraulic System Relief Valve Test

T206639-UN: Hydraulic System Relief Valve

LEGEND:
104 - Hydraulic Pump
132 - Hydraulic Pump-to-Control Valve Inlet Hose
151 - Hydraulic System Relief Valve

-: Specifications

SPECIFICATIONS

System Relief Valve Pressure 28 269—28 786 kPa

282.7—287.9 bar
4100—4175 psi

979
 Hydraulic System Relief Valve Test
-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JT07192 Electric/Hydraulic Pump

Gauge (0—35 000 kPa) (0—350 bar) (0—5000 psi)

1. Relieve hydraulic system pressure.

2. Tilt cab.

3. NOTE:

Hydraulic system relief valve (151) is located in the control valve inlet section.

Disconnect and cap hydraulic pump-to-control valve inlet hose (132).

4. Connect JT07192 Electric/Hydraulic Pump pressure hose to control valve inlet section.

5. Start pump to pressurize valve inlet. Record relief valve pressure setting.

6. Adjust system relief valve to specification or replace. To adjust pressure setting, loosen nut on system
relief valve. Turn adjusting hex screw in to increase pressure or out to decrease pressure.

Item Measurement Specification

System Relief Valve Pressure 28 269—28 786 kPa
282.7—287.9 bar
4100—4175 psi

Go to Section_9025:Group_25

OUO1020,0001625-19-20090527

980
 Hydraulic System Relief Valve Test—IGC

Hydraulic System Relief Valve Test—IGC

TX1058380-UN: Hydraulic System Relief Valve—IGC

LEGEND:
104 - Hydraulic Pump
132 - Hydraulic Pump-to-Control Valve Inlet Hose
221 - System Relief Valve
222 - Control Valve—IGC

-: Specifications

SPECIFICATIONS

System Relief Valve Pressure 28 000—30 800 kPa

280—308 bar
4060—4466 psi

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JT07192 Electric/Hydraulic Pump

Gauge (0—35 000 kPa) (0—350 bar) (0—5000 psi)

1. Relieve hydraulic system pressure.

2. Tilt cab.

3. NOTE:

Hydraulic system relief valve (221) is located in the control valve end section.

Disconnect and cap hydraulic pump-to-control valve inlet hose (132).

981
 Hydraulic System Relief Valve Test—IGC

4.

TX1059756A-UN: Hydraulic Test Ports

LEGEND:
203 - Pump Pressure Test Port
204 - JT02156A Digital Pressure/Temperature Analyzer

Install JT02156A Digital Pressure Analyzer (204) with transducer and adapter fitting to the hydraulic test
port (203).

5. Connect JT07192 Electric/Hydraulic Pump pressure hose to inlet port (port P) on control valve
inlet/outlet section.

6. Start pump to pressurize control valve inlet port. Record relief valve pressure setting.

7. NOTE:

System relief valve is not adjustable.

If system relief valve is not within specification, replace system relief valve.

Item Measurement Specification

System Relief Valve Pressure 28 000—30800 kPa
280—308 bar
4060—4466 psi

Go to Section_9025:Group_25

RH60123,0000730-19-20130909

982
 Circuit Relief Valve Test

Circuit Relief Valve Test

-: Specifications

SPECIFICATIONS

Angle Cylinder Circuit Relief Valve Pressure 26 200—26 717 kPa

262—267 bar
3800—3875 psi

Lift Rod End Cylinder Circuit Relief Valve Pressure 27 579—28 096 kPa
276—281 bar
4000—4075 psi

Lift Head End Cylinder Circuit Relief Valve Pressure 15 513—16 030 kPa
155—160 bar
2250—2325 psi

Ripper Lift Rod End Cylinder Circuit Relief Valve Pressure 38 610 kPa
386 bar
5600 psi

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JT07192 Electric/Hydraulic Pump

Gauge (0—35 000 kPa) (0—350 bar) (0—5000 psi)

JT02156A Digital Pressure/Temperature Analyzer

1. Relieve hydraulic system pressure.

2. Tilt cab.

3. NOTE:

Power Angle Tilt (PAT) machines have circuit relief valves on the blade angle valve
section. Outside Dozers (OSD) have circuit relief valves on the blade lift valve section.

Disconnect and cap work port hose of circuit relief valve to be tested.

4. Connect JT07192 Electric/Hydraulic Pump pressure hose to work port that hose disconnected from.

5. Start pump to pressurize valve inlet. Record circuit relief valve pressure setting.

6. Adjust circuit relief valve to specification or replace. To adjust setting, loosen nut on circuit relief valve.
Turn adjusting hex screw in to increase pressure or out to decrease pressure.

983
 Circuit Relief Valve Test

Item Measurement Specification

Angle Cylinder Circuit Relief Valve Pressure 26 200—26 717 kPa
262—267 bar
3800—3875 psi
Lift Rod End Cylinder Circuit Relief Valve Pressure 27 579—28 096 kPa
276—281 bar
4000—4075 psi
Lift Head End Cylinder Circuit Relief Valve Pressure 15 513—16 030 kPa
155—160 bar
2250—2325 psi
Ripper Lift Rod End Cylinder Circuit Relief Valve Pressure 38 610 kPa
386 bar
5600 psi

Go to Section_9025:Group_25

OUO1020,0001624-19-20070208

984
 Circuit Relief Valve Test—IGC

Circuit Relief Valve Test—IGC

-: Specifications

SPECIFICATIONS

Hydraulic Oil Temperature 60—71°C

140—160°F

Blade Angle Circuit Relief Valve—IGC Pressure 38 000—41 800 kPa

380—418 bar
5511—6063 psi

Auxiliary Circuit Relief Valve—IGC Pressure 38 000—41 800 kPa

380—418 bar
5511—6063 psi

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JT07192 Electric/Hydraulic Pump

JT02160 Pressure Transducer (0—70 000 kPa) (0—700 bar) (0—10000 psi)

JT02156A Digital Pressure/Temperature Analyzer

NOTE:

Integrated Grade Control (IGC) is available as an option.

1. Warm hydraulic oil to specification.

Item Measurement Specification

Hydraulic Oil Temperature 60—71°C
140—160°F

2. CAUTION:
To avoid injury from escaping fluid under pressure, stop engine and relieve the
pressure in the system before disconnecting or connecting hydraulic or other
lines. Tighten all connections before applying pressure.

Relieve hydraulic system pressure.

3. Tilt cab.

4. NOTE:

Integrated Grade Control (IGC) machines have circuit relief valves on the auxiliary and
blade angle valve sections.

Disconnect work port hose of circuit relief valve to be tested. Close open end of work port hose with a

985
 Circuit Relief Valve Test—IGC
plug.

5. Connect JT07192 Electric/Hydraulic Pump pressure hose, JT02160 Pressure Transducer, and
JT02156A Digital Pressure/Temperature Analyzer to open fitting of work port.

6. NOTE:

Make sure pump relief valve is set higher than circuit relief valve being checked.

Start pump to pressurize function circuit. Record circuit relief valve pressure setting.

7. Circuit relief valve is not adjustable. Circuit relief valve pressure setting must be to specification. If
pressure setting is not to specification, replace circuit relief valve. See Hydraulic Control Valve
Disassemble and Assemble—IGC . (Group 3260.)

Item Measurement Specification

Blade Angle Circuit Relief Valve—IGC Pressure 38 000—41 800 kPa
380—418 bar
5511—6063 psi
Auxiliary Circuit Relief Valve—IGC Pressure 38 000—41 800 kPa
380—418 bar
5511—6063 psi

Go to Section_9025:Group_25

OUO1020,0001621-19-20070208

986
 Pump Load Sense Differential and System Pressure (Pump Cut-Off) Test and Adjustment

Pump Load Sense Differential and System Pressure (Pump Cut-Off) Test and Adjustment

-: Specifications

SPECIFICATIONS

Hydraulic Oil Temperature 60—71°C

140—160°F

Pump Load Sense Differential Test and Adjustment

Engine Speed Fast Idle

Load Sense Differential Pressure 1793—2000 kPa

17.9—20 bar
260—290 psi

System Pressure (Pump Cut-Off) Test and Adjustment

Engine Speed Slow Idle

Hydraulic System (pump cut-off) Pressure 24 700—25 300 kPa

247—253 bar
3582—3670 psi

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JT02156A Digital Pressure/Temperature Analyzer

JT02162 Transducer (0—34 000 kPa) (0—350 bar) (0—5000 psi)

RE60700 Adapter Fitting

The purpose of this test is to adjust pump load sense differential and system pressure (pump cut-off pressure).
The pump cut-off pressure is set lower than the system relief valve in the control valve, and will limit overall
hydraulic system pressure.

Machine Preparation

1.

T206452A-UN: Hydraulic Test Ports

LEGEND:
202 - Load Sense Test Port
203 - Pump Pressure Test Port

987
 Pump Load Sense Differential and System Pressure (Pump Cut-Off) Test and Adjustment
204 - JT02156A Digital Pressure Analyzer

Install JT02156A Digital Pressure Analyzer (204) with transducers and adapter fittings to the hydraulic
test ports (202 and 203).

2. Warm hydraulic oil to specification.

Item Measurement Specification

Hydraulic Oil Temperature 60—71°C
140—160°F

Pump Load Sense Differential Test and Adjustment

1.

T206453A-UN: Hydraulic Pump Control Valve

LEGEND:
177 - High Pressure Cut-Off Adjustment Screw
178 - Load Sense Differential Pressure Adjustment Screw

Run engine at specification.

Item Measurement Specification
Pump Load Sense Differential Test and Adjustment
Engine Speed Fast Idle

2. Slowly tilt blade and record load sense differential (port 203 pressure – port 202 pressure = load sense
differential). Compare to specification.

Item Measurement Specification

Pump Load Sense Differential Test and Adjustment
Load Sense Differential Pressure 1793—2000 kPa
17.9—20 bar
260—290 psi

3. If load sense differential pressure is not within specification, adjust pressure using load sense differential
adjusting screw (178).

1. Remove cap covering load sense differential adjusting screw.

2. Loosen lock nut on load sense differential adjusting screw.

3. Turn adjusting screw in to increase pressure or out to decrease pressure.

4. Tighten lock nut, and replace cap.

988
 Pump Load Sense Differential and System Pressure (Pump Cut-Off) Test and Adjustment

System Pressure (Pump Cut-Off) Test and Adjustment

1. Run engine at specification.

Item Measurement Specification

System Pressure (Pump Cut-Off) Test and Adjustment
Engine Speed Slow Idle

2. Hold blade tilt function over relief and record system (pump cut-off) pressure (port 203 pressure).
Compare to specification.

Item Measurement Specification

System Pressure (Pump Cut-Off) Test and Adjustment
Hydraulic System (pump cut-off) Pressure 24 700—25 300 kPa
247—253 bar
3582—3670 psi

3.

T206453A-UN: Hydraulic Pump Control Valve

LEGEND:
177 - High Pressure Cut-Off Adjustment Screw
178 - Load Sense Differential Pressure Adjustment Screw

If system (pump cut-off) pressure is not within specification, adjust pressure using high pressure cut-off
adjustment screw (177).

1. Remove cap covering high pressure cut-off adjustment screw.

2. Loosen lock nut on high pressure cut-off adjustment screw.

3. Turn adjusting screw in to increase pressure or out to decrease pressure.

4. Tighten lock nut, and replace cap.

4. When all adjustments have been made, remove test equipment from machine.

Go to Section_9025:Group_25

OUO1020,0001622-19-20100621

989
 Pump Load Sense Differential and System Pressure Test and Adjustment—IGC

Pump Load Sense Differential and System Pressure Test and Adjustment—IGC

-: Specifications

SPECIFICATIONS

Hydraulic Oil Temperature 60—71°C

140—160°F

Engine Speed Fast Idle

Load Sense Differential—IGC [Machine with integrated grade control (IGC).] Pressure 1793—2000 kPa
17.9—20 bar
260—290 psi

Engine Speed Slow Idle

Hydraulic System—IGC Pressure 24 700—25 300 kPa

247—253 bar
3582—3670 psi

Load Sense Relief—IGC Pressure 23 100—23 800 kPa

231—238 bar
3350—3452 psi

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JT02156A Digital Pressure/Temperature Analyzer

JT02162 Transducer (0—34 000 kPa) (0—350 bar) (0—5000 psi)

RE60700 Adapter Fitting

NOTE:

Integrated Grade Control (IGC) is available as an option.

The purpose of this test is to adjust pump load sense differential and system pressure.

1.

T206452A-UN: Hydraulic Test Ports

LEGEND:
202 - Load Sense Test Port

990
 Pump Load Sense Differential and System Pressure Test and Adjustment—IGC
203 - Pump Pressure Test Port
204 - JT02156A Digital Pressure/Temperature Analyzer

Install JT02156A Digital Pressure Analyzer (204) with transducers and adapter fittings to the hydraulic
test ports (202 and 203).

2. Warm hydraulic oil to specification.

Item Measurement Specification

Hydraulic Oil Temperature 60—71°C
140—160°F

3.

T206453A-UN: Hydraulic Pump Control Valve

LEGEND:
177 - High Pressure Cut-Off Adjustment Screw (system pressure)
178 - Load Sense Differential Pressure Adjustment Screw

Remove hydraulic pump control valve caps.

4. Run engine at specification.

Item Measurement Specification

Engine Speed Fast Idle

5. Record load sense differential pressure reading at test port (202) while slowly tilting blade. Adjust load
sense differential pressure adjusting screw (178) to specification, while slowly tilting blade.

Item Measurement Specification

Load Sense Differential—IGC [Machine with integrated grade control Pressure 1793—2000
(IGC).] kPa
17.9—20 bar
260—290 psi

6. Run engine at specification.

Item Measurement Specification

Engine Speed Slow Idle
7. IMPORTANT:

The load sense relief valve may be used to adjust system pressure but also must be kept within load
sense relief valve pressure specifications.

991
 Pump Load Sense Differential and System Pressure Test and Adjustment—IGC
Hold blade function over relief and record system pressure reading from test port (203). If load sense
differential pressure was met, adjust the load sense relief valve at the hydraulic control valve to adjust
system pressure to specification. See Hydraulic Control Valve Operation—IGC . (Group 9025-05.) If load
sense differential pressure was not met, adjust the high pressure cut-off adjustment screw (177) to
adjust system pressure to specification.

Item Measurement Specification

Hydraulic System—IGC Pressure 24 700—25 300 kPa
247—253 bar
3582—3670 psi

8. With blade function over relief, record load sense relief pressure reading from test port (202). Adjust load
sense relief valve adjustment screw to specification. See Hydraulic Control Valve Operation—IGC .
(Group 9025-05.)

Item Measurement Specification

Load Sense Relief—IGC Pressure 23 100—23 800 kPa
231—238 bar
3350—3452 psi

Go to Section_9025:Group_25

OUO1020,0001623-19-20090527

992
 Lift and Tilt Cylinder Function Drift Test

Lift and Tilt Cylinder Function Drift Test

-: Specifications

SPECIFICATIONS

Hydraulic Oil Temperature 60—72°C

140—160°F

Lift Cylinder Rod Drift Maximum 4 mm/min

0.16 in./min

Tilt Cylinder Rod Drift Maximum 2 mm/min

0.08 in./min

Lift Cylinder Rod Drift Maximum 4 mm/min

0.16 in./min

Tilt Cylinder Rod Drift Maximum 2 mm/min

0.08 in./min

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Tape and Ruler

X9811-UN: Escaping Fluid

993
 Lift and Tilt Cylinder Function Drift Test
T6222AM-UN: Measure Movement of Cylinder Rod

CAUTION:
Relieve pressure in circuit prior to disconnecting hydraulic lines.

NOTE:

Cylinder rod movement is an indication of cylinder drift. Drift can be caused by leakage in cylinder
packing, cylinder bypass valve poppets, circuit relief valve, control valve, or quick-drop valve.
Cylinders are tested for both blade raise and blade lower rod movement.

1. Warm hydraulic oil to specification.

Item Measurement Specification

Hydraulic Oil Temperature 60—72°C
140—160°F

2. Raise blade approximately two feet from ground. Place control valve in neutral.

3. Stop engine.

4. Measure movement of lift and tilt cylinder rod for 5 minutes. Divide measured rod movement by five to
determine drift per minute.

Item Measurement Specification

Lift Cylinder Rod Maximum Drift 4 mm/min
0.16 in./min
Tilt Cylinder Rod Maximum Drift 2 mm/min
0.08 in./min

5. Start machine. Lower blade to ground.

6. Raise front of machine off ground 2—3 inches. Place control valve in neutral.

7. Stop engine.

8. Measure movement of lift and tilt cylinder rod for five minutes.Divide measured rod movement by five to
determine drift per minute.

Item Measurement Specification

Lift Cylinder Rod Maximum Drift 4 mm/min
0.16 in./min
Tilt Cylinder Rod Maximum Drift 2 mm/min
0.08 in./min

9. If cylinders drift in rod extend function only, perform Cylinder Leakage Test . (Group 9025-25.)

10. If cylinder drifts in both directions, leakage could be in the control valve.

994
Lift and Tilt Cylinder Function Drift Test

Go to Section_9025:Group_25

TX,9025,BS457-19-19950228

995
 Cylinder Leakage Test

Cylinder Leakage Test

-: Specifications

SPECIFICATIONS

Oil Temperature 60—72°C

140—160°F

Approximate Engine Speed 1000 rpm

Cylinder Leakage Test Maximum Allowable Flow 5 mL/min

1/6 oz./min

1.

X9811-UN: Avoid High-Pressure Fluids

T6222AL-UN: Cylinder Leakage Test

Heat hydraulic oil to specification.
Item Measurement Specification
Oil Temperature Temperature 60—72°C
140—160°F

2. Fully extend rod on cylinder to be checked. Turn engine off.

3. CAUTION:
Escaping fluid under pressure can 996
penetrate the skin causing serious injury.
 Cylinder Leakage Test
Escaping fluid under pressure can penetrate the skin causing serious injury.
Relieve pressure before disconnecting hydraulic or other lines. Tighten all
connections before applying pressure. Keep hands and body away from pinholes
and nozzles which eject fluids under high pressure. Use a piece of cardboard or
paper to search for leaks. Do not use you hand.

If ANY fluid is injected into the skin, it must be surgically removed within a few
hours by a doctor familiar with this type of injury or gangrene may result.

Remove hose from rod end of cylinder. Position a beaker under rod end port.

4. Plug hose that was disconnected from rod end of cylinder.

5. Start and run engine at specification.

Item Measurement Specification

Approximate Engine Speed 1000 rpm

6. Activate rod extend function and record leakage from rod end of cylinder for one minute.

Item Measurement Specification

Cylinder Leakage Test Maximum Allowable Flow 5 mL/min
1/6 oz./min

If leakage is in one direction, but not both directions, disassemble cylinder and inspect bypass valve
poppet.

If leakage in a cylinder is in both directions, disassemble cylinder and repair seals and packing.

If no cylinder leakage in either direction is found, the problem is in the control valve or quick-drop valve if
equipped. Check relief valve for contamination and O-ring leakage. Disassemble control valve and
check for spool or bore scoring. Test quick-drop valve drift.

Go to Section_9025:Group_25

CED,TX03768,2287-19-20120801

997
 Pressure Reducing Valve Pressure Test and Adjustment

Pressure Reducing Valve Pressure Test and Adjustment

-: Specifications

SPECIFICATIONS

Hydraulic Oil Temperature 57—66°C

135—150°F

Engine Speed Slow Idle

Pressure Reducing Valve Pressure 4137—4826 kPa

41.4—48.3 bar
600—700 psi

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JTO2156A Digital Pressure Analyzer

JTO2162 34 000 kPa (350 bar) (5000 psi) Transducer

The purpose of this test is to determine the pressure setting of the Pressure Reducing Valve (PRV). The PRV
regulates pressure to the pilot control systems.

This procedure is used to test and adjust regulated pressure in the pilot control system.

1. Warm hydraulic oil to specification.

Item Measurement Specification

Hydraulic Oil Temperature 57—66°C
135—150°F

2. Relieve all hydraulic system pressure by cycling hydraulic functions with key in on position.

3.

T206458A-UN: Pressure Reducing Valve

LEGEND:
204 - JTO2156A Digital Pressure Analyzer
205 - Pressure Reducing Adjustment Screw
206 - Pressure Reducing Valve Test Port

998
 Pressure Reducing Valve Pressure Test and Adjustment
Install JTO2156A Digital Pressure Analyzer with pressure transducers to PRV test port (206).

4. Start engine and hold a blade function over relief at slow idle. Record pressure reading. Pressure should
be within specification.

Item Measurement Specification Item Measurement Specification

Engine Speed Slow Idle Pressure Reducing Valve Pressure 4137—4826 kPa
41.4—48.3 bar
600—700 psi

5. If pressure is not within specification, remove spool end cap and adjust pressure. While holding a blade
function over relief at slow idle, turn pressure reducing adjustment screw (205) in to increase pressure
and out to decrease pressure .

Go to Section_9025:Group_25

BR81691,0000006-19-20041217

999
 Blade Down Accumulator Hydraulic Discharge

Blade Down Accumulator Hydraulic Discharge

The purpose of this procedure is to ensure that no hydraulic pressure remains in accumulator prior to charging
accumulator.

CAUTION:
Prevent possible injury from high pressure fluid. Discharge accumulator before servicing
any hydraulic components. Hydraulic oil in accumulator can be stored at pressures equal
to or above system relief pressures.

1. Warm hydraulic oil to specification.

Item Measurement Specification

Hydraulic Oil Temperature 60—71°C
140—160°F

2. Lower blade to ground and stop engine.

3. Install JT02156A Digital Pressure Analyzer with pressure transducers to Pressure Reducing Valve
(PRV) test port.

4. Turn key switch to on position. Without starting engine and hydraulic enable switch in unlocked position,
cycle hydraulic control lever in all directions.

5. Hold hydraulic control lever in forward position until digital pressure analyzer reads zero. All hydraulic
accumulator pressure has been discharged.

Go to Section_9025:Group_25

OUO1020,000162F-19-20070220

1000
 Blade Down Accumulator Precharge Test

Blade Down Accumulator Precharge Test

-: Specifications

SPECIFICATIONS

Hydraulic Oil Temperature 57—66°C

135—150°F

Pressure Reducing Valve Pressure 4137—4826 kPa

41.4—48.3 bar
600—700 psi

Blade Down Accumulator Precharge Pressure 1034—1241 kPa

10.3—12.4 bar
150—180 psi

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JTO2156A Digital Pressure Analyzer

JTO2162 34 000 kPa (350 bar) (5000 psi) Transducer

The purpose of this test is to determine blade down accumulator precharge pressure.

1. Install JTO2156A Digital Pressure Analyzer with pressure transducer to Pressure Reducing Valve (PRV)
test port.

2. Start engine, warm hydraulic oil to specification.

Item Measurement Specification

Hydraulic Oil Temperature 57—66°C
135—150°F

3. Operate pilot function to fully charge accumulator.

4. Record PRV pressure. Pressure should be within specification.

Item Measurement Specification

Pressure Reducing Valve (PRV) Pressure 4137—4826 kPa
41.4—48.3 bar
600—700 psi
If pressure is not within specification, see Pressure Reducing Valve Pressure Test and Adjustment .
(Group 9025-25.)

5. Stop engine with blade on ground.

6. Turn key switch to on position.

7. NOTE:

Blade down accumulator pressure will drop slowly when cycling lever. The last pressure
seen before pressure drop of 345 kPa (3.4 bar) (50 psi), is the blade down accumulator
precharge pressure. Accumulator precharge pressure must be within specification.
1001
 Blade Down Accumulator Precharge Test

Record pressure while slowly cycling hydraulic control lever to blade up and down positions.

Item Measurement Specification

Blade Down Accumulator Precharge Pressure 1034—1241 kPa
10.3—12.4 bar
150—180 psi

Go to Section_9025:Group_25

BR81691,0000007-19-20080130

1002
 Hydraulic Pump Flow Test

Hydraulic Pump Flow Test

-: Specifications

SPECIFICATIONS

Engine Speed 2200 rpm

Hydraulic Oil Temperature 60—72°C

140—160°F

Hydraulic Oil Pressure 13 700 kPa

137 bar
2000 psi

New, (63 cm 3) Minimum Flow 130 L/min.

34 gpm

New, (100 cm 3) Minimum Flow 210 L/min.

55 gpm

Used, (63 cm 3) Minimum Flow 110 L/min.

29 gpm

Used, (100 cm3) Minimum Flow 176 L/min.

46 gpm

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JT07148 Flowmeter

CAUTION:

X9811-UN: Avoid High-Pressure Fluids

Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve
pressure before disconnecting hydraulic or other lines. Tighten all connections before
applying pressure. Keep hands and body away from pinholes and nozzles which eject
fluids under high pressure. Use a piece of cardboard or paper to search for leaks. Do not
use your hand.

If ANY fluid is injected into the skin, it must be surgically removed within a few hours by a
1003
 Hydraulic Pump Flow Test
doctor familiar with this type injury or gangrene may result.

1. Relieve hydraulic system pressure.

2. Tilt cab.

3. Pull vacuum on hydraulic reservoir.

4.

T206566A-UN: Hydraulic Flow Test

LEGEND:
131 - Load Sense Hose
132 - Hydraulic Pump-to-Control Valve Inlet Hose
166 - Control Valve-to-Hydraulic Filter Hose
167 - Tee Fitting
168 - Flowmeter

Disconnect hydraulic pump-to-control valve inlet hose (132).

5. Disconnect load sense hose (131) (hydraulic pump-to-control valve) from control valve outlet section.

6. Disconnect control valve-to-hydraulic filter hose (166) from control valve.

7. Connect hoses (131 and 132) from hydraulic pump to tee fitting (167) before flowmeter (168), as shown.

8. Connect control valve-to-hydraulic filter hose (166) to flowmeter outlet port.

9. Start engine and run at specification.

Item Measurement Specification

Engine Speed 2200 rpm

10. Slowly close flowmeter loading valve to obtain specified temperature and pressure.

Item Measurement Specification

Hydraulic Oil Temperature 60—72°C
140—160°F
Hydraulic Oil Pressure 13 700 kPa
137 bar
2000 psi

1004
 Hydraulic Pump Flow Test

11. NOTE:

Machines with high output hydraulic option are equipped with a 100 cm 3hydraulic pump.

Record pump flow reading.

Item Measurement Specification

3
New, (63 cm ) Minimum Flow 130 L/min.
34 gpm
New, (100 cm 3) Minimum Flow 210 L/min.
55 gpm
Used, (63 cm 3) Minimum Flow 110 L/min.
29 gpm
Used, (100 cm3) Minimum Flow 176 L/min.
46 gpm

Go to Section_9025:Group_25

OUO1020,0001626-19-20120801

1005
 Hydraulic Pump Case Drain Test

Hydraulic Pump Case Drain Test

-: Specifications

SPECIFICATIONS

Hydraulic Oil Temperature 60—71°C

140—160°F

Engine Speed 2200 rpm

New, (63 cm 3) Hydraulic Pump Case Drain Maximum Leakage 7 L/min.

1.8 gpm

New, (100 cm 3) Hydraulic Pump Case Drain Maximum Leakage 10 L/min.

2.6 gpm

Used, (63 cm 3) Hydraulic Pump Case Drain Maximum Leakage 27 L/min.

7.1 gpm

Used, (100 cm3) Hydraulic Pump Case Drain Maximum Leakage 44 L/min.
11.6 gpm

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JT07148 Flowmeter

The purpose of this test is to determine efficiency of the pump rotating group by measuring amount of case drain
with pump at maximum pressure. Case drain flow is combined result of built-in pump cooling flow and leakage
from rotating group and pump control. Perform this test before removing or replacing pump.

1. Pull vacuum on hydraulic reservoir.

1006
 Hydraulic Pump Case Drain Test
2.

T206793-UN: Hydraulic Pump Case Drain

LEGEND:
104 - Hydraulic Pump
130 - Hydraulic Reservoir-to-Hydraulic Pump Inlet Hose
199 - Hydraulic Pump Case Drain Hose

Disconnect pump case drain hose (199) from top of pump (104).
3. IMPORTANT:

Non-adjustable flowmeter is the best tool for this test. If using adjustable flowmeter, flowmeter control
valve must be open at all times. Serious hydraulic pump damage may result if pump back pressure is
increased.

Connect a non-adjustable flowmeter to pump case drain port with a test hose.

4. Connect flowmeter outlet to hydraulic hose (199) which was previously removed from pump case drain
port.

5. Remove vacuum from hydraulic reservoir.

6. Start engine and warm hydraulic oil to specification.

Item Measurement Specification

Hydraulic Oil Temperature 60—71°C
140—160°F

1007
 Hydraulic Pump Case Drain Test

7. Run engine at specification.

Item Measurement Specification

Engine Speed 2200 rpm

8. NOTE:

Machines with high output hydraulic option are equipped with a 100 cm 3hydraulic pump.

Hold blade lift function over relief and record flow. Case drain flow must be within specification.

Item Measurement Specification

3
New, (63 cm ) Hydraulic Pump Case Drain Maximum Leakage 7 L/min.
1.8 gpm
New, (100 cm 3) Hydraulic Pump Case Drain Maximum Leakage 10 L/min.
2.6 gpm
Used, (63 cm 3) Hydraulic Pump Case Drain Maximum Leakage 27 L/min.
7.1 gpm
Used, (100 cm3) Hydraulic Pump Case Drain Maximum Leakage 44 L/min.
11.6 gpm

Go to Section_9025:Group_25

OUO1020,0001627-19-20120801

1008
 Table of Contents

Section 9026: Hydrostatic System

Group 05: Theory of Operation

Hydrostatic System

Transmission Control Circuit Operation (Flow Chart)

Charge Pump Operation

Hydrostatic Charge Oil Filter Operation

Neutral Charge Relief Valve Operation

Multi-Function Valve Operation

Hydraulic Integrated Circuit (HIC) Valve Operation

Park Brake Valve Operation

Oil Cooler and Reservoir Bypass Operation

Pump Pressure Control Pilot (PCP) Operation

Pump Displacement Control Valve (PDCV) Operation

Hydrostatic Pump Operation

Flushing Valve and Operating Charge Relief Valve Operation

Hydrostatic Motor Operation

Hydraulic Reversing Fan Drive Operation

Hydraulic Non-Reversing Fan Drive Operation

Hydraulic Fan Return Filter Operation

Group 15: Diagnostic Information

Overheating Malfunctions

Low Charge Pressure Malfunctions

Mistrack/Index Malfunctions

Machine Full Speed Malfunctions

Low Power Malfunctions

Track Malfunctions

TCU Calibration Malfunctions

Hydrostatic System Component Location

Park Brake System Component Location

Hydrostatic System Schematic—Neutral (Park Brake On)

Hydrostatic System Diagram—Neutral (Park Brake On)

Hydrostatic System Diagram—Reverse (Slow Speed)

Hydrostatic System Diagram—Forward (Fast Speed)

1009
 Table of Contents
Group 25: Tests

JT02156A Digital Pressure/Temperature Analyzer Installation

Ultra Clean® Hand Launcher

Machine Supporting Procedure

Transmission Oil Warm-Up Procedure

Releasing Park Brake to Tow the Machine

Hydrostatic Pump and Motor Initial Start-Up Procedure

Hydrostatic Pump Flushing Procedure

Hydraulic Oil Cleanup Procedure

Pressure Control Pilot (PCP) Manual Override Test

Pressure Control Pilot (PCP) Test

Pressure Control Pilot (PCP) Internal Adjustment

Multi-Function Relief Valve Test

Transmission Efficiency Test

Neutral Charge Relief and Operating Charge Relief Pressure Test

Pump Displacement Control Valve (PDCV) Neutral (Null) Adjustment

Pump Servo Pressure Test

Motor Displacement Control Valve (MDCV) Adjustment

Hydrostatic Motor Min./Max. Angle Servo Piston Pressure Test

Charge Pump Flow Test

Charge Pressure Sensor Test

Hydrostatic Oil Cooler Bypass Test

Hydrostatic Oil Reservoir Bypass Test

Park Brake Test

Park Brake Relief Valve Test

Cab Tilt Relief Valve Test

Fan Pump Pressure Test

Fan Pump Flow Test

Fan Motor Speed Test

Fan Motor Case Drain Test

1010
 Hydrostatic System

Hydrostatic System

The transmission consists of an automatic, dual-path, hydrostatic drive with a load sensing feature that
automatically adjusts speed and power to match changing load conditions. An electronic controller governs
transmission control. Each individually controlled track is powered by a variable displacement axial piston pump
and a variable displacement bent axis motor combination. Travel speeds (forward and reverse) are controlled by a
rocker switch on the Transmission Control Lever (TCL). Independently selectable reverse speed ratios of 80%,
100%, 115%, or 130% of forward ground speed are selected through the monitor. A decelerator pedal controls
ground speed down to a complete stop.

The pumps are mounted directly to the engine in a tandem configuration and are designed for through torque
capability. This means the main hydraulic pump and winch can be driven from the back of the tandem hydrostatic
pump. High pressure hoses transmit pump flow to the motors. The variable displacement bent axis motors are
mounted directly to the final drives.

Transmission control can be divided into three groups: inputs, outputs, and feedbacks.

The operator sends inputs into the Transmission Control Unit (TCU) from the steering sensor, TCL sensor,
transmission speed control switch, decelerator sensor, decelerator mode switch, and engine speed control
sensor.

The TCU sends a current signal to the Pressure Control Pilot (PCP) on each pump. The PCP is a servo valve
which produces a hydraulic pressure differential relative to the amount of current. The pressure differential is sent
to the Pump Displacement Control Valve (PDCV) on the pump. This shifts the servo piston causing the angle of
the swash plate to increase or decrease, controlling the amount of displacement produced by the axial pistons.

The TCU also sends a current signal to energize the motor shift solenoid on the motor. The motor is normally held
at its maximum displacement (slower speed, greater torque). Energizing the solenoid will cause the servo piston
to shift causing the angle of the swash plate to decrease. As the swash plate angle decreases the displacement
decreases (faster speed, less torque).

The left and right motor speed sensors provide feedback to the TCU for tracking. The Engine Control Unit (ECU)
provides engine speed feedback to the TCU for antistall control. The TCU compares operator input commands
and feedback from the sensors to regulate output accordingly.

Go to Section_9026:Group_05

AA95137,0000814-19-20120801

1011
 Hydrostatic System

Hydrostatic System

The transmission consists of an automatic, dual-path, hydrostatic drive with a load sensing feature that
automatically adjusts speed and power to match changing load conditions. An electronic controller governs
transmission control. Each individually controlled track is powered by a variable displacement axial piston pump
and a variable displacement bent axis motor combination. Travel speeds (forward and reverse) are controlled by a
rocker switch on the Transmission Control Lever (TCL). Independently selectable reverse speed ratios of 80%,
100%, 115%, or 130% of forward ground speed are selected through the monitor. A decelerator pedal controls
ground speed down to a complete stop.

The pumps are mounted directly to the engine in a tandem configuration and are designed for through torque
capability. This means the main hydraulic pump and winch can be driven from the back of the tandem hydrostatic
pump. High pressure hoses transmit pump flow to the motors. The variable displacement bent axis motors are
mounted directly to the final drives.

Transmission control can be divided into three groups: inputs, outputs, and feedbacks.

The operator sends inputs into the Transmission Control Unit (TCU) from the steering sensor, TCL sensor,
transmission speed control switch, decelerator sensor, decelerator mode switch, and engine speed control
sensor.

The TCU sends a current signal to the Pressure Control Pilot (PCP) on each pump. The PCP is a servo valve
which produces a hydraulic pressure differential relative to the amount of current. The pressure differential is sent
to the Pump Displacement Control Valve (PDCV) on the pump. This shifts the servo piston causing the angle of
the swash plate to increase or decrease, controlling the amount of displacement produced by the axial pistons.

The TCU also sends a current signal to energize the motor shift solenoid on the motor. The motor is normally held
at its maximum displacement (slower speed, greater torque). Energizing the solenoid will cause the servo piston
to shift causing the angle of the swash plate to decrease. As the swash plate angle decreases the displacement
decreases (faster speed, less torque).

The left and right motor speed sensors provide feedback to the TCU for tracking. The Engine Control Unit (ECU)
provides engine speed feedback to the TCU for antistall control. The TCU compares operator input commands
and feedback from the sensors to regulate output accordingly.

Go to Section_9026:Group_05

AA95137,0000814-19-20120801

1012
 Transmission Control Circuit Operation (Flow Chart)

Transmission Control Circuit Operation (Flow Chart)

TX1075011-UN: Transmission Control Circuit (Flow Chart)

LEGEND:
1 - Operator Input Commands
2 - Power in 24 V DC
3 - Tracking Feedback
4 - Current
5 - To Left Track
6 - To Right Track
7 - Throttle Command
8 - Anti-Stall

1013
 Transmission Control Circuit Operation (Flow Chart)
9 - Voltage
10 - Differential Control Pressure
11 - Fuel Delivery Command
12 - Rear Pump Displacement Control Valve (PDCV)
13 - Front Pump Displacement Control Valve (PDCV)
14 - Engine
15 - Front Pump
16 - Rear Pump
17 - Left Motor
18 - Right Motor
19 - Control Pressure
20 - Charge Pressure
21 - Closed Loop Pressure
A1 - Transmission Control Unit (TCU)
A2 - Engine Control Unit (ECU)
A3 - CAN Monitor Unit (CMU)
B1 - Decelerator Sensor
B2 - Motor Speed Sensor Left
B3 - Motor Speed Sensor Right
B7 - Pump Pressure Control Pilot (PCP) Rear
B8 - Pump Pressure Control Pilot (PCP) Front
B32 - FNR Sensor
B33 - Steer Sensor
B34 - Transmission Speed Control Switch
R10 - Engine Speed Control
S7 - Decelerator Mode Switch
Y3 - Motor Shift Solenoid Left
Y4 - Motor Shift Solenoid Right

Go to Section_9026:Group_05

AA95137,00008EE-19-20120627

1014
 Charge Pump Operation

Charge Pump Operation

T197492-UN: Charge Pump Operation

LEGEND:
1 - To Hydrostatic Charge Oil Filter
2 - From Reservoir
3 - Return Oil
4 - Charge Oil

The charge pump is an integral part of each hydrostatic pump. The charge pump is a gerotor type pump and is
driven directly at engine speed. Each pump has a separate suction line from the reservoir. Charge pressure oil
from each pump is sent through separate hoses to the Hydraulic Integrated Circuit (HIC) valve. There it is
combined and sent to a single filter located on the bottom of the HIC valve.

After passing through the filter, charge oil is routed to the park brake solenoid 1, hydrostatic oil cooler bypass
solenoid, and neutral charge relief valve that regulates charge pressure and protects the charge pumps. These
components are also located in the HIC valve.

Charge oil is also routed to the multi-function valves, and control circuit for each hydrostatic pump.

Go to Section_9026:Group_05

TE14778,000004B-19-20120801

1015
 Hydrostatic Charge Oil Filter Operation

Hydrostatic Charge Oil Filter Operation

T206402-UN: Hydrostatic Charge Oil Filter Schematic

LEGEND:
2 - To Multi-Function Valves and Control Circuits
3 - Diagnostic Test Port
16 - Hydrostatic Charge Oil Filter Bypass Valve
17 - Hydrostatic Charge Oil Filter Restriction Switch
18 - Hydrostatic Charge Oil Filter
39 - Hydraulic Integrated Circuit (HIC) valve
73 - Charge Pressure Lines (charge pump to HIC valve ports CHG_IN)

The hydrostatic charge oil filter (18) removes contaminants from the hydrostatic oil. The Hydraulic Integrated
Circuit (HIC) valve (39) contains the hydrostatic charge oil filter bypass valve (16) and restriction switch (17). The
filter element is located on the bottom of the HIC valve.

Under normal operation, charge pressure oil enters the HIC valve at the two CHG_IN ports (73), flows through the
filter element, up through the filter canister and out the two HIC valve CHG_OUT ports to the multi-function valves
and control circuits for each hydrostatic pump and motor (2).

If the pressure differential between the inlet and outlet increases past a set level due to cold oil or partially
restricted filter element, inlet pressure in the HIC valve increases, moving the restriction switch piston against
spring force and outlet pressure. The piston contacts the terminal, completing a circuit that causes the charge
filter restriction indicator light to illuminate.

As the filter element becomes plugged, the pressure differential between the inlet and outlet increases. Inlet
pressure is sensed on one side of the bypass valve that opens against spring force and outlet pressure. The oil
then bypasses the filter while the restriction indicator light illuminates.

It is normal for the restriction indicator light to be illuminated when operating the machine with cold oil. If the
restriction indicator light is still illuminated after the oil reaches operating temperature, the filter is being bypassed
and the filter element should be replaced. Extended operation in the bypass mode could cause damage to the
hydrostatic system.

For more Charge Oil Filter information, see Hydraulic Integrated Circuit (HIC) Valve Operation . (Group 9026-05.)

1016
 Hydrostatic Charge Oil Filter Operation
For Charge Oil Filter circuit information, see Hydrostatic System Schematic—Neutral (Park Brake On) . (Group
9026-15.)

Go to Section_9026:Group_05

TE14778,0000056-19-20050804

1017
 Neutral Charge Relief Valve Operation

Neutral Charge Relief Valve Operation

T206124-UN: Neutral Charge Relief Valve

LEGEND:
1 - Neutral Charge Relief Valve
2 - Pilot Valve
3 - Main Poppet Orifice
4 - Main Poppet
5 - Adjusting Screw
6 - Edge Filter
7 - From Hydrostatic Charge Oil Filter
8 - To Hydrostatic Pump Cases
93 - Charge Oil
98 - Return Oil

The neutral charge relief valve is a screw-in, cartridge-style, pilot operated (two stage), spool-type hydraulic relief
valve. It is located in the Hydraulic Integrated Circuit (HIC) valve and is used to regulate hydrostatic charge oil
pressure.

While the machine is in neutral, charge pressure (7) on the pilot valve (2) overcomes the spring force on it causing
it to move off its seat. In this condition there is oil flow through the main poppet orifice (3), through the unseated
pilot valve, and out of the relief valve to both pump cases (8). The oil flow through the orifice causes a pressure
drop across the main poppet (4) moving it off it’s seat. This allows charge pressure oil to flow past the main
poppet and out of the relief valve to both pump cases (8).

Go to Section_9026:Group_05

TE14778,0000071-19-20050804

1018
 Multi-Function Valve Operation

Multi-Function Valve Operation

T197495-UN: Multi-Function Valve - Make-Up operation

LEGEND:
1 - High Pressure Relief Valve Poppet
2 - Check Valve Poppet
3 - Pressure Limiter Poppet
4 - Spring Seat
5 - Pressure Limiter Poppet Seat
6 - Charge Oil
7 - Return Oil

The multi-function valves are located in the pump end cap. There are two multi-function valves for each pump.
The valves are in the closed-loop circuit. They sense closed-loop pressure. Two functions performed by each
valve include closed-loop charge and high pressure relief.

Closed-Loop Charge As soon as there is charge pressure, it is sensed at the check valve poppet (2). The check
valve also senses closed-loop pressure. Any time the closed-loop pressure is less than charge pressure the
check valve moves the high pressure relief valve poppet (1) off its seat and there is charge flow into the closed
loop. This keeps the closed loop filled with charge oil under all normal operating conditions. This function is
similar to that of an anticavitation valve in a hydraulic system.

1019
 Multi-Function Valve Operation

T197496-UN: Multi-Function Valve - High Pressure Relief Operation

LEGEND:
1 - High Pressure Relief Valve Poppet
2 - Check Valve Poppet
3 - Pressure Limiter Poppet
4 - Spring Seat
5 - Pressure Limiter Poppet Seat
6 - High Pressure Oil
7 - Reduced High Pressure Oil
8 - Charge Oil
9 - Return Oil

High Pressure Relief During normal operation of the machine, the pressure limiter poppet (3) senses closed-
loop pressure and is held against its seat by spring force through the spring seat (4).

Relief operation occurs when the closed-loop pressure on the limiter poppet overcomes the spring force on it
causing it to move off its seat. In this condition there is oil flow through the high pressure relief valve poppet orifice
(1), the unseated limiter poppet (3), and out of the housing to pump case. The oil flow through the orifice causes a
pressure drop across the high pressure relief moving it off the valve seat. This allows closed-loop high pressure
oil to flow past the poppet and into the charge circuit.

Go to Section_9026:Group_05

TE14778,0000050-19-20041013

1020
 Hydraulic Integrated Circuit (HIC) Valve Operation

Hydraulic Integrated Circuit (HIC) Valve Operation

T213602-UN: Hydraulic Integrated Circuit (HIC) Valve

LEGEND:
2 - Ball Shuttle Valve
8 - Hydrostatic Oil Temperature Sensor
9 - Park Brake Solenoid 1
10 - Park Brake Solenoid 2
11 - Hydrostatic Oil Cooler Bypass Solenoid
12 - Hydrostatic Oil Cooler Bypass Valve
13 - Hydrostatic Oil Reservoir Bypass Solenoid
14 - Hydrostatic Oil Reservoir Bypass Valve
16 - Hydrostatic Charge Oil Filter Bypass Valve
17 - Hydrostatic Charge Oil Filter Restriction Switch
18 - Hydrostatic Charge Oil Filter
19 - Neutral Charge Relief Valve
20 - Hand Pump Park Brake Relief Valve
21 - Hand Pump
22 - Hand Pump Selector Valve 1
23 - Hand Pump Selector Valve 2
24 - Hand Pump Cab Tilt Relief Valve
39 - Hydraulic Integrated Circuit (HIC) Valve
51 - Park Brake Pressure Sensor
52 - Hydrostatic Charge Pressure Sensor

The Hydraulic Integrated Circuit (HIC) valve (39) is located inside the left rear access door next to the hydrostatic
reservoir. The HIC valve contains components for four different hydraulic circuits.

First, it contains the components for the hydrostatic charge oil circuit:

Hydrostatic Charge Oil Filter (18)

1021
 Hydraulic Integrated Circuit (HIC) Valve Operation
Neutral Charge Relief Valve (19)
Hydrostatic Charge Pressure Sensor (52)
Hydrostatic Charge Oil Filter Restriction Switch (17)
Hydrostatic Charge Oil Filter Bypass Valve (16)

For information on the charge oil circuit, see Charge Pump Operation . (Group 9026-05.) Also, see Hydrostatic
Charge Oil Filter Operation . (Group 9026-05.)

Second, it contains components for the hydrostatic oil cooling circuit:

Hydrostatic Oil Cooler Bypass Solenoid (11)

Hydrostatic Oil Cooler Bypass Valve (12)
Hydrostatic Oil Reservoir Bypass Solenoid (13)
Hydrostatic Oil Reservoir Bypass Valve (14)
Hydrostatic Oil Temperature Sensor (8)

For information on the hydrostatic oil cooling circuit, see Oil Cooler and Reservoir Bypass Operation . (Group
9026-05.)

Third, it contains components for the park brake circuit:

Park Brake Solenoid 1 (9)

Park Brake Solenoid 2 (10)
Park Brake Pressure Sensor (51)

For information on the park brake circuit, see Park Brake Valve Operation . (Group 9026-05.)

Fourth, it contains components for the hydraulic hand pump circuit:

Hand Pump (21)

Hand Pump Selector Valve 1 (22)
Hand Pump Selector Valve 2 (23)
Hand Pump Park Brake Relief Valve (20)
Hand Pump Cab Tilt Relief Valve (24)
Ball Shuttle Valve (2)

The hand pump can be used to either release park brake for towing machine, or for raising operator’s station. For
more information on hand pump operation, see Releasing Park Brake to Tow the Machine and see Cab or ROPS
Tilting Procedure . (Operator’s Manual.)

For more HIC valve information see Hydrostatic System Schematic—Neutral (Park Brake On) . (Group 9026-15.)

Go to Section_9026:Group_05

TE14778,000005A-19-20131007

1022
 Park Brake Valve Operation

Park Brake Valve Operation

T203005-UN: Park Brake Valves - Brake On

LEGEND:
2 - Ball Shuttle Valve
9 - Park Brake Solenoid 1
10 - Park Brake Solenoid 2
16 - Hydrostatic Charge Oil Filter Bypass Valve
17 - Hydrostatic Charge Oil Filter Restriction Switch
18 - Hydrostatic Charge Oil Filter
27 - Brake Piston (2 used)
39 - Hydrostatic Integrated Circuit (HIC) Valve
40 - Hydrostatic Reservoir
60 - Return Line (HIC valve T port to hydrostatic reservoir)
61 - To hand pump circuit
66 - Charge Pressure Line (HIC valve BRK port to final drives)
73 - Charge Pressure Lines (charge pump to HIC valve ports CHG_IN)

The multiple wet disk park brakes are located in the final drives. The park brakes are spring applied and
hydraulically released. When the park lock lever is in the up position or the decelerator pedal is fully depressed or
the machine is shut off, spring force applies the park brakes. When the park lock lever is in the down position and
pressure on the decelerator pedal is removed, the park brake is released.

The separator plates are held stationary with the brake housing. The friction disks are splined to the final drive
gear. Two park brake solenoid valves are located in the Hydraulic Integrated Circuit (HIC) valve, Park Brake
Solenoid 1 and Park Brake Solenoid 2.

When the park brake is released, the park brake solenoids are energized. Park Brake Solenoid 2 closes, blocking
return flow to the hydrostatic reservoir. Park Brake Solenoid 1 opens, allowing charge pressure oil flow to the
cavity behind the piston compressing the springs. This allows the friction disks to rotate with the final drive gear
and the machine is free to move.

When the park brake is applied or the machine is shut off, the park brake solenoids are de-energized. Park Brake
Solenoid 1 blocks oil from the charge pump. Park Brake Solenoid 2 opens the piston cavity to return. The springs
force the piston towards the final drive compressing the pressure plates against the friction disks. This locks the
final drive gear to the brake housing to apply the brake.

1023
 Park Brake Valve Operation
For park brake component location see Park Brake System Component Location . (Group 9026-15.)

To manually release the park brake, See Releasing Park Brake to Tow the Machine . (Group 9026-25.)

Go to Section_9026:Group_05

TE14778,0000058-19-20080408

1024
 Oil Cooler and Reservoir Bypass Operation

Oil Cooler and Reservoir Bypass Operation

T203809-UN: Oil Cooler and Reservoir Bypass Operation

LEGEND:
8 - Hydrostatic Oil Temperature Sensor
11 - Hydrostatic Oil Cooler Bypass Solenoid
12 - Hydrostatic Oil Cooler Bypass Valve
13 - Hydrostatic Oil Reservoir Bypass Solenoid
14 - Hydrostatic Oil Reservoir Bypass Valve
25 - Hydrostatic Oil Cooler
39 - Hydraulic Integrated Circuit (HIC) Valve
40 - Hydrostatic Reservoir
68 - Case Drain Line (hydrostatic pumps and motors to HIC valve CSE_IN port)
93 - Charge Oil

The oil cooler and reservoir bypass system is comprised of the Hydrostatic Oil Cooler Bypass Solenoid (11),
Hydrostatic Oil Cooler Bypass Valve (12), Hydrostatic Oil Reservoir Bypass Solenoid (13), Hydrostatic Oil
Reservoir Bypass Valve (14), Hydrostatic Oil Cooler (25), and Hydrostatic Reservoir (40). The solenoids and
valves are located in the Hydraulic Integrated Circuit (HIC) Valve (39).

The Hydrostatic Oil Temperature Sensor (8) is located in Test Port 7 on the HIC valve. It sends transmission oil
temperature to an indicator on the monitor.

This system provides a means of quickly warming up the transmission oil after machine start-up by preventing
transmission oil from entering the cooler until oil temperature has reached specification. It also routes cooling flow
from the pump and motor cases directly to the reservoir in case the oil cooler becomes plugged.

At startup, Oil Cooler Bypass Solenoid (11) is energized, allowing charge pressure oil (93) to flow to the Oil Cooler
Bypass Valve (12). This causes the valve to shift, blocking case drain oil to the Oil Cooler (25). Oil Reservoir
Bypass Solenoid (13) is also energized, allowing previously trapped oil to drain to the reservoir. This creates a
pressure drop causing case drain oil to shift Oil Reservoir Bypass Valve (14) allowing full case drain oil flow to the
reservoir.

1025
 Oil Cooler and Reservoir Bypass Operation
As case drain oil temperature rises, Oil Cooler Bypass Solenoid de-energizes, blocking charge pressure oil to Oil
Cooler Bypass Valve. This causes a pressure drop and allows case drain oil to shift the cooler bypass valve. Oil
flow is now divided between the oil cooler and reservoir.

As case oil temperature rises further, Oil Reservoir Bypass Solenoid starts de-energizing. Pressure starts rising
ahead of the solenoid which causes the Oil Reservoir Bypass Valve to start closing. Less oil is now directed to the
reservoir and more oil is directed to the oil cooler.

If the oil cooler becomes plugged, pressure overcomes the relief spring on the Oil Reservoir Bypass Solenoid and
the valve opens. Case drain oil flows directly to the reservoir, protecting the case seals and oil cooler from
excessive pressure buildup.

Go to Section_9026:Group_05

TE14778,0000070-19-20041210

1026
 Pump Pressure Control Pilot (PCP) Operation

Pump Pressure Control Pilot (PCP) Operation

T197498-UN: Pressure Control Pilot (PCP) - Neutral

LEGEND:
1 - Torque Motor
2 - Coil
3 - Orifice
4 - Nozzle
5 - Flapper Valve
6 - Charge Pressure Oil
7 - Low Pressure Control Oil
8 - Return Oil

There are two identical pressure control pilots (PCP), one for each pump. The basic function of each PCP is to
take a current signal from the transmission controller and convert it to a differential control pressure which is sent
to each pump displacement control valve to regulate swash angles.

The major components of the PCP are the torque motor (1) and the flapper valve (5). The coil (2) establishes a
magnetic force to position the flapper valve. One coil is used for forward and reverse. The flapper is centered
between two nozzles (4). Centering springs help keep the flapper at null. Upstream from each nozzle is an orifice
(3) which provides a nominal pressure drop when the system is at null. With the flapper at null there is equal
charge pressure oil (6) flow and both output pressures are equal.

When the machine is in neutral, no current signal is sent to the torque motor. The centering springs hold the
flapper in a null (centered) position. Charge pressure oil is equal through both upstream orifices and through each
nozzle. With equal flow and pressure drop the two output pressures are exactly the same and the pressure
differential is zero. In this condition the pump swash angle will be zero and the motor will be at maximum swash
angle.

When the machine is in forward, the transmission controller will send a positive current signal to the coil in the
pump PCP's. The coil produces a magnetic field in a given direction which in turn causes the flapper to move
accordingly. The flapper restricts oil flow through one nozzle and opens the other. This produces a higher
pressure at the restricted nozzle and a lower pressure at the unrestricted nozzle. Thus an output pressure

1027
 Pump Pressure Control Pilot (PCP) Operation
differential is produced. This in turn will cause the pump displacement control valve to increase the pump swash
angle and increase machine speed.

For reverse operation, the transmission controller sends a negative current signal in the opposite direction
compared to forward. Thus the magnetic field in the pump PCP is in the opposite direction which cause the
flapper to move toward the opposite nozzle orifice.

There is a manual mode which is controlled by a small external lever on the PCP. The lever is connected to the
flapper valve. The lever can be moved in both directions which causes the flapper valve to move the same as with
a current signal. This will manually override the transmission controller current signal.

Go to Section_9026:Group_05

TE14778,000004C-19-20041013

1028
 Pump Displacement Control Valve (PDCV) Operation

Pump Displacement Control Valve (PDCV) Operation

T197499-UN: Pump Displacement Control Valve (PDCV) - Neutral

LEGEND:
1 - Null Adjustment Screw
2 - Control Pressure From Pressure Control Pilot (PCP)
3 - Connects To Pump Swashplate Feedback Linkage
4 - To Reservoir
5 - Charge Pressure Inlet
6 - Control Pressure From Pressure Control Pilot (PCP)
7 - To Pump Servo
8 - To Pump Servo
9 - Charge Pressure Oil
10 - Low Pressure Control Oil
11 - Return Oil

The major components in the Pump Displacement Control Valve (PDCV) are the valve spool with centering
spring, feedback linkage (3) to the pump swash plate, and a null adjusting screw (1).

The PDCV is supplied with charge pressure (5) and a differential control pressure (2 and 6) from the Pressure
Control Pilot (PCP). It produces a servo pressure at two output ports (7 and 8) which directs the pump servo
piston.

In a neutral condition with zero differential control pressure, the valve spool is centered by the feedback linkage
and the centering spring. Charge pressure is blocked at the spool center and both output ports are connected to
case (4).

In forward, a given differential control pressure will shift the spool against the centering spring. Charge oil is now
directed to the servo piston that swashes the pump in forward. As the swash plate moves, the feedback linkage
causes a movement on the centering spring opposite to that of the differential control pressure. The spool moves
back toward neutral to a point where a given servo pressure is maintained to the servo piston. This provides
control of the pump swash plate relative to differential control pressure.

1029
 Pump Displacement Control Valve (PDCV) Operation
In reverse the PCP produces a differential control pressure of the opposite polarity, the spool is moved in the
opposite direction and charge oil is directed to the opposite servo piston. Thus the pump is swashed for reverse
operation.

The null adjust screw through the feedback linkage adjusts the centering position of the spool. The adjustment is
made so that with no current signal to the PCP the valve spool is exactly centered. Charge pressure is blocked
and both output ports are connected to case.

Go to Section_9026:Group_05

TE14778,000004D-19-20040827

1030
 Hydrostatic Pump Operation

Hydrostatic Pump Operation

T197500-UN: Hydrostatic Pump - Neutral

LEGEND:
1 - Swash Plate
2 - Case Drain
3 - Piston
4 - Servo Piston
5 - From Neutral Charge Relief Valve
6 - Charge Pressure Oil
7 - Return Oil

Two pumps are mounted directly to the engine in a tandem configuration and are designed for through torque
capability. This means the main hydraulic pump and the winch can be driven from the back of the tandem pump.

Each pump consists of a nine piston rotating group of the parallel axial piston/slipper design, a tiltable cradle
swash plate that controls pump flow and direction and a integral geroter type charge pump mounted on the pump
drive shaft. A hydraulic displacement control valve directs swash plate angle through a double servo piston
assembly and a pressure control pilot (PCP) which controls the hydraulic displacement control valve. The output
of the PCP is controlled by a milliamp current signal from the transmission controller. In addition each pump has
two multi-function valves in the end cap. The front pump is connected to the right motor by pressure hoses. In the
same manner the rear pump is connected to the left motor.

Both pump rotating groups turn at engine speed. In neutral the swash plate is at zero and there is no axial
movement of the pistons and no pump flow. In forward the transmission controller sends an current signal to the
pressure control pilot (PCP) which sends a differential control pressure to the pump displacement control valve
(PDCV). The PDCV sends a controlled charge pressure to one of the servo pistons. As the piston is moved the
swash plate which is connected to it also moves. Now with a given amount of swash plate angle, there will be a
given amount of axial movement of pistons and a given amount of pump flow.

In reverse the transmission controller sends a current signal of opposite polarity to the PCP. In turn then all the
control signals and movements are reversed. With the swash plate movement reversed the pump output will be
switched from one side of the closed loop to the other side. The pump is protected from high pressure by two

1031
 Hydrostatic Pump Operation
multi-function valves, one for each direction.

Go to Section_9026:Group_05

TE14778,000004F-19-20041013

1032
 Flushing Valve and Operating Charge Relief Valve Operation

Flushing Valve and Operating Charge Relief Valve Operation

T197501-UN: Flushing Valve and Operating Charge Relief Valve - Neutral

LEGEND:
1 - Flushing Valve
2 - Operating Charge Relief Valve
3 - To Motor Case
4 - From Closed Loop
5 - Charge Pressure Oil
6 - Return Oil

The flushing valve (1) and the operating charge relief valve (2) are a part of the closed loop and are used to cool
both the oil and the hydraulic components of the closed loop circuit.

The flushing valve (shuttle valve) is a spring balanced spool that senses pressure on both sides of the closed
loop. The operating charge pressure relief valve is of the direct acting, orificed, poppet type design.

In neutral with equal pressure on both sides of the closed loop (4), the springs center the flushing valve spool. In
the centered position operating charge pressure relief valve is not connected to the closed loop. The closed loop
pressure is controlled by the neutral charge pressure relief valve.

In forward, one side of the closed loop will be at a higher pressure than the other. The flushing valve senses this
and shifts away from the high pressure. In this position the lower pressure side of the closed loop is connected to
the operating charge relief valve. Its setting is lower than the neutral charge pressure relief valve. With this
pressure difference relationship and with pressure oil taking the path of least resistance, there will be oil flow
through the operating charge pressure relief valve. In this condition, oil on the low pressure side of the closed
loop will be lost through the flushing and operating charge pressure relief valves. To make up for this loss, cool
filtered oil from the charge circuit will enter the low side of the closed loop through the multi-function valve. Thus
there is constant flow of clean cool oil into the closed loop when in forward.

In reverse, the closed loop pressures switch from one side to the other, the flushing valve shifts to the opposite
side and the low side pressure is again connected to the operating charge pressure relief valve. As in forward the
hot oil in the closed loop is routed out and clean oil is directed in.

1033
Flushing Valve and Operating Charge Relief Valve Operation

Go to Section_9026:Group_05

TE14778,0000051-19-20041013

1034
 Hydrostatic Motor Operation

Hydrostatic Motor Operation

T205062-UN: Hydrostatic Motor Operation - Reverse (slow speed)

LEGEND:
1 - Servo Piston
2 - Feedback Pin
3 - Motor Displacement Control Valve (MDCV)
4 - Ball Shuttle
5 - Rotating Group
7 - Motor Shift Solenoid
8 - Control Spring Adjusting Screw
9 - Motor Speed Sensor
10 - Closed Loop High Pressure
11 - Closed Loop Charge Pressure
12 - Case Drain Oil
13 - High Pressure Oil
14 - Charge Oil
15 - Return Oil

The synchronizing shaft with spherical rollers synchronizes the rotation of the output shaft and the cylinder block.
The ball end of each piston runs in a socket bushing pressed into the output shaft. No other parts are used to
connect the pistons to the shaft.

The motor displacement unit consists of a servo piston (1), a Motor Displacement Control Valve (MDCV) (3)
assembly and a direct acting variable solenoid control (7).

1035
 Hydrostatic Motor Operation
The servo piston is connected to the cylinder block (5) with the feedback pin (2). The servo piston positions the
cylinder block between maximum and minimum angle. A spacer connected to the piston provides a stop for
minimum angle.

In forward or reverse operation, the Transmission Control Unit (TCU) sends a current signal to the motor shift
solenoid which directly acts (applies a force) on the MDCV. The MDCV sends a controlled closed loop pressure to
the servo piston.

Neutral Operation

With the Transmission Control Lever (TCL) in neutral, the TCU sends zero control signal current to the motor shift
solenoid, which in turn applies no force to the MDCV. The ball shuttle sends closed loop pressure, charge
pressure when in neutral, to the MDCV. With no force applied to the MDCV, it directs charge pressure to low
speed end of the servo piston. Since the opposite end of the piston is connected to return, the piston moves to the
low speed, maximum angle position. Therefore, when the TCL is moved out of neutral, the motor always starts
turning at low speed, maximum torque.

Forward or Reverse (Low Speed)

The TCU sends a low current signal to the motor shift solenoid which in turn sends an applied force to the MDCV.
The MDCV is spring biased so that the small applied force will not move it. The ball shuttle now directs the high
pressure (10) side of the closed loop to the MDCV. Since it has not moved from the previous neutral operation
position, high pressure from the closed loop continues to hold the servo piston at maximum angle.

Forward or Reverse (High Speed)

As the TCU gets input commands for increased speed, the current signal to the motor solenoids increases. In
turn, the solenoid applied force increases. As applied force increases, the MDCV starts moving against spring
force. At this point, pressure to the servo piston is blocked, the low speed (maximum angle) side is connected to
return and high pressure from the closed loop is directed to the high speed (minimum angle) side of the piston.
The piston movement starts de-swashing the motor and increases the feedback spring force on the displacement
valve. The displacement valve now goes to a "hold" position when the solenoid applied force is equal to the
opposing spring force and maintains the motor at a given displacement angle. Thus, the transmission controller
with a given current signal out to the motor solenoid has positional control of the motor displacement angle

Go to Section_9026:Group_05

TE14778,000006F-19-20100616

1036
 Hydraulic Reversing Fan Drive Operation

Hydraulic Reversing Fan Drive Operation

NOTE:

Fan reversing valve is a factory installed option. Not all machines may be equipped with reversing
option.

The hydraulic fan drive system consists of:

Gear type pump

Gear type motor
Fan reversing valve
Fan directional valve
Fan proportional solenoid
Fan reversing solenoid
Fan oil filter

T202967-UN: Hydraulic Reversing Fan Drive Component Location (S.N. —178462)

LEGEND:
41 - Hydraulic Fan Pump
42 - Hydraulic Fan Motor
43 - Hydraulic Fan Reversing Valve
44 - Hydraulic Fan Reversing Solenoid
45 - Hydraulic Fan Directional Valve
46 - Hydraulic Fan Proportional Solenoid
48 - Hydraulic Fan Oil Filter Bypass Valve
49 - Hydraulic Fan Oil Filter Restriction Switch
50 - Hydraulic Fan Oil Filter
54 - Suction Line (hydrostatic reservoir through bulkhead to hydraulic fan pump)
55 - High Pressure Line (hydraulic fan pump to hydraulic fan reversing valve)
56 - Forward Pressure Line (hydraulic fan reversing valve through bulkhead to hydraulic fan motor)

1037
 Hydraulic Reversing Fan Drive Operation
57 - Reverse Pressure Line (hydraulic fan reversing valve through bulkhead to hydraulic fan motor)
58 - Return Line (hydraulic fan reversing valve to hydraulic fan oil filter)
59 - Case Drain Line (hydraulic fan motor to hydraulic fan oil filter)
96 - High Pressure Oil
98 - Return Oil

TX1201813-UN: Hydraulic Reversing Fan Drive Component Location (S.N. 178463— )

LEGEND:
41 - Hydraulic Fan Pump
42 - Hydraulic Fan Motor
43 - Hydraulic Fan Reversing Valve
44 - Hydraulic Fan Reversing Solenoid
45 - Hydraulic Fan Directional Valve
46 - Hydraulic Fan Proportional Solenoid
48 - Hydraulic Fan Oil Filter Bypass Valve
49 - Hydraulic Fan Oil Filter Restriction Switch
50 - Hydraulic Fan Oil Filter
54 - Suction Line (hydrostatic reservoir through bulkhead to hydraulic fan pump)
55 - High Pressure Line (hydraulic fan pump to hydraulic fan reversing valve)
56 - Forward Pressure Line (hydraulic fan reversing valve through bulkhead to hydraulic fan motor)
57 - Reverse Pressure Line (hydraulic fan reversing valve through bulkhead to hydraulic fan motor)
58 - Return Line (hydraulic fan reversing valve to hydraulic fan oil filter)
62 - Case Drain Line (hydraulic fan motor to hydrostatic reservoir)
96 - High Pressure Oil
98 - Return Oil

1038
 Hydraulic Reversing Fan Drive Operation

T202928-UN: Hydraulic Reversing Fan Drive Schematic (S.N. —178462)

LEGEND:
40 - Hydrostatic Reservoir
41 - Hydraulic Fan Pump
42 - Hydraulic Fan Motor
43 - Hydraulic Fan Reversing Valve
44 - Hydraulic Fan Reversing Solenoid
45 - Hydraulic Fan Directional Valve
46 - Hydraulic Fan Proportional Solenoid
47 - Hydraulic Fan Check Valve (3 used)
48 - Hydraulic Fan Oil Filter Bypass Valve
49 - Hydraulic Fan Oil Filter Restriction Switch
50 - Hydraulic Fan Oil Filter
54 - Suction Line (hydrostatic reservoir through bulkhead to hydraulic fan pump)
55 - High Pressure Line (hydraulic fan pump to hydraulic fan reversing valve)
56 - Forward Pressure Line (hydraulic fan reversing valve through bulkhead to hydraulic fan motor)
57 - Reverse Pressure Line (hydraulic fan reversing valve through bulkhead to hydraulic fan motor)
58 - Return Line (hydraulic fan reversing valve to hydraulic fan oil filter)
59 - Case Drain Line (hydraulic fan motor to hydraulic fan oil filter)
96 - High Pressure Oil
98 - Return Oil

1039
 Hydraulic Reversing Fan Drive Operation

TX1201823-UN: Hydraulic Reversing Fan Drive Schematic (S.N. 178463— )

LEGEND:
40 - Hydrostatic Reservoir
41 - Hydraulic Fan Pump
42 - Hydraulic Fan Motor
43 - Hydraulic Fan Reversing Valve
44 - Hydraulic Fan Reversing Solenoid
45 - Hydraulic Fan Directional Valve
46 - Hydraulic Fan Proportional Solenoid
47 - Hydraulic Fan Check Valve (3 used)
48 - Hydraulic Fan Oil Filter Bypass Valve
49 - Hydraulic Fan Oil Filter Restriction Switch
50 - Hydraulic Fan Oil Filter
54 - Suction Line (hydrostatic reservoir through bulkhead to hydraulic fan pump)
55 - High Pressure Line (hydraulic fan pump to hydraulic fan reversing valve)
56 - Forward Pressure Line (hydraulic fan reversing valve through bulkhead to hydraulic fan motor)
57 - Reverse Pressure Line (hydraulic fan reversing valve through bulkhead to hydraulic fan motor)
58 - Return Line (hydraulic fan reversing valve to hydraulic fan oil filter)
62 - Case Drain Line (hydraulic fan motor to hydrostatic reservoir)
96 - High Pressure Oil
98 - Return Oil

Normal Operation

Fan pump (41) is powered by a gear on the front of the engine. Pump output is directed to the fan reversing valve
(43) inlet. Oil flows to the reversing solenoid (44), through the directional valve (45), and on to fan motor (42) inlet.
Oil also flows past check valves (47) to proportional solenoid (46). This solenoid is used to control fan speed by
electronic control of the proportional relief valve.

Proportional fan speed is controlled by the transmission control unit (TCU) based upon machine fluid and air
temperatures. Fan speed may be manually set to Minimum, 70%, Maximum, or Normal in the standard display

1040
 Hydraulic Reversing Fan Drive Operation
monitor (CMU). With fan speed set at Minimum, proportional solenoid (46) allows a large amount of oil from fan
pump (41) to return to reservoir (40). As fan speed setting increases to Maximum, proportional solenoid allows
less oil to return to reservoir and more oil to flow to fan motor (42). An electrical malfunction will default fan speed
to Maximum to avoid overheating.

Reverse Operation

The fan reverse function allows the fan to reverse direction, blowing air through the heat exchanger and ejecting
trapped foreign material. When the reversing solenoid (44) is energized, oil flows through the reversing solenoid
and shifts position of the directional valve. This sends oil flow to the outlet port of the fan motor, reversing the
direction of the fan.

Fan reversal can be set in the CMU to automatically reverse direction every 0.5 hour, 1 hour, or 1.5 hour. Fan
reversal can also be started manually by pushing the fan reversing switch on the side of the monitor. The monitor
contains a fan reversal indicator light to alert the operator when a fan reversal is set to occur. The indicator also
lights when the operator pushes the fan reversing switch. The indicator light goes off once the reversal cycle is
complete.

For access to fan speed settings, see CAN Monitor Unit (CMU) Circuit Theory of Operation . (Group 9015-15.)

For more electrical fan drive information, see Transmission Control Unit (TCU) Circuit Theory of Operation .
(Group 9015-15.)

Go to Section_9026:Group_05

JW40272,00000F1-19-20150917

1041
 Hydraulic Non-Reversing Fan Drive Operation

Hydraulic Non-Reversing Fan Drive Operation

TX1022716-UN: Hydraulic Non-Reversing Fan Drive Component Location

The hydraulic non-reversing fan drive system consists of:

Gear type pump

Gear type motor
Fan proportional solenoid
Fan oil filter

1042
 Hydraulic Non-Reversing Fan Drive Operation

TX1022717-UN: Hydraulic Non-Reversing Fan Drive Schematic

LEGEND:
39 - Hydraulic Integrated Circuit (HIC) Valve
40 - Hydrostatic Reservoir
41 - Hydraulic Fan Pump
42 - Hydraulic Fan Motor
46 - Hydraulic Fan Proportional Solenoid
48 - Hydraulic Fan Oil Filter Bypass Valve
49 - Hydraulic Fan Oil Filter Restriction Switch
50 - Hydraulic Fan Oil Filter
54 - Suction Line (hydrostatic reservoir through bulkhead to hydraulic fan pump)
55 - High Pressure Line (hydraulic fan pump to hydraulic fan motor)
57 - Reverse Pressure Line (hydraulic fan reversing valve through bulkhead to hydraulic fan motor)
58 - Return Line (hydraulic fan motor to hydraulic fan oil filter)
59 - Case Drain Line (hydraulic fan motor to hydraulic fan oil filter)
96 - High Pressure Oil
98 - Return Oil

Operation— Fan pump (41) is powered by a gear on the front of the engine. Pump output is directed the fan
motor (42) inlet. Oil also flows past check valves (48) to proportional solenoid (46). This solenoid is used to
control fan speed by electronic control of the proportional relief valve.

Proportional fan speed is controlled by the Transmission Control Unit (TCU) based upon machine fluid and air
temperatures. Fan speed may be manually set to minimum, 70%, maximum, or normal in the standard display
monitor (CMU). With fan speed set at minimum, proportional solenoid (46) allows a large amount of oil from fan
pump (41) to return to reservoir (40). As fan speed setting increases to maximum, proportional solenoid allows
less oil to return to reservoir and more oil to flow to fan motor (42). An electrical malfunction will default fan speed
1043
 Hydraulic Non-Reversing Fan Drive Operation
to maximum to avoid overheating.

For access to fan speed settings, see CAN Monitor Unit (CMU) Circuit Theory of Operation . (Group 9015-15.)

For more electrical fan drive information, see Transmission Control Unit (TCU) Circuit Theory of Operation .
(Group 9015-15.)

Go to Section_9026:Group_05

MR50960,0000256-19-20120816

1044
 Hydraulic Fan Return Filter Operation

Hydraulic Fan Return Filter Operation

T205038-UN: Hydraulic Fan Return Filter Operation

LEGEND:
40 - Hydrostatic Reservoir
48 - Hydraulic Fan Oil Filter Bypass Valve
49 - Hydraulic Fan Oil Filter Restriction Switch
50 - Hydraulic Fan Oil Filter
58 - Return Line (from fan drive system)
59 - Case Drain Line (hydraulic fan motor to hydraulic fan oil filter) (machines with non-reversing fan and machines with
reversing fan [S.N. —178462])
72 - Hydraulic Fan Oil Filter Bypass Valve Piston
75 - Hydraulic Fan Oil Filter Restriction Switch Terminal
82 - Hydraulic Fan Oil Filter Main Inlet
83 - Hydraulic Fan Oil Filter Auxilliary Inlet
84 - Hydraulic Fan Oil Filter Outlet
89 - Switch Spring
90 - To Hydrostatic Reservoir
98 - Return Oil

1045
 Hydraulic Fan Return Filter Operation

T205039-UN: Hydraulic Fan Return Filter Operation

LEGEND:
40 - Hydrostatic Reservoir
48 - Hydraulic Fan Oil Filter Bypass Valve
49 - Hydraulic Fan Oil Filter Restriction Switch
50 - Hydraulic Fan Oil Filter
58 - Return Line (from fan drive system)
59 - Case Drain Line (hydraulic fan motor to hydraulic fan oil filter) (machines with non-reversing fan and machines with
reversing fan [S.N. —178462])
72 - Hydraulic Fan Oil Filter Bypass Valve Piston
75 - Hydraulic Fan Oil Filter Restriction Switch Terminal
82 - Hydraulic Fan Oil Filter Main Inlet
83 - Hydraulic Fan Oil Filter Auxilliary Inlet
84 - Hydraulic Fan Oil Filter Outlet
89 - Switch Spring
90 - To Hydrostatic Reservoir
98 - Return Oil

The hydraulic fan oil filter (50) is located inside the left rear access door. It is mounted on the hydrostatic reservoir
(40) and removes contaminants from the hydrostatic oil system. The filter housing contains a bypass valve (48)
and filter restriction switch (49).

Under normal operation, return oil (58) flows from fan drive system into the main inlet (82). For machines with
non-reversing fan and machines with reversing fan (S.N. —178462), case drain oil (59) flows from the hydraulic
fan motor into the auxiliary inlet (83). This return oil (98) then flows through the hydraulic fan oil filter (50), through
the outlet (84), and into hydrostatic reservoir (40).

If the pressure differential between the inlet and outlet increases past a set level due to cold oil or partially
restricted filter element, inlet pressure increases (95), moving the restriction switch piston (72) against spring
force and outlet pressure. The piston contacts the terminal (73), completing a circuit that causes the hydraulic fan
oil filter restriction indicator light to illuminate.

As the filter element becomes plugged, the pressure differential between the inlet and outlet increases. High inlet
pressure (96) is sensed on inlet side of the bypass valve that opens against spring force and outlet pressure. The
oil then bypasses the filter while the restriction indicator light illuminates.
1046
 Hydraulic Fan Return Filter Operation
It is normal for the restriction indicator light to be illuminated when operating the machine with cold oil. If the
restriction indicator light is still illuminated after the oil reaches operating temperature, the filter is being bypassed
and the filter element should be replaced. Extended operation in the bypass mode could cause damage to the
hydrostatic system.

For complete circuit theory, see Hydraulic Reversing Fan Drive Operation or see Hydraulic Non-Reversing Fan
Drive Operation . (9026-05.)

Go to Section_9026:Group_05

TE14778,0000059-19-20150917

1047
 Overheating Malfunctions

Overheating Diagnostic Procedure

Launch Close Expand List Collapse List

1 Oil Level
Action:

Check oil level.

Is oil level low?

Record of Actual Results:

Result:
YES:
Add recommended oil. See Transmission and Hydraulic Reservoir Oil . (Operator's Manual.)
NO:
Go to Reduced Air Flow Check .

2 Reduced Air Flow Check

Action:

Inspect components that could reduce air flow.

Is there external debris in cooler?

Record of Actual Results:

Result:
YES:
Operate reversing fan (if equipped).
NO:
Go to Cooling Fins Check .

3 Cooling Fins Check

Action:

Inspect cooling fins.

Are cooling fins damaged?

Record of Actual Results:

Result:
YES:
Repair cooler. Install sand shield in abrasive conditions.

1048
 Overheating Malfunctions

NO:
Go to Temperature Measurement .

4 Temperature Measurement
Action:

Install temperature gauge in HIC valve test port 8 and verify temperature reading.

Is temperature reading correct?

Record of Actual Results:

Result:
YES:
Go to Fan Installation Check .
NO:
Repair or replace sensor or wiring.

5 Fan Installation Check

Action:

Check that fan is installed correctly. Refer to illustration in fan motor speed test or decal on fan. See Fan
Motor Speed Test . (Group 9026-25.)

Is fan installed correctly?

Record of Actual Results:

Result:
YES:
Go to Fan Motor Speed Check .
NO:
Remove fan and install per illustration in fan speed test.

6 Fan Motor Speed Check

Action:

Perform Fan Motor Speed Test . (Group 9026-25.)

Is fan motor speed within specification?

Record of Actual Results:

Result:
YES:
1049
 Overheating Malfunctions
Go to Motor Maximum Angle Check .
NO:
Repair fan system.

7 Motor Maximum Angle Check

Action:

NOTE:

For information on navigating the CMU menu structure, see CAN Monitor Unit (CMU) Menu
Structure—Service Mode . (Group 9015-20.)

Turn off tracker by accessing the appropriate CMU menu.

Turn off motor solenoids by accessing the appropriate CMU menu.

Set and maintain engine speed at 2100 rpm.

Set transmission speed to 1.8.

Observe hydrostatic motor rpm by accessing the appropriate CMU menu.

Is motor speed over 1370 rpm (approximate)?

Record of Actual Results:

Result:
YES:
Go to Severe Mistrack Check .
NO:
Go to Transmission Efficiency Test Check .

8 Severe Mistrack Check

Action:

NOTE:

For information on navigating the CMU menu structure, see CAN Monitor Unit (CMU) Menu
Structure—Service Mode . (Group 9015-20.)

Turn on motor solenoids by accessing the appropriate CMU menu.

With tracker off, operate machine and check for mistracking.

If mistracking is severe, determine which is the faster side.

Turn off motor solenoids by accessing the appropriate CMU menu.

Check for voltage at the motor solenoid connector.

1050
 Overheating Malfunctions
Is 0 voltage present?

Record of Actual Results:

Result:
YES:
Go to Motor Displacement Control Valve Check .
NO:
If voltage is present when solenoids have been turned off, check wiring between TCU and motor solenoid for
short circuit.

If wiring is good, reprogram TCU.

9 Motor Displacement Control Valve Check

Action:

Perform Motor Displacement Control Valve (MDCV) Adjustment . (Group 9026-15.)

Is motor displacement control valve (MDCV) adjustment within specification?

Record of Actual Results:

Result:
YES:
Go to Hydrostatic Motor Check .
NO:
Repair or adjust as necessary.

10 Hydrostatic Motor Check

Action:

Perform Hydrostatic Motor Min./Max. Angle Servo Piston Pressure Test . (Group 9026-15.)

Is hydrostatic motor min/max angle servo piston pressure test within specification?

Record of Actual Results:

Result:
YES:
Check for swash plate not returning to maximum angle stop. Repair as necessary.
NO:
Repair or adjust.

11 Transmission Efficiency Test Check

1051
 Overheating Malfunctions

Action:

Perform Transmission Efficiency Test . (Group 9026-25.)

Are the pumps and motors functioning correctly?

Record of Actual Results:

Result:
YES:
Go to Oil Cooler and Tank Bypass Valves Check .
NO:
Check for cause of inefficiency in pumps and motors. Repair as necessary.

12 Oil Cooler and Tank Bypass Valves Check

Action:

Check oil cooler and tank bypass valves. See See Hydrostatic Oil Cooler Bypass Test and see Hydrostatic
Oil Reservoir Bypass Test . (Group 9026-25.)

Are the oil cooler and tank bypass valves within specification?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Repair or replace oil cooler bypass valve or oil reservoir bypass valve.

Go to Section_9026:Group_15

MM61211,0001744-19-20070308

1052
 Overheating Malfunctions

Overheating Diagnostic Procedure

Launch Close Expand List Collapse List

1 Oil Level
Action:

Check oil level.

Is oil level low?

Record of Actual Results:

Result:
YES:
Add recommended oil. See Transmission and Hydraulic Reservoir Oil . (Operator's Manual.)
NO:
Go to Reduced Air Flow Check .

2 Reduced Air Flow Check

Action:

Inspect components that could reduce air flow.

Is there external debris in cooler?

Record of Actual Results:

Result:
YES:
Operate reversing fan (if equipped).
NO:
Go to Cooling Fins Check .

3 Cooling Fins Check

Action:

Inspect cooling fins.

Are cooling fins damaged?

Record of Actual Results:

Result:
YES:
Repair cooler. Install sand shield in abrasive conditions.

1053
 Overheating Malfunctions

NO:
Go to Temperature Measurement .

4 Temperature Measurement
Action:

Install temperature gauge in HIC valve test port 8 and verify temperature reading.

Is temperature reading correct?

Record of Actual Results:

Result:
YES:
Go to Fan Installation Check .
NO:
Repair or replace sensor or wiring.

5 Fan Installation Check

Action:

Check that fan is installed correctly. Refer to illustration in fan motor speed test or decal on fan. See Fan
Motor Speed Test . (Group 9026-25.)

Is fan installed correctly?

Record of Actual Results:

Result:
YES:
Go to Fan Motor Speed Check .
NO:
Remove fan and install per illustration in fan speed test.

6 Fan Motor Speed Check

Action:

Perform Fan Motor Speed Test . (Group 9026-25.)

Is fan motor speed within specification?

Record of Actual Results:

Result:
YES:
1054
 Overheating Malfunctions
Go to Motor Maximum Angle Check .
NO:
Repair fan system.

7 Motor Maximum Angle Check

Action:

NOTE:

For information on navigating the CMU menu structure, see CAN Monitor Unit (CMU) Menu
Structure—Service Mode . (Group 9015-20.)

Turn off tracker by accessing the appropriate CMU menu.

Turn off motor solenoids by accessing the appropriate CMU menu.

Set and maintain engine speed at 2100 rpm.

Set transmission speed to 1.8.

Observe hydrostatic motor rpm by accessing the appropriate CMU menu.

Is motor speed over 1370 rpm (approximate)?

Record of Actual Results:

Result:
YES:
Go to Severe Mistrack Check .
NO:
Go to Transmission Efficiency Test Check .

8 Severe Mistrack Check

Action:

NOTE:

For information on navigating the CMU menu structure, see CAN Monitor Unit (CMU) Menu
Structure—Service Mode . (Group 9015-20.)

Turn on motor solenoids by accessing the appropriate CMU menu.

With tracker off, operate machine and check for mistracking.

If mistracking is severe, determine which is the faster side.

Turn off motor solenoids by accessing the appropriate CMU menu.

Check for voltage at the motor solenoid connector.

1055
 Overheating Malfunctions
Is 0 voltage present?

Record of Actual Results:

Result:
YES:
Go to Motor Displacement Control Valve Check .
NO:
If voltage is present when solenoids have been turned off, check wiring between TCU and motor solenoid for
short circuit.

If wiring is good, reprogram TCU.

9 Motor Displacement Control Valve Check

Action:

Perform Motor Displacement Control Valve (MDCV) Adjustment . (Group 9026-15.)

Is motor displacement control valve (MDCV) adjustment within specification?

Record of Actual Results:

Result:
YES:
Go to Hydrostatic Motor Check .
NO:
Repair or adjust as necessary.

10 Hydrostatic Motor Check

Action:

Perform Hydrostatic Motor Min./Max. Angle Servo Piston Pressure Test . (Group 9026-15.)

Is hydrostatic motor min/max angle servo piston pressure test within specification?

Record of Actual Results:

Result:
YES:
Check for swash plate not returning to maximum angle stop. Repair as necessary.
NO:
Repair or adjust.

11 Transmission Efficiency Test Check

1056
 Overheating Malfunctions

Action:

Perform Transmission Efficiency Test . (Group 9026-25.)

Are the pumps and motors functioning correctly?

Record of Actual Results:

Result:
YES:
Go to Oil Cooler and Tank Bypass Valves Check .
NO:
Check for cause of inefficiency in pumps and motors. Repair as necessary.

12 Oil Cooler and Tank Bypass Valves Check

Action:

Check oil cooler and tank bypass valves. See See Hydrostatic Oil Cooler Bypass Test and see Hydrostatic
Oil Reservoir Bypass Test . (Group 9026-25.)

Are the oil cooler and tank bypass valves within specification?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Repair or replace oil cooler bypass valve or oil reservoir bypass valve.

Go to Section_9026:Group_15

MM61211,0001744-19-20070308

1057
 Low Charge Pressure Malfunctions

Low Charge Pressure Diagnostic Procedure

Launch Close Expand List Collapse List

1 Diagnostic Trouble Code Check

Action:

Are diagnostic trouble codes displayed?

Record of Actual Results:

Result:
YES:
See Diagnostic Trouble Codes (DTC) Quick Reference List . (Group 9015-20.)
NO:
Check oil level.
IF OK:
See Hydraulic Blade Functions Check .

2 Hydraulic Blade Functions Check

Action:

Operate the dozer blade functions.

Are the dozer blade hydraulics functioning properly?

Record of Actual Results:

Result:
YES:
Go to Charge Pressure Check .
NO:
Go to Charge Pump Flow Check .

3 Charge Pressure Check

Action:

Check charge pressure by accessing the appropriate CMU menu. See CAN Monitor Unit (CMU) Menu
Structure—Service Mode . (Group 9015-20.)

Does charge pressure drop and stay low when brakes are released in neutral?

Record of Actual Results:

Result:
YES:
1058
 Low Charge Pressure Malfunctions
Perform valve portion of park brake test. See Park Brake Test . (Group 9026-25.)
NO:
Go to Brake Test Mode Charge Pressure Check .

4 Brake Test Mode Charge Pressure Check

Action:

Set brakes to Test Mode by accessing the appropriate CMU menu. See CAN Monitor Unit (CMU) Menu
Structure—Service Mode . (Group 9015-20.)

Operate machine against brakes while monitoring charge pressure for each of the following conditions:

Forward with left stop track steer.

Forward with right stop track steer.
Reverse with left stop track steer.
Reverse with right stop track steer.

Is charge pressure low for all four conditions?

Record of Actual Results:

Result:
YES:
Go to Reading with Gauge Installed Pressure Check .
NO:
Go to next step in this check.
Action:

Is charge low for one direction and on one side?

Record of Actual Results:

Result:
YES:
Inspect/replace loop flushing valve in motor on side with low pressure reading.
NO:
Go to Charge Pump Flow Check.

5 Charge Pump Flow Check

Action:

Perform charge pump flow test for front and rear HST pumps. See Charge Pump Flow Test . (Group 9026-
25.)

Are front and rear pumps within specification?

Record of Actual Results:

1059
 Low Charge Pressure Malfunctions

Result:
YES:
Perform Transmission Efficiency Test . (Group 9026-15.) Repair pump or motors as indicated.
NO:
For low flow at rear pump, inspect coupler between HST pumps. Repair as necessary.
NO:
For low flow from both pumps, inspect engine coupler. Repair as necessary.

6 Reading with Gauge Installed Pressure Check

Action:

Compare charge pressure readings with gauge installed in HIC valve test port 2.

Are the charge pressure readings equal?

Record of Actual Results:

Result:
YES:
Go to Neutral and Operating Charge Pressure Check .
NO:
Check sensor wiring. If wiring is good, replace sensor.

7 Neutral and Operating Charge Pressure Check

Action:

Identify position of the neutral charge pressure set screw before performing the neutral charge relief valve
adjustment procedure.

Count number of turns when adjusting the neutral charge pressure set screw. See Neutral Charge Relief and
Operating Charge Relief Pressure Test . (Group 9026-25.)

Can specified pressure be obtained by adjusting the neutral charge pressure set screw?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Return neutral charge pressure set screw to original position and setting, then go to Neutral Charge Relief
Valve Check .

8 Neutral Charge Relief Valve Check

1060
 Low Charge Pressure Malfunctions

Action:

Remove and inspect the neutral charge relief valve.

Is the valve closed?

Does it take a reasonable amount of force to open the valve?

Are the valve and seals in good condition?

Record of Actual Results:

Result:
YES:
Go to Charge Pump Flow Check .
NO:
Replace neutral charge relief valve and seals, as necessary, then go to Neutral and Operating Charge
Pressure Check .

Go to Section_9026:Group_15

MM61211,0001745-19-20091217

1061
 Mistrack/Index Malfunctions

Mistrack or Index
Launch Close Expand List Collapse List

1 Diagnostic Trouble Code Check

Action:

Are diagnostic trouble codes displayed?

Record of Actual Results:

Result:
YES:
See Diagnostic Trouble Codes (DTC) Quick Reference List . (Group 9015-20.)
NO:
Go to Track Tension Check .

2 Track Tension Check

Action:

Is the track tension within specification?

Record of Actual Results:

Result:
YES:
Go to TCU Calibration Check .
NO:
Adjust tracks. See Track Sag Adjustment . (Group 0130.)

3 TCU Calibration Check

Action:

Record the existing calibrated values of the items listed here by accessing the appropriate CMU menu. See
CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Pump thresh mA.

Pump max mA.
Motor max mA.

NOTE:

If TCU calibration fails, the menu will reset to factory values.

Perform Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Record pump and motor mA during the calibration process by accessing the appropriate CMU menu.

1062
 Mistrack/Index Malfunctions
Did the calibration procedure generate any diagnostic trouble codes?

Record of Actual Results:

Result:
YES:
See TCU Calibration Malfunctions . (Group 9026-15.)
NO:
Compare new and old calibration values for large changes, then go to Relief Pressure Check .

4 Relief Pressure Check

Action:

Perform Neutral Charge Relief and Operating Charge Relief Pressure Test . (Group 9026-15.)

Are the charge relief pressures within specification?

Record of Actual Results:

Result:
YES:
Go to Tracker On/Off Check .
NO:
Go to Low Charge Pressure Malfunctions . (Group 9026-15.)

5 Tracker On/Off Check

Action:

Turn off tracker control by accessing the appropriate CMU menu. See CAN Monitor Unit (CMU) Menu
Structure—Service Mode . (Group 9015-20.)

Is mistracking less severe?

Record of Actual Results:

Result:
YES:
Check both motor speed sensors. See Transmission Harness (W11) Component Location . (Group 9015-
10.)
NO:
Go to Motor Solenoid On/Off Check .

6 Motor Solenoid On/Off Check

Action:

Turn off motor solenoids by accessing the appropriate

1063CMU menu. See CAN Monitor Unit (CMU) Menu
 Mistrack/Index Malfunctions
Turn off motor solenoids by accessing the appropriate CMU menu. See CAN Monitor Unit (CMU) Menu
Structure—Service Mode . (Group 9015-20.)

Is mistracking less severe?

Record of Actual Results:

Result:
YES:
Go to Motor Displacement Control Valve (MDCV) Check .
NO:
Go to Efficiency/Relief Check .

7 Motor Displacement Control Valve (MDCV) Check

Action:

Perform Motor Displacement Control Valve (MDCV) Adjustment . (Group 9026-25.)

Is MDCV adjustment within specification?

Record of Actual Results:

Result:
YES:
Go to Motor Min/Max Angle Servo Piston Pressure Check .
NO:
Repair or adjust motor control.

8 Motor Min/Max Angle Servo Piston Pressure Check

Action:

Perform Hydrostatic Motor Min./Max. Angle Servo Piston Pressure Test . (Group 9026-25.)

Is motor min/max angle servo pressure test within specification?

Record of Actual Results:

Result:
YES:
Check for swash plate not returning to maximum angle stop. Repair or replace as necessary. See
Hydrostatic Motor Disassemble . (Group 0360.)
NO:
Repair or adjust motor control.

9 Efficiency/Relief Check

1064
 Mistrack/Index Malfunctions

Action:

Perform Transmission Efficiency Test . (Group 9026-25.)

Operate machine against brakes for each of the following conditions:

Forward with left stop track steer.

Forward with right stop track steer.
Reverse with left stop track steer.
Reverse with right stop track steer.

Are all conditions within specification?

Record of Actual Results:

Result:
YES:
See Pressure Control Pilot (PCP) Test and see Pump Displacement Control Valve (PDCV) Neutral (Null)
Adjustment . (Group 9026-25.)
NO:
Go to Loop Flushing Valve Check .

10 Loop Flushing Valve Check

Action:

Are one of the conditions in the Efficiency/Relief Check not within specification?

Record of Actual Results:

Result:
YES:
Inspect/replace loop flushing valve in motor on the side not within specification. Repair or replace if
necessary.
IF OK:
Swap multi-function valves. If problem moves, repair or replace the problem multi-function valve.
NO:
Go to Front and Rear Pump Displacement Control Valves (PDCV) Check .

11 Front and Rear Pump Displacement Control Valves (PDCV) Check

Action:

Swap front and rear PDCVs. Inspect control screens located under the PDCVs. Replace screens if
necessary.

Did the mistrack and inefficiency problem move with the PDCV?

Record of Actual Results:

1065
 Mistrack/Index Malfunctions

Result:
YES:
Repair or replace PDCV.
NO:
Isolate pump(s) and/or motor(s). Repair or replace as necessary.

After repair, perform Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Go to Section_9026:Group_15

MM61211,0001746-19-20091217

1066
 Machine Full Speed Malfunctions

Machine Will Not Reach Full Speed Diagnostic Procedure

Launch Close Expand List Collapse List

1 Diagnostic Trouble Codes

Action:

Are diagnostic trouble codes displayed?

Record of Actual Results:

Result:
YES:
See Diagnostic Trouble Codes (DTC) Quick Reference List . (Group 9015-20.)
NO:
Go to Engine Speed Check .

2 Engine Speed Check

Action:

Set engine speed control to fast idle.

Does the CMU show approximately 2255—2285 rpm?

Record of Actual Results:

Result:
YES:
Go to Transmission Speed Check .
NO:
Perform Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

3 Transmission Speed Check

Action:

Set transmission speed to 3.0.

Is the engine speed during machine travel at least 2100 rpm?

Record of Actual Results:

Result:
YES:
Go to Reverse Ratio Setting Check .
NO:
See Low Power Malfunctions . (Group 9026-15.)
1067
 Machine Full Speed Malfunctions

4 Reverse Ratio Setting Check

Action:

NOTE:

For information on navigating the CMU menu structure, see CAN Monitor Unit (CMU) Menu
Structure—Service Mode . (Group 9015-20.)

Verify intended reverse ratio setting is correct by accessing the appropriate CMU menu.

Verify intended rate setting for Maximum—Forward and Reverse speeds by accessing the appropriate CMU
menu.

Compare rate setting with motor rpm values as follows:

Turn off tracker by accessing the appropriate CMU menu.

Set and maintain engine speed to 2100 rpm.
Hold transmission speed at high setting.
Read motor rpm on CMU menu.

-: Rate Setting and Motor RPM Values

Rate Motor RPM

Low 2600

Low 3130

High 3540

Turn off tracker by accessing the appropriate CMU menu.

Does machine mistrack substantially?

Record of Actual Results:

Result:
YES:
See Mistrack/Index Malfunctions . (Group 9026-15.)
NO:
Go to Neutral Charge Relief and Operating Charge Relief Pressure Check .

5 Neutral Charge Relief and Operating Charge Relief Pressure Check

Action:

Perform Neutral Charge Relief and Operating Charge Relief Pressure Test . (Group 9026-25.)

Are the charge relief pressures within specification?

Record of Actual Results:

1068
 Machine Full Speed Malfunctions

Result:
YES:
Go to Calibrate TCU .
NO:
See Low Charge Pressure Malfunctions . (Group 9026-15.)

6 Calibrate TCU
Action:

NOTE:

If TCU calibration fails, the menu will reset to factory values.

Record pump and motor mA during the calibration process by accessing the appropriate CMU menu. See
CAN Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Did the calibration procedure generate any diagnostic trouble codes?

Record of Actual Results:

Result:
YES:
See TCU Calibration Malfunctions . (Group 9026-15.)
NO:
Diagnostic checks complete.

Go to Section_9026:Group_15

MM61211,0001747-19-20091217

1069
 Low Power Malfunctions

Low Power Diagnostic Procedure

Launch Close Expand List Collapse List

1 Diagnostic Trouble Codes

Action:

Are any diagnostic trouble codes displayed?

Record of Actual Results:

Result:
YES:
See Diagnostic Trouble Codes (DTC) Quick Reference List . (Group 9015-20.)
NO:
Go to Track Tension Check .

2 Track Tension Check

Action:

Check track tension.

Is track tension within specification?

Record of Actual Results:

Result:
YES:
Go to Neutral Charge Relief and Operating Charge Relief Pressure Check .
NO:
Adjust tracks. See Track Sag Adjustment . (Group 0130.)

3 Neutral Charge Relief and Operating Charge Relief Pressure Check

Action:

Perform Neutral Charge Relief and Operating Charge Relief Pressure Test . (Group 9026-25.)

Are the charge relief pressures results within specification?

Record of Actual Results:

Result:
YES:
Go to Tracker Off Mistrack Check .
NO:
See Low Charge Pressure Malfunctions . (Group 9026-15.)
1070
 Low Power Malfunctions

4 Tracker Off Mistrack Check

Action:

Turn off tracker by accessing the appropriate CMU menu. See CAN Monitor Unit (CMU) Menu Structure—
Service Mode . (Group 9015-20.)

Operate machine while checking for mistracking.

Does machine mistrack substantially?

Record of Actual Results:

Result:
YES:
See Mistrack/Index Malfunctions . (Group 9026-15.)
NO:
Go to Transmission Efficiency/Relief Check .

5 Transmission Efficiency/Relief Check

Action:

Perform Transmission Efficiency Test . (Group 9026-25.)

Operate machine against brakes for each of the following conditions:

Forward with left stop track steer.

Forward with right stop track steer.
Reverse with left stop track steer.
Reverse with right stop track steer.

Are all conditions within specification?

Record of Actual Results:

Result:
YES:
Go to Load Test Engine Power Check .
NO:
Go to Low Efficiency/Relief Check .

6 Low Efficiency/Relief Check

Action:

Was efficiency or relief pressure low in one direction on one side only?

Record of Actual Results:

1071
 Low Power Malfunctions

Result:
YES:
Inspect/replace loop flushing valve in motor on side not within specification. Repair or replace if necessary.
IF OK:
Go to Loop Flushing Valves Check .
NO:
Go to Calibrate TCU .

7 Loop Flushing Valves Check

Action:

Swap multi-function valves.

Does the problem move with the multi-function valves?

Record of Actual Results:

Result:
YES:
Repair or replace the problem multi-function valve.
NO:
Go to Calibrate TCU

8 Calibrate TCU

Action:

Record existing calibrated values of items listed here by accessing the appropriate CMU menu. See CAN
Monitor Unit (CMU) Menu Structure—Service Mode . (Group 9015-20.)

Pump threshold mA.

Pump max mA.
Motor max mA.

NOTE:

If TCU calibration fails, the menu will reset to factory values.

Perform Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Record pump and motor mA during the calibration process by accessing the appropriate CMU menu.

Did the calibration procedure generate any diagnostic trouble codes?

Record of Actual Results:

1072
 Low Power Malfunctions

Result:
YES:
See TCU Calibration Malfunctions . (Group 9026-15.)
NO:
Compare new and old calibration values for large changes.

Isolate efficiency problem to pump(s) and/or motor(s). Repair if necessary.

Calibrate TCU after repairs and recheck for diagnostic trouble codes.

9 Load Test Engine Power Check

Action:

NOTE:

For information on navigating the CMU menu structure, see CAN Monitor Unit (CMU) Menu
Structure—Service Mode . (Group 9015-15.)

Record forward left and forward right pump threshold mA by accessing the appropriate CMU menu.

Calculate load mA using the following table:

-: Load mA

Model Load mA Left Load mA Right

750J 54 + threshold mA =

750J LGP 59 + threshold mA =

Start engine.

Set decelerator mode switch to transmission mode.

Set engine speed to fast idle.

In the appropriate CMU menus, set:

Brake rate setting to Test Mode

Fan speed to Maximum
Antistall to Off

Select the Eff and Relief screen in the CMU menus, the perform the following:

1. Move park lever to LOCK (up) position.

2. Push decel pedal down.
3. Move TCL to Forward.
4. Steer right stop track.
5. Slowly raise decel pedal to load mA.

At approximate load mA, is engine speed greater than 1700 rpm?

NOTE:

Repeat procedure for opposite steer and load mA.

1073
 Low Power Malfunctions
Repeat procedure for opposite steer and load mA.

Record of Actual Results:

Result:
YES:
Go to Park Brake Check .
NO:
Perform Intake Manifold Pressure Test—Turbocharger Boost . (Group 9010-25.)

If test results are not within specification, check engine fuel and air.

10 Park Brake Check

Action:

Perform Park Brake Test . (Group 9026-25.)

Are brake valves functioning correctly with no binding or drag from disks or final drive?

Record of Actual Results:

Result:
YES:
Go to Motor Swash Plate Maximum Angle Check .
NO:
Repair brake valves, final drive, or brake disks as needed.

11 Motor Swash Plate Maximum Angle Check

Action:

Verify motor swash plate is reaching maximum angle.

Perform Motor Displacement Control Valve (MDCV) Adjustment . (Group 9026-25.)

Are test results within specification?

Record of Actual Results:

Result:
YES:
Go to Motor Min/Max Angle Servo Piston Pressure Test Check .
NO:
Repair or adjust.

1074
 Low Power Malfunctions

12 Motor Min/Max Angle Servo Piston Pressure Test Check

Action:

Perform Hydrostatic Motor Min./Max. Angle Servo Piston Pressure Test . (Group 9026-25.)

Are test results within specification?

Record of Actual Results:

Result:
YES:
All systems normal. Machine may be too heavy.
NO:
Repair or adjust.

Go to Section_9026:Group_15

MM61211,0001748-19-20120606

1075
 Track Malfunctions

Engine Starts But One Or Both Tracks Will Not Move Diagnostic Procedure
Launch Close Expand List Collapse List

1 Diagnostic Trouble Codes

Action:

Are any diagnostic trouble codes displayed?

Record of Actual Results:

Result:
YES:
See Diagnostic Trouble Codes (DTC) Quick Reference List . (Group 9015-20.)
NO:
Go to Park Brake Lever Position Check .

2 Park Brake Lever Position Check

Action:

Cycle park brake lever.

Does indicator on monitor cycle from "P" to "N"?

Record of Actual Results:

Result:
YES:
Go to Neutral Charge Relief and Operating Charge Relief Pressure Test Check .
NO:
Check park lever switch. Adjust or repair as necessary.

3 Neutral Charge Relief and Operating Charge Relief Pressure Test Check

Action:

Perform Neutral Charge Relief and Operating Charge Relief Pressure Test . (Group 9026-25.)

Are test results within specification?

Record of Actual Results:

Result:
YES:
Go to Multi-Function Relief Valve Check .
NO:
See Low Charge Pressure Malfunctions . (Group 9026-15.)
1076
 Track Malfunctions

4 Multi-Function Relief Valve Check

Action:

Perform Multi-Function Relief Valve Test . (Group 9026-25.)

Are test results within specification?

Record of Actual Results:

Result:
YES:
Perform Park Brake Test . (Group 9026-25.)
NO:
Go to Monitor Display Motor Speed Check .

5 Monitor Display Motor Speed Check

Action:

Check motor speed by accessing the appropriate CMU menu. See CAN Monitor Unit (CMU) Menu Structure
—Service Mode . (Group 9015-20.)

Is motor speed indicated, but no track movement?

Record of Actual Results:

Result:
YES:
Check for mechanical malfunction of final drive or motor.
NO:
Go to Pump Manual Overrides Check .

6 Pump Manual Overrides Check

Action:

Activate pump manual overrides. See Pressure Control Pilot (PCP) Manual Override Test. (Group 9026-25.)

Do tracks move?

Record of Actual Results:

Result:
YES:
Go to Pump Servo Check .
NO:

1077
 Track Malfunctions
Go to System Pressure Check .

7 System Pressure Check

Action:

Does system pressure build in circuit while activating pump manual overrides?

Record of Actual Results:

Result:
YES:
Check complete.
NO:
Adjust or replace multi-function relief valve.

8 Pump Servo Check

Action:

Install test harness as described in pump servo test. See Pump Servo Pressure Test . (Group 9026-25.)

Activate switch to Forward and Reverse.

Do tracks move?

Record of Actual Results:

Result:
YES:
Check wire harness.
IF OK:
Reprogram TCU.
NO:
Go to Pressure Control Pilot (PCP) Check .

9 Pressure Control Pilot (PCP) Check

Action:

Perform Pressure Control Pilot (PCP) Test . (Group 9026-25.)

Is PCP differential pressure within specification?

Record of Actual Results:

Result:
YES:

1078
 Track Malfunctions
Go to Pump Displacement Control Valve (PDCV) Check .
NO:
If neutral (PCP) differential pressure is greater than specification but less than 103 kPa (1.03 bar) (15 psi),
PCP must be adjusted. See Pressure Control Pilot (PCP) Internal Adjustment . (Group 9026-25.)

If neutral (PCP) differential pressure is over 103 kPa (1.03 bar) (15 psi), PCP must be replaced.

10 Pump Displacement Control Valve (PDCV) Check

Action:

Perform Pump Displacement Control Valve (PDCV) Neutral (Null) Adjustment . (Group 9026-25.)

Is pump displacement control valve (PDCV) neutral (Null) adjustment within specification?

Record of Actual Results:

Result:
YES:
If total number of turns is more than 1/2 but less than 2 turns, perform Transmission Control Unit (TCU)
Calibration . (Group 9015-20.)
NO:
If total number of turns is 1/2 turn or less, disassemble pump and level swash plate again. See Hydrostatic
Pump Disassemble . (Group 0360.)

If total number of turns is more than 2 turns, disassemble pump displacement control valve and check for a
worn feedback link. See Pump Displacement Control Valve (PDCV) Disassemble and Assemble . (Group
0360.)

Go to Section_9026:Group_15

MM61211,0001749-19-20070308

1079
 TCU Calibration Malfunctions

TCU Calibration Malfunctions Diagnostic Procedure

Launch Close Expand List Collapse List

1 Begin Calibration Process Check

Action:

Does TCU start the calibration process?

Record of Actual Results:

Result:
YES:
Go to Sensor Portion of Calibration Check .
NO:
Go to CAN Monitor Unit (CMU) Check .

2 CAN Monitor Unit (CMU) Check

Action:

Check if CMU is powered up and functioning correctly.

Check CMU for the following:

Normal start-up display.

CMU menu buttons function correctly.
Engine rpm is displayed.

Is monitor functioning properly?

Record of Actual Results:

Result:
YES:
Go to Diagnostic Trouble Codes Check .
NO:
Check fuses F4 and F28. See Fuse and Relay Specifications . (Group 9015-10.)
IF OK:
See CAN Monitor Unit (CMU) Circuit Theory of Operation . (Group 9015-15.)

3 Diagnostic Trouble Codes Check

Action:

Check for codes by accessing the appropriate CMU menu. See CAN Monitor Unit (CMU) Menu Structure—
Service Mode . (Group 9015-20.)

Are any codes active?

1080
 TCU Calibration Malfunctions

Record of Actual Results:

Result:
YES:
Correct problems causing the codes. See Diagnostic Trouble Codes (DTC) Quick Reference List . (Group
9015-20.)
NO:
Go to CMU Park Lock Status Check .

4 CMU Park Lock Status Check

Action:

Cycle park lock lever.

Does monitor display “N” when park lock lever is down and “P” when park lock lever is up?

Record of Actual Results:

Result:
YES:
Go to TCU Circuit Harness Check .
NO:
Check monitor wire harness and connectors. Repair or replace if necessary. See CAN Monitor Unit (CMU)
Circuit Theory of Operation . (Group 9015-15.)

5 TCU Circuit Harness Check

Action:

Check TCU wire harness for open circuits or short to power and/or to ground at connectors X1 and X2. See
Operator's Station Harness (W7) Wiring Diagram and see Transmission Harness (W11) Wiring Diagram .
(Group 9015-10.) Also see Transmission Control Unit (TCU) Circuit Theory of Operation . (Group 9015-15.)

Is TCU wiring harness ok?

Record of Actual Results:

Result:
YES:
Reprogram TCU. If reprogramming does not solve
NO:
Repair or replace wire harness. See Operator's Station Harness (W7) Wiring Diagram and see Transmission
Harness (W11) Wiring Diagram . (Group 9015-10.)

6 Sensor Portion of Calibration Check

1081
 TCU Calibration Malfunctions

Action:

Does TCU calibration pass sensor portion of calibration?

Record of Actual Results:

Result:
YES:
Go to Pump Threshold Portion of Calibration Check .
NO:
If a code occurs, correct problem causing the code. See Diagnostic Trouble Codes (DTC) Quick Reference
List . (Group 9015-20.)

If no code appears, go to Sensor Output Check .

7 Sensor Output Check

Action:

NOTE:

For information on navigating the CMU menu structure, see CAN Monitor Unit (CMU) Menu
Structure—Service Mode . (Group 9015-20.)

Display sensor live values on the CMU by accessing the appropriate CMU menu.

Actuate sensor where calibration stops and read voltage output of the sensor on the appropriate CMU menu.

View calibrated values on the appropriate CMU menu and note the sensor output calibration value.

Is sensor output voltage the same as calibrated output voltage?

Record of Actual Results:

Result:
YES:
Check TCU for internal malfunction.
NO:
Check sensor and wiring. See Operator's Station Harness (W7) Wiring Diagram , Engine Harness (W10)
Wiring Diagram , and Transmission Harness (W11) Wiring Diagram . (Group 9015-10.)

8 Pump Threshold Portion of Calibration Check

Action:

Does TCU calibration pass pump threshold portion of calibration?

Record of Actual Results:

1082
 TCU Calibration Malfunctions

Result:
YES:
Go to Pump Maximum Portion of Calibration Check .
NO:
Go to Pump Threshold DTC Check .

9 Pump Threshold DTC Check

Action:

Check for codes by accessing the appropriate CMU menu.

A pump threshold DTC containing failure mode identifier (FMI) 15 indicates that pump threshold high current
is greater than 25 mA.

A pump threshold DTC containing FMI 17 indicates that pump threshold low current is less than 6 mA.

Pump threshold used for the DTCs depends on pump coil being calibrated. For example, left forward refers
to left forward pump threshold. Right forward refers to right forward pump threshold.

Are any of the following codes active?

-: Pump Threshold Codes

Pump Threshold Codes

Codes With FMI 15 Codes With FMI 17

522450.15—Left Track Fwd 522450.17—Left Track Fwd

522447.15—Right Track Fwd 522447.17—Right Track Fwd

522449.15—Left Track Rev 522449.17—Left Track Rev

522448.15—Right Track Rev 522448.17—Right Track Rev

Record of Actual Results:

Result:
YES:
If a pump threshold code occurs containing FMI 15, go to Motor Speed Display Check .

If a pump threshold code occurs containing FMI 17, cycle PCP manual overrides to flush contaminant, then
go to Pressure Control Pilot Test Check .

NO:
Check complete.

10 Motor Speed Display Check

Action:

Is motor rpm displayed on the appropriate CMU menu when tracks are moving?
1083
 TCU Calibration Malfunctions
Is motor rpm displayed on the appropriate CMU menu when tracks are moving?

Record of Actual Results:

Result:
YES:
Track malfunction. See Track Malfunctions . (Group 9026-15.)
NO:
Check motor speed sensors. See Engine Harness (W10) Component Location . (Group 9015-10.)
IF OK:
Check motor speed sensors wiring for opens and shorts. See Engine Harness (W10) Wiring Diagram .
(Group 9015-10.)

11 Pressure Control Pilot Test Check

Action:

Perform Pressure Control Pilot (PCP) Test . (Group 9026-25.)

Is differential pressure less than 34.5 kPa (0.35 bar) (5 psi)?

Record of Actual Results:

Result:
YES:
Go to Pump Displacement Control Valve Turn Check
NO:
Go to next step in this check.
Action:

Is differential pressure more than 5 psi, but less than 15 psi?

Record of Actual Results:

Result:
YES:
Adjust pressure control pilot (PCP). See Pressure Control Pilot (PCP) Internal Adjustment . (Group 9026-25.)

After completing the PCP adjustment, go to Pump Displacement Control Valve Turn Check .

NO:
Go to next step in this check.
Action:

Is differential pressure more than 15 psi?

Record of Actual Results:

1084
 TCU Calibration Malfunctions

Result:
YES:
Replace PCP, then go to Pump Displacement Control Valve Turn Check .

12 Pump Displacement Control Valve Turn Check

Action:

Perform Pump Displacement Control Valve (PDCV) Neutral (Null) Adjustment . (Group 9026-25.)

NOTE:

The servo oil pressure rise for a new machine will be approximately 138 kPa (1.38 bar) (20
psi). The servo oil pressure rise for a used machine will be approximately 345 kPa (3.45 bar)
(50 psi).

Count number of turns between pressure rise of forward servo oil pressure and pressure rise of reverse
servo oil pressure as stated in the PDCV Neutral (Null) Adjustment procedure.

Are the number of turns one half turn or less?

Record of Actual Results:

Result:
YES:
Disassemble pump and re-level. See Hydrostatic Pump Disassemble and see Hydrostatic Pump Assemble .
(Group 0360.)

After repairs are complete, perform Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

NO:
Go to next step in this check.
Action:

Are the number of turns more than a half turn, but less than 2 turns?

Record of Actual Results:

Result:
YES:
Perform Transmission Control Unit (TCU) Calibration . (Group 9015-20.)
NO:
Go to next step in this check.
Action:

1085
 TCU Calibration Malfunctions

Are the number of turns more than 2 turns?

Record of Actual Results:

Result:
YES:
Perform Transmission Control Unit (TCU) Calibration . (Group 9015-20.)
NO:
If number of turns is more than 2 turns, disassemble PDCV and check for worn feed back link. See Pump
Displacement Control Valve (PDCV) Disassemble and Assemble . (Group 0360.)

After PDCV repairs, perform Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

NO:
Check complete.

13 Pump Maximum Portion of Calibration Check

Action:

Does TCU calibration pass pump max portion of the calibration?

Record of Actual Results:

Result:
YES:
Go to Motor Maximum Portion of Calibration Check .
NO:
Go to Max Pump Calibration DTC Check .

14 Max Pump Calibration DTC Check

Action:

Check for codes by accessing the appropriate CMU menu.

FMI 16—Indicates that max pump calibration is greater than pump threshold (mA) + 83 mA or max pump
calibration is greater than 95 mA.

FMI 18—Indicates that max pump calibration is less than pump threshold (mA) + 51 mA.

Pump threshold used for the DTCs depends on pump coil being calibrated. For example, left forward refers
to left forward pump threshold. Right forward refers to right forward pump threshold.

Are any of the codes listed in the following table active?

-: Max Pump Calibration Codes

1086
 TCU Calibration Malfunctions

Max Pump Calibration Codes

Codes With FMI 16 Codes With FMI 18

522450.16—Left Track Fwd 522450.18—Left Track Fwd

522447.16—Right Track Fwd 522447.18—Right Track Fwd

522449.16—Left Track Rev 522449.18—Left Track Rev

522448.16—Right Track Rev 522448.18—Right Track Rev

Record of Actual Results:

Result:
YES:
If a max pump calibration code occurs containing FMI 16, go to Track Tension Check .

If a max pump calibration code occurs containing FMI 18, go to Motor Displacement Control Valve (MDCV)
Adjustment Check .

NO:
Check complete.

15 Motor Displacement Control Valve (MDCV) Adjustment Check

Action:

Turn off tracker by accessing the appropriate CMU menu. See CAN Monitor Unit (CMU) Menu Structure—
Service Mode . (Group 9015-20.)

Operate machine. Check if mistrack is severe and which side is slow.

Perform Motor Displacement Control Valve (MDCV) Adjustment . (Group 9026-25.)

Is motor displacement control valve (MDCV) within specification?

Record of Actual Results:

Result:
YES:
Go to Hydrostatic Motor Min / Max Angle Servo Piston Pressure Test Check .
NO:
Repair or adjust motor displacement control valve. See Hydrostatic Motor Disassemble and see Hydrostatic
Motor Assemble . (Group 0360.)

16 Hydrostatic Motor Min / Max Angle Servo Piston Pressure Test Check

Action:

Perform Hydrostatic Motor Min./Max. Angle Servo Piston Pressure Test . (Group 9026-25.)

1087
 TCU Calibration Malfunctions
Are pressures within specification?

Record of Actual Results:

Result:
YES:
Check hydrostatic motor for not returning to a stop at maximum angle. Repair motor if necessary. See
Hydrostatic Motor Disassemble and see Hydrostatic Motor Assemble . (Group 0360.)
NO:
Repair or adjust hydrostatic motor. See Hydrostatic Motor Disassemble and see Hydrostatic Motor Assemble
. (Group 0360.)

17 Track Tension Check

Action:

Check track tension. See Check Track Sag . (Operator's Manual.)

Is track tension OK?

Record of Actual Results:

Result:
YES:
Go to Engine No Load Speed Check .
NO:
Adjust tracks. See Adjust Track Sag . (Operator's Manual.)

18 Engine No Load Speed Check

Action:

Operate machine with no load.

Is a minimum engine speed of 2100 rpm maintained when traveling under no load conditions?

Record of Actual Results:

Result:
YES:
Go to Neutral Charge Relief and Operating Charge Relief Pressure Test Check .
NO:
Diagnose engine. See Observable Diagnostics and Tests in CTM502 . Repair and adjust if necessary. See
CTM104 .

19 Neutral Charge Relief and Operating Charge Relief Pressure Test Check
Action:
1088
 TCU Calibration Malfunctions
Perform Neutral Charge Relief and Operating Charge Relief Pressure Test . (Group 9026-25.)

Is pressure within specifications?

Record of Actual Results:

Result:
YES:
Go to Transmission Efficiency Test Check .
NO:
See Low Charge Pressure Malfunctions . (Group 9026-15.)

20 Transmission Efficiency Test Check

Action:

Turn off tracker.

Operate machine. Check if mistrack is severe and which side it slow.

Perform Transmission Efficiency Test . (Group 9026-25.)

Operate machine against brakes for each of the following conditions:

Forward with left stop track steer.

Forward with right stop track steer.
Reverse with left stop track steer.
Reverse with right stop track steer.

Was efficiency low in one direction and on one side only?

Record of Actual Results:

Result:
YES:
Inspect and replace loop flushing valve in hydrostatic motor on side where efficiency is low. See Hydrostatic
Motor Disassemble and see Hydrostatic Motor Assemble . (Group 0360.)
IF OK:
Check multi-function valves. Repair or replace if necessary. See Multi-Function Valve Disassemble and
Assemble . (Group 0360).
NO:
Go to Motor Solenoid Check .

21 Motor Solenoid Check

Action:

Check motor shift solenoid left (Y3) and motor shift solenoid right (Y4). See Transmission Harness (W11)
Component Location . (Group 9015-10.)

Are solenoids within specifications?

1089
 TCU Calibration Malfunctions

Item Measurement Specification

Y3—Motor Shift Solenoid Left Resistance 21.3 ohms at 20°C (68°F)
Y4—Motor Shift Solenoid Right Resistance 21.3 ohms at 20°C (68°F)

Record of Actual Results:

Result:
YES:
Go to Motor Servo Piston Check .
NO:
Replace malfunctioning motor shift solenoid(s).

22 Motor Servo Piston Check

Action:

Perform Hydrostatic Motor Min./Max. Angle Servo Piston Pressure Test . (Group 9026-25.)

Are pressures within specification?

Record of Actual Results:

Result:
YES:
Go to Pump Control Check .
NO:
Repair or adjust hydrostatic motor. See Hydrostatic Motor Disassemble and see Hydrostatic Motor Assemble
. (Group 0360.)

23 Pump Control Check

Action:

Check to see if pump control systems are functioning properly. Perform Pressure Control Pilot (PCP) Test
and perform Pump Displacement Control Valve (PDCV) Neutral (Null) Adjustment . (Group 9026-25.)

Are all control systems operating properly?

Record of Actual Results:

Result:
YES:
Isolate pump(s) and/or motor(s). Repair or replace as necessary. See Hydrostatic Motor Disassemble and
see Hydrostatic Motor Assemble . (Group 0360.) See Hydrostatic Pump Disassemble and see Hydrostatic
Pump Assemble . (Group 0360.)

After repair, perform Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

1090
 TCU Calibration Malfunctions

NO:
Go to next step in this check.
Action:

Swap front and rear PDCVs. Inspect control screens located under the PDCVs. Replace screens if
necessary.

Does problem follow PDCVs?

Record of Actual Results:

Result:
YES:
Repair or replace PDCV.
NO:
Repair or replace pressure control pilot if necessary.

24 Motor Maximum Portion of Calibration Check

Action:

Does TCU calibration pass motor max portion of calibration?

Record of Actual Results:

Result:
YES:
Calibration complete.
NO:
Go to Max Motor Calibration DTC Check .

25 Max Motor Calibration DTC Check

Action:

Check for codes by accessing the appropriate CMU menu.

NOTE:

A max motor calibration DTC containing FMI 16 indicates that max motor calibration low
current is less than 700 mA.

A max motor calibration DTC containing FMI 18 indicates that max motor calibration low
current is less than 400 mA.

Are any of the codes listed in the following table active?

-: Max Motor Calibration Codes

1091
 TCU Calibration Malfunctions

Max Motor Calibration Codes

Codes With FMI 16 Codes With FMI 18

523578.16—Right Track 523578.18—Right Track

523577.16—Left Track 523577.18—Left Track

Record of Actual Results:

Result:
YES:
If a max motor calibration code occurs containing FMI 16, go to Track Tension Check .

If a max motor calibration code occurs containing FMI 18, go to Motor Displacement Control Valve (MDCV)
Adjustment Check .

NO:
Check complete.

Go to Section_9026:Group_15

AA95137,000080B-19-20160216

1092
 Hydrostatic System Component Location

Hydrostatic System Component Location

TX1021504-UN: Hydrostatic System Component Location

LEGEND:
1 - Motor Shift Solenoid
4 - Operating Charge Pressure Relief Valve
5 - Hydrostatic Motor Left
6 - Hydrostatic Motor Right
18 - Hydrostatic Charge Oil Filter
19 - Neutral Charge Relief Valve
28 - Multi-Function Valve
35 - Pressure Control Pilot (PCP) Valve
37 - Hydrostatic Front Pump (Right Track)
38 - Hydrostatic Rear Pump (Left Track)
39 - Hydraulic Integrated Circuit (HIC) Valve
65 - Suction Line (hydrostatic reservoir to hydrostatic charge pumps)
67 - Case Flushing Line (HIC valve P_CSE_OUT port to bottom of hydrostatic pump cases)
68 - Case Drain Line (hydrostatic pumps and motors to HIC valve CSE_IN port)
69 - Return Line (HIC valve TO_CLR_BOT port to bottom of hydrostatic oil cooler)
70 - Return Line (top of hydrostatic oil cooler through bulkhead to hydrostatic reservoir)
71 - Minimum Displacement Limiter
73 - Charge Pressure Line (charge pump to HIC valve port CHG_IN)
74 - Charge Pressure Line (HIC valve CHG_OUT port to hydrostatic pumps)
76 - Forward Pressure Line (left motor)
77 - Reverse Pressure Line (left motor)
78 - Forward Pressure Line (right motor)
79 - Reverse Pressure Line (right motor)
80 - Motor Speed Sensor Left
81 - Motor Speed Sensor Right
85 - Diagnostic Test Port Left Forward (LF) (S.N. -139828)

1093
 Hydrostatic System Component Location
86 - Diagnostic Test Port Left Reverse (LR) (S.N. -139828), Left Forward and Reverse (S.N. 139829-)
87 - Diagnostic Test Port Right Reverse (RR) (S.N. -139828), Right Forward and Reverse (S.N. 139829-)
88 - Diagnostic Test Port Right Forward (RF) (S.N. -139828)

Go to Section_9026:Group_15

KV70328,00001F3-19-20070509

1094
 Park Brake System Component Location

Park Brake System Component Location

T203006-UN: Park Brake System Component Location (park brake released)

LEGEND:
9 - Park Brake Solenoid 1
10 - Park Brake Solenoid 2
19 - Neutral Charge Relief Valve
36 - Charge Pump
39 - Hydraulic Integrated Circuit (HIC) Valve
60 - Return Line (HIC valve T port to hydrostatic reservoir)
63 - Final Drive Left
64 - Final Drive Right

1095
 Park Brake System Component Location
65 - Suction Line (hydrostatic reservoir to hydrostatic charge pumps)
66 - Charge Pressure Line (HIC valve BRK port to final drives)
73 - Charge Pressure Line (charge pump to HIC valve port CHG_IN)
93 - Charge Pressure Oil
98 - Return Oil

Go to Section_9026:Group_15

TX04577,00001B8-19-20120606

1096
 Hydrostatic System Schematic—Neutral (Park Brake On)

Hydrostatic System Schematic—Neutral (Park Brake On)

TX1075013-UN: Hydrostatic System Schematic—Neutral (park brake on) (S.N. —178462)

LEGEND:
1 - Motor Shift Solenoid
2 - Ball Shuttle Valve
3 - Flushing Valve
4 - Operating Charge Pressure Relief Valve
5 - Hydrostatic Motor Left
6 - Hydrostatic Motor Right
7 - Motor Servo Piston
8 - Hydrostatic Oil Temperature Sensor
9 - Park Brake Solenoid 1
10 - Park Brake Solenoid 2
11 - Hydrostatic Oil Cooler Bypass Solenoid
12 - Hydrostatic Oil Cooler Bypass Valve
13 - Hydrostatic Oil Reservoir Bypass Solenoid
14 - Hydrostatic Oil Reservoir Bypass Valve
16 - Hydrostatic Charge Oil Filter Bypass Valve
17 - Hydrostatic Charge Oil Filter Restriction Switch
18 - Hydrostatic Charge Oil Filter
19 - Neutral Charge Relief Valve
20 - Hand Pump Park Brake Relief Valve
21 - Hand Pump
22 - Hand Pump Selector Valve 1
23 - Hand Pump Selector Valve 2
24 - Hand Pump Cab Tilt Relief Valve
25 - Hydrostatic Oil Cooler
26 - Cab Tilt Cylinder
27 - Brake Piston
28 - Multi-Function Valve
29 - Multi-Function Check Valve
30 - Multi-Function Relief Valve
31 - Pump Servo Piston
32 - Screen
33 - Pump Displacement Control Valve (PDCV)
1097
 Hydrostatic System Schematic—Neutral (Park Brake On)
34 - Left Forward (LF) Pressure Sensor
35 - Pressure Control Pilot (PCP) Valve
36 - Charge Pump
37 - Hydrostatic Pump Front (Right Track)
38 - Hydrostatic Pump Front (Left Track)
39 - Hydraulic Integrated Circuit (HIC) Valve
40 - Hydrostatic Reservoir
41 - Hydraulic Fan Pump
42 - Hydraulic Fan Motor
43 - Hydraulic Fan Reversing Valve
44 - Hydraulic Fan Reversing Solenoid
45 - Hydraulic Fan Directional Valve
46 - Hydraulic Fan Proportional Solenoid
47 - Hydraulic Fan Check Valve
48 - Hydraulic Fan Oil Filter Bypass Valve
49 - Hydraulic Fan Oil Filter Restriction Switch
50 - Hydraulic Fan Oil Filter
51 - Hydrostatic Pump Case Pressure Sensor
52 - Hydrostatic Charge Pressure Sensor
53 - Right Forward (RF) Pressure Sensor
60 - Diagnostic Test Port Left Forward and Reverse
61 - Diagnostic Test Port Right Forward and Reverse
92 - Quick Coupler
93 - Charge Oil
94 - Low Pressure Oil
95 - Not Used
96 - High Pressure Oil
97 - Not Used
98 - Return Oil
99 - Trapped Oil

TX1201830-UN: Hydrostatic System Schematic—Neutral (park brake on) (S.N. 178463— )

LEGEND:
1 - Motor Shift Solenoid
2 - Ball Shuttle Valve
3 - Flushing Valve

1098
 Hydrostatic System Schematic—Neutral (Park Brake On)
4 - Operating Charge Pressure Relief Valve
5 - Hydrostatic Motor Left
6 - Hydrostatic Motor Right
7 - Motor Servo Piston
8 - Hydrostatic Oil Temperature Sensor
9 - Park Brake Solenoid 1
10 - Park Brake Solenoid 2
11 - Hydrostatic Oil Cooler Bypass Solenoid
12 - Hydrostatic Oil Cooler Bypass Valve
13 - Hydrostatic Oil Reservoir Bypass Solenoid
14 - Hydrostatic Oil Reservoir Bypass Valve
16 - Hydrostatic Charge Oil Filter Bypass Valve
17 - Hydrostatic Charge Oil Filter Restriction Switch
18 - Hydrostatic Charge Oil Filter
19 - Neutral Charge Relief Valve
20 - Hand Pump Park Brake Relief Valve
21 - Hand Pump
22 - Hand Pump Selector Valve 1
23 - Hand Pump Selector Valve 2
24 - Hand Pump Cab Tilt Relief Valve
25 - Hydrostatic Oil Cooler
26 - Cab Tilt Cylinder
27 - Brake Piston
28 - Multi-Function Valve
29 - Multi-Function Check Valve
30 - Multi-Function Relief Valve
31 - Pump Servo Piston
32 - Screen
33 - Pump Displacement Control Valve (PDCV)
34 - Left Forward (LF) Pressure Sensor
35 - Pressure Control Pilot (PCP) Valve
36 - Charge Pump
37 - Hydrostatic Pump Front (Right Track)
38 - Hydrostatic Pump Front (Left Track)
39 - Hydraulic Integrated Circuit (HIC) Valve
40 - Hydrostatic Reservoir
41 - Hydraulic Fan Pump
42 - Hydraulic Fan Motor
43 - Hydraulic Fan Reversing Valve
44 - Hydraulic Fan Reversing Solenoid
45 - Hydraulic Fan Directional Valve
46 - Hydraulic Fan Proportional Solenoid
47 - Hydraulic Fan Check Valve
48 - Hydraulic Fan Oil Filter Bypass Valve
49 - Hydraulic Fan Oil Filter Restriction Switch
50 - Hydraulic Fan Oil Filter
51 - Hydrostatic Pump Case Pressure Sensor
52 - Hydrostatic Charge Pressure Sensor

1099
 Hydrostatic System Schematic—Neutral (Park Brake On)
53 - Right Forward (RF) Pressure Sensor
60 - Diagnostic Test Port Left Forward and Reverse
61 - Diagnostic Test Port Right Forward and Reverse
92 - Quick Coupler
93 - Charge Oil
94 - Low Pressure Oil
95 - Not Used
96 - High Pressure Oil
97 - Not Used
98 - Return Oil
99 - Trapped Oil

Go to Section_9026:Group_15

KV70328,00001F4-19-20150917

1100
 Hydrostatic System Diagram—Neutral (Park Brake On)

Hydrostatic System Diagram—Neutral (Park Brake On)

TX1094403-UN: Hydrostatic System Diagram - Neutral (park brake on)

LEGEND:
1 - Motor Shift Solenoid
2 - Ball Shuttle Valve
3 - Flushing Valve
4 - Operating Charge Pressure Relief Valve
6 - Hydrostatic Motor
9 - Park Brake Solenoid 1
10 - Park Brake Solenoid 2
11 - Hydrostatic Oil Cooler Bypass Solenoid
12 - Hydrostatic Oil Cooler Bypass Valve
13 - Hydrostatic Oil Reservoir Bypass Solenoid
14 - Hydrostatic Oil Reservoir Bypass Valve
18 - Hydrostatic Charge Oil Filter
19 - Neutral Charge Relief Valve
25 - Hydrostatic Oil Cooler
28 - Multi-Function Valve
31 - Pump Servo Piston
32 - Screen
33 - Pump Displacement Control Valve (PDCV)
35 - Pressure Control Pilot (PCP) Valve
36 - Charge Pump
37 - Hydrostatic Pump
40 - Hydrostatic Reservoir
61 - To Hand Pump Circuit
66 - Charge Pressure Line (HIC valve BRK port to final drives)
81 - Motor Speed Sensor
93 - Charge Oil
94 - Low Pressure Oil
98 - Return Oil

Go to Section_9026:Group_15

TE14778,0000079-19-20120606

1101
 Hydrostatic System Diagram—Reverse (Slow Speed)

Hydrostatic System Diagram—Reverse (Slow Speed)

T206119-UN: Hydrostatic System Diagram - Reverse (slow speed)

LEGEND:
1 - Motor Shift Solenoid
2 - Ball Shuttle Valve
3 - Flushing Valve
4 - Operating Charge Pressure Relief Valve
6 - Hydrostatic Motor
9 - Park Brake Solenoid 1
10 - Park Brake Solenoid 2
11 - Hydrostatic Oil Cooler Bypass Solenoid
12 - Hydrostatic Oil Cooler Bypass Valve
13 - Hydrostatic Oil Reservoir Bypass Solenoid
14 - Hydrostatic Oil Reservoir Bypass Valve
18 - Hydrostatic Charge Oil Filter
19 - Neutral Charge Relief Valve
25 - Hydrostatic Oil Cooler
28 - Multi-Function Valve
31 - Pump Servo Piston
32 - Screen
33 - Pump Displacement Control Valve (PDCV)
35 - Pressure Control Pilot (PCP) Valve
36 - Charge Pump
37 - Hydrostatic Pump
40 - Hydrostatic Reservoir
61 - To Hand Pump Circuit
66 - Charge Pressure Line (HIC valve BRK port to final drives)
81 - Motor Speed Sensor
93 - Charge Oil
94 - Low Pressure Oil
98 - Return Oil

Go to Section_9026:Group_15

TX04577,00001B6-19-20120606

1102
 Hydrostatic System Diagram—Forward (Fast Speed)

Hydrostatic System Diagram—Forward (Fast Speed)

T206120-UN: Hydrostatic System Diagram - Forward (fast speed)

LEGEND:
1 - Motor Shift Solenoid
2 - Ball Shuttle Valve
3 - Flushing Valve
4 - Operating Charge Pressure Relief Valve
6 - Hydrostatic Motor
9 - Park Brake Solenoid 1
10 - Park Brake Solenoid 2
11 - Hydrostatic Oil Cooler Bypass Solenoid
12 - Hydrostatic Oil Cooler Bypass Valve
13 - Hydrostatic Oil Reservoir Bypass Solenoid
14 - Hydrostatic Oil Reservoir Bypass Valve
18 - Hydrostatic Charge Oil Filter
19 - Neutral Charge Relief Valve
25 - Hydrostatic Oil Cooler
28 - Multi-Function Valve
31 - Pump Servo Piston
32 - Screen
33 - Pump Displacement Control Valve (PDCV)
35 - Pressure Control Pilot (PCP) Valve
36 - Charge Pump
37 - Hydrostatic Pump
40 - Hydrostatic Reservoir
61 - To Hand Pump Circuit
66 - Charge Pressure Line (HIC valve BRK port to final drives)
81 - Motor Speed Sensor
93 - Charge Oil
94 - Low Pressure Oil
98 - Return Oil

Go to Section_9026:Group_15

TX04577,00001B7-19-20120606

1103
 JT02156A Digital Pressure/Temperature Analyzer Installation

JT02156A Digital Pressure/Temperature Analyzer Installation

T8543AI-UN: JT02156A Digital Pressure and Temperature Analyzer Kit

LEGEND:
A - Digital Pressure and Temperature Analyzer
B - 3400 kPa (35 bar) (500 psi) Transducer
- 34 000 kPa (350 bar) (5000 psi) Transducer
- 70 000 kPa (700 bar) (10 000 psi) Transducer

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JT02156A Digital Pressure and Temperature Analyzer Kit

JT02158 Digital Pressure and Temperature Analyzer

JT02159 6 m (20 ft.) Cable with Couplers

JT02161 3400 kPa (35 bar) (500 psi) Transducer

JT02162 34 000 kPa (350 bar) (5000 psi) Transducer

JT05969 Thermo-Coupler

312883 Carry Case

JT02160 70 000 kPa (700 bar) (10 000 psi) Transducer (optional, order separately)

Use the digital pressure and temperature analyzer (A) and transducers (B) in place of analog gauges and a
separate temperature reader.

Transducers are temperature sensitive. Allow transducer to warm to system temperature. After transducer is
warmed and no pressure applied, push sensor zero button for one second to set the true zero point.

When using for different pressures, turn selector to OFF for two seconds and then to the pressure range.
Readings are inaccurate if proper range for transducer is not used.

Go to Section_9026:Group_25

MF82180,0000048-19-20111214

1104
 JT02156A Digital Pressure/Temperature Analyzer Installation

JT02156A Digital Pressure/Temperature Analyzer Installation

T8543AI-UN: JT02156A Digital Pressure and Temperature Analyzer Kit

LEGEND:
A - Digital Pressure and Temperature Analyzer
B - 3400 kPa (35 bar) (500 psi) Transducer
- 34 000 kPa (350 bar) (5000 psi) Transducer
- 70 000 kPa (700 bar) (10 000 psi) Transducer

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JT02156A Digital Pressure and Temperature Analyzer Kit

JT02158 Digital Pressure and Temperature Analyzer

JT02159 6 m (20 ft.) Cable with Couplers

JT02161 3400 kPa (35 bar) (500 psi) Transducer

JT02162 34 000 kPa (350 bar) (5000 psi) Transducer

JT05969 Thermo-Coupler

312883 Carry Case

JT02160 70 000 kPa (700 bar) (10 000 psi) Transducer (optional, order separately)

Use the digital pressure and temperature analyzer (A) and transducers (B) in place of analog gauges and a
separate temperature reader.

Transducers are temperature sensitive. Allow transducer to warm to system temperature. After transducer is
warmed and no pressure applied, push sensor zero button for one second to set the true zero point.

When using for different pressures, turn selector to OFF for two seconds and then to the pressure range.
Readings are inaccurate if proper range for transducer is not used.

Go to Section_9026:Group_25

MF82180,0000048-19-20111214

1105
 Ultra Clean® Hand Launcher

Ultra Clean® Hand Launcher

Use the Ultra Clean® Hand Launcher Kit to help eliminate contamination in hydraulic systems. All newly installed
hose and tube assemblies should be cleaned using this tool.

Go to Section_9026:Group_25

MF82180,0000045-19-20160229

1106
 Machine Supporting Procedure

Machine Supporting Procedure

-: Specifications

SPECIFICATIONS

750J SAE Operating (approximate) Weight 15 875 kg

35 000 lb

850J SAE Operating (approximate) Weight 25 411 kg

45 000 lb

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

D01182AA 20-Ton Floor Stand

JDG10013 750J/850J Floor Stand Kit

Follow this procedure to raise and support machine for test or repair that require tracks to rotate.

1. Park machine on hard level concrete surface.

Raise blade approximately 300 mm (1 ft.) off ground and stop engine.

Item Measurement Specification

750J SAE Operating (approximate) Weight 15 875 kg
36 000 lb
850J SAE Operating (approximate) Weight 25 411 kg
45 000 lb

2. CAUTION:
Prevent possible injury from unexpected track movement. Raise the machine off
the ground and support with 20-Ton Floor Stands. Tracks must be clear of tools
and objects before rotating.

1107
 Machine Supporting Procedure

TX1036790A-UN: Rear 20-Ton Floor Stand Installation

Use floor jack under rear frame to raise rear of machine until tracks are off ground under rear drive
sprockets.

Install two 20-Ton Floor Stands as shown.

3.

T205099A-UN: Front 750J/850J Floor Stand Kit Installation

LEGEND:
1 - 20-Ton Floor Stand (2 used)
2 - Floor Stand Adapter (2 used)
3 - Floor Stand Rod
4 - Washer (2 used)
5 - Cap Screw (2 used)

1108
 Machine Supporting Procedure
Start engine and use blade to raise front of machine until tracks are off ground.

Support front of machine with 750J/850J Floor Stand Kit as shown.

Lower blade to ground.

Operate each track to check if they are free to rotate in either direction.

Stop engine and prepare machine for testing or repair. See Transmission Oil Warm-Up Procedure .
(Group 9026-25.)

Go to Section_9026:Group_25

MR50960,000000B-19-20080221

1109
 Transmission Oil Warm-Up Procedure

Transmission Oil Warm-Up Procedure

-: Specifications

SPECIFICATIONS

Engine Speed Fast Idle

Speed-In-Grip (SIG) (heating cycle) Position 3.0

Speed-In-Grip (SIG) (circulating cycle) Position 1.4

Transmission Oil Temperature 57—66°C

135—150°F

750J SAE Operating (approximate) Weight 15 875 kg

35,000 lb

850J SAE Operating (approximate) Weight 25 411 kg

45,000 lb

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

D01182AA 20-Ton Floor Stand

JDG10013 750J/850J Floor Stand Kit

Follow this procedure to heat hydrostatic oil to a specified temperature.

1. CAUTION:
Prevent possible injury from unexpected track movement. Raise the machine off
the ground and support with 20-Ton Floor Stands. Tracks must be clear of tools
and objects before rotating.

T205099A-UN: 750J/850J Floor Stand Kit

1110
 Transmission Oil Warm-Up Procedure

TX1036790A-UN: Rear 20-Ton Floor Stand Installation

LEGEND:
1 - 20-Ton Floor Stand (4 used)
2 - Floor Stand Adapter (2 used)
3 - Floor Stand Rod
4 - Washer (2 used)
5 - Cap Screw (2 used)

Raise machine off the ground and support with 20-Ton Floor Stands. Lower blade to ground. Tracks
must be free to rotate in either direction. See Machine Supporting Procedure . (Group 9026-25.)
Item Measurement Specification
750J SAE Operating (approximate) Weight 15 875 kg
35,000 lb
850J SAE Operating (approximate) Weight 25 411 kg
45,000 lb

2. Start engine.

3. Set hydrostatic transmission Speed-In-Grip (SIG) to specification.

Item Measurement Specification

Speed-In-Grip (SIG) (heating cycle) Position 3.0

4. NOTE:

The TEST setting is located in the service menu. To enter the service menu, press the
MENU button and hold it down for 5 seconds.

Set brake control setting to TEST.

1. Access Service Menu on monitor.

1111
 Transmission Oil Warm-Up Procedure

2. Select Machine Settings.

3. Select Brake Ctrl.

4. Select Test.

NOTE:

Do not leave machine in brake Test setting during normal operation.

5. Set monitor display setting to Transmission Temperature.

1. Access Menu on monitor.

2. Select Diagnostics.

3. Select Live Values.

4. Select Temperatures.

5. Select Other Temperatures

6. Select Transmission.

6. Set engine speed to specification.

Item Measurement Specification

Engine Speed Fast Idle

7. Set front dash Decelerator Mode Switch to transmission mode, Decel Function icon will come on.

8. NOTE:

There is a feature built in to the brake test mode that allows you to remain out of neutral
for 13 seconds, after which, the TCU will kick out to neutral. Then you have to shift the
trans lever to neutral and leave it there for 13 more seconds before going back in range.
Then the cycle starts again

Heating oil:

1. Push decel pedal to floor.

2. Put park lock lever in UP position.

3. Put Transmission Control Lever (TCL) in forward.

4. Slowly release decel pedal.

5. Heat oil for 20 seconds while reading transmission temperature on monitor.

6. Push decel pedal to floor.

1112
 Transmission Oil Warm-Up Procedure
7. Move TCL to neutral.

9. Set hydrostatic transmission Speed-In-Grip (SIG) to specification.

Item Measurement Specification

Speed-In-Grip (SIG) (circulating cycle) Position 1.4

10. Circulating oil:

1. Push decel pedal to floor.

2. Put park lock lever in DOWN position.

3. Put TCL in forward.

4. Release decel and cycle TCL in forward and reverse for a total of 20 seconds.

5. Push decel pedal to floor.

11. Alternate heating and circulating cycles until transmission oil temperature reaches specification.

Item Measurement Specification

Transmission Oil Temperature 57—66°C
135—150°F

12. Turn machine OFF to reset brake to normal setting.

Go to Section_9026:Group_25

TE14778,000005B-19-20090527

1113
 Releasing Park Brake to Tow the Machine

Releasing Park Brake to Tow the Machine

This procedure is used to release park brake for towing the machine.

T158857C-UN: Multi-Function Valves

LEGEND:
1 - Forward Multi-Function Valve
2 - Reverse Multi-Function Valve

CAUTION:
Prevent possible injury from unexpected machine movement. Place blocks at front and
rear of tracks and secure machine to prevent it from rolling.

Do not allow an operator on the machine being towed unless the operator can control the
steering and brakes.

IMPORTANT:

DO NOT tow machine faster than 2.4 km/h (1.5 mph) or extensive machine damage may result.

NOTE:

Multi-function valves can be turned out using a 1 3/8 in. socket and a flexible head ratchet.
Engine does not have to be running to tow machine.

The top multi-function valves are in the forward side of the closed loop circuit and must be
loosened to tow the machine in reverse. Likewise, the bottom multi-function valves are in the
reverse side of the closed loop circuit and must be loosened to tow the machine in forward.

1114
 Releasing Park Brake to Tow the Machine
Towing Machine With Engine OFF

1. Tilt cab or ROPS up. See Cab or ROPS Tilting Procedure . (Operator’s Manual.)

2. TO TOW MACHINE FORWARD: both front and rear pump bottom multi-function relief valves MUST be
turned out (counterclockwise) 1/2 to 1 turn and blade must be raised off the ground. (If engine will crank
but will not start, blade can be raised by cranking engine while holding blade raise function on control
valve.)

TO TOW MACHINE IN REVERSE: both front and rear pump top multi-function valves MUST be turned
out (counterclockwise) 1/2 to 1 turn.

3. Tilt cab down.

4. Turn key switch ON.

5. NOTE:

When towing the machine with person in operator's seat, the park brake can be applied
to stop machine at any time by moving the park lock lever to the up (locked) position.

Put park lock lever in DOWN position and transmission control lever (TCL) in NEUTRAL.

6. NOTE:

TOW will allow the machine to be towed without automatically applying the brakes (hill
hold disabled).

The TOW setting is located in the menu.

Set brake control setting to Tow.

1. Access Menu on monitor.

2. Select Machine Settings.

3. Select Brake Ctrl Set.

4. Select Tow.

7. Display brake pressure on monitor.

1. Select Diagnostics.

2. Select Live Values.

3. Select Pressures.

4. Select Trans. Pressure.

5. Select Brake Pressure.

8. Pull and turn the RED knob on HIC valve to the extended [out] (tow) position.

1115
 Releasing Park Brake to Tow the Machine
9. Use pump handle and apply pressure to release brakes.

10. NOTE:

There’s a relief valve for the park brake in the HIC valve. You will hear oil flow through
relief and feel increased pressure on handle when brakes are totally released.

Verify that the brake pressure is above specification.

Item Measurement Specification

Brake Release Pressure Pressure 2070 kPa
21 bar
300 psi

11. NOTE:

Brake pressure does not exceed specification, refer to Park Brake Relief Valve Test.

Tow machine.

Towing Machine With Engine ON

1. Tilt cab up. See Cab or ROPS Tilting Procedure . (Operator’s Manual.)

2. TO TOW MACHINE FORWARD both front and rear pump bottom multi-function relief valves MUST be
turned out (counterclockwise) 1/2 to 1 turn and blade must be raised off the ground. (If engine will crank
but will not start, blade can be raised by cranking engine while holding blade raise function on control
valve.)

TO TOW MACHINE IN REVERSE both front and rear pump top multi-function valves MUST be turned
out (counterclockwise) 1/2 to 1 turn.

3. Tilt cab down.

4. Start engine.

5. Put park lock lever in DOWN position and transmission control lever (TCL) in NEUTRAL.

6. Tow machine.

Go to Section_9026:Group_25

TE14778,0000067-19-20120801

1116
 Hydrostatic Pump and Motor Initial Start-Up Procedure

Hydrostatic Pump and Motor Initial Start-Up Procedure

-: Specifications

SPECIFICATIONS

Transmission Charge Pressure 345 kPa

3.45 bar
50 psi

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

D01182AA 20-Ton Floor Stand

JDG10013 750J/850J Floor Stand Kit

This procedure is used to bleed air from the hydrostatic circuit after a major component repair.

1. CAUTION:
Prevent possible injury from unexpected track movement. Raise the machine off
the ground and support with 20-Ton Floor Stands. Tracks MUST be clear of tools
and objects before rotating.

T205099A-UN: 750J/850J Floor Stand Kit

LEGEND:
1 - 20-Ton Floor Stand (4 used)
2 - Floor Stand Adapter (2 used)
3 - Floor Stand Rod
4 - Washer (2 used)
5 - Cap Screw (2 used)

Raise machine off the ground and support with 20-Ton Floor Stands. See Machine Supporting
Procedure . (Group 9026-25.)

1117
 Hydrostatic Pump and Motor Initial Start-Up Procedure
Lower blade to ground. Tracks MUST be free to rotate in either direction.

2. Fill reservoir with specified oil. See Check Transmission Oil Level . (Operators Manual.) Leave reservoir
cap OFF.

3. Disconnect engine harness from crankshaft position sensor.

4. Set monitor display to CHARGE.

5. IMPORTANT:

Never operate starting motor more than 30 seconds. Allow at least 2 minutes for cooling and battery
recovery before operating again. Overheating, caused by excessive operation, will seriously damage
starting motor.

Crank engine in 30 second intervals until transmission charge pressure reaches specification.

Item Measurement Specification

Transmission Charge Pressure 345 kPa
3.45 bar
50 psi

6. Reconnect engine harness onto crankshaft position sensor.

7. Start engine and leave at low idle for one minute. Operate machine at low speed in forward and reverse
cycles through counter-rotate for several minutes. This will flush the displacement control valve areas.

8. Recheck reservoir oil level and install cap.

Go to Section_9026:Group_25

TE14778,0000031-19-20080221

1118
 Hydrostatic Pump Flushing Procedure

Hydrostatic Pump Flushing Procedure

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

D01182AA 20-Ton Floor Stand

JDG10013 750J/850J Floor Stand Kit

38H1004 90° Fitting (2 used)

38H1160 Fitting (4 used)

Parker 1JS43-6-6 Fitting 9/16 ORB (4 used)

Parker #601-6 Hose 2134 mm (7 ft) (4 used)

This procedure is used whenever major repair has been done to the hydrostatic circuit.

1. CAUTION:
Prevent possible injury from unexpected track movement. Raise the machine off
the ground and support with 20-Ton Floor Stands. Tracks MUST be clear of tools
and objects before rotating.

T205099A-UN: 750J/850J Floor Stand Kit

LEGEND:
1 - 20-Ton Floor Stand (4 used)
2 - Floor Stand Adapter (2 used)
3 - Floor Stand Rod
4 - Washer (2 used)
5 - Cap Screw (2 used)

Raise machine off the ground and support with 20-Ton Floor Stands. See Machine Supporting
Procedure . (Group 9026-25.) Lower blade to ground. Tracks MUST be free to rotate in either direction.

2. NOTE:

1119
 Hydrostatic Pump Flushing Procedure
Test ports (1) MUST be closed to shift displacement control valve and allow flow from
servos (2).

T206311A-UN: Hydrostatic Pump Test Ports

LEGEND:
1 - Pump Displacement Control Valve (PDCV) Test Ports
2 - Pump Servo Test Port Ports
3 - Pump Pressure Control Pilot (PCP) Connector

Install test hoses and fittings into ports (1) on both pump displacement control valves. Route opposite
end of hoses back to reservoir.

3. Start engine. Leave engine speed at slow idle.

4. CAUTION:
Tracks will rotate when TCL is moved to forward or reverse.

NOTE:

Operate machine in 20 second intervals allowing sufficient time for cooling.

Put transmission speed control to midrange. Cycle Transmission Control Lever (TCL) from forward left
counter rotate through right counter rotate positions. This will flush the displacement control valve areas.

Continue cycling machine at slow idle for several minutes. Increase engine speed to 1500 rpm and
continue cycling TCL to actuate transmission pumps for approximately 10 minutes.

5. Repeat procedure using servo test ports (2).

Go to Section_9026:Group_25

AA95137,0000815-19-20080220

1120
 Hydraulic Oil Cleanup Procedure

Hydraulic Oil Cleanup Procedure

A hydraulic oil cleanup procedure must be done prior to starting machine after a component has been repaired or
replaced. The use of attachments increases the need to monitor and filter oil to a safe contamination level. See
750J and 850J Crawler Dozer General Oil Cleanup Procedure . (CTM310—Super Caddy Oil Cleanup Procedure.)

Go to Section_9026:Group_25

MF82180,0000046-19-20050128

1121
 Pressure Control Pilot (PCP) Manual Override Test

Pressure Control Pilot (PCP) Manual Override Test

-: Specifications

SPECIFICATIONS

Engine Speed Slow Idle

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

D01182AA 20-Ton Floor Stand

JDG10013 750J/850J Floor Stand Kit

This procedure will help isolate between electrical and hydraulic problems. Moving the manual override lever
produces a hydraulic differential pressure signal to the pump displacement control valve (PDCV). If operation is
normal, pressure will be produced in the closed loop and tracks will rotate.

1. CAUTION:
Prevent possible injury from unexpected track movement. Raise the machine off
the ground and support with 20-Ton Floor Stands. Tracks MUST be clear of tools
and objects before rotating.

T205099A-UN: 750J/850J Floor Stand Kit

LEGEND:
1 - 20-Ton Floor Stand (4 used)
2 - Floor Stand Adapter (2 used)
3 - Floor Stand Rod
4 - Washer (2 used)
5 - Cap Screw (2 used)

Raise machine off the ground and support with 20-Ton Floor Stands. See Machine Supporting
Procedure . (Group 9026-25.)

Lower blade to ground. Tracks MUST be free to rotate in either direction.

1122
 Pressure Control Pilot (PCP) Manual Override Test
2. Tilt cab or ROPS to midway position. Install operator's station tilt cylinder lock. See Cab or ROPS Tilting
Procedure . (Operator’s Manual.)

3. Start engine and run at slow idle. Access Transmission Controller Motor Speed Check in Service
ADVISOR™ system template.

Item Measurement Specification

Engine Speed Slow Idle

4. NOTE:

In order to allow manual override in neutral, the brake control setting must be set to
TEST. In Normal mode the brakes will engage after three seconds.

The TEST setting is located in the service menu. To enter the service menu, press the
MENU button and hold it down for 5 seconds.

Set brake control setting to TEST.

1. Access Service Menu on monitor.

2. Select Machine Settings.

3. Select Brake Ctrl.

4. Select Test.

5. Put park lock lever in DOWN position.

6. CAUTION:
Tracks will rotate when PCP manual override lever is moved.

T8437AI-UN: PCP Manual Override Lever

LEGEND:
1 - Pump PCP Manual Override Lever

Momentarily move the PCP manual override lever (1) in each direction.

The tracks will rotate as the lever is moved in each direction. This indicates normal hydraulic operation
in the closed-loop system.

1123
 Pressure Control Pilot (PCP) Manual Override Test
7. NOTE:

Do not leave machine in brake Test setting during normal operation.

Set brake control setting to Normal by turning key off.

Go to Section_9026:Group_25

TE14778,0000077-19-20120823

1124
 Pressure Control Pilot (PCP) Test

Pressure Control Pilot (PCP) Test

-: Specifications

SPECIFICATIONS

Transmission Oil Temperature 57—66°C

135—150°F

Engine Speed Fast Idle

Neutral PCP Differential Pressure 0—34 kPa

0—0.34 bar
0—5 psi

Transmission Speed-In-Grip (SIG) Position 1.0—3.0

Input Current-to-Control Pressure 1 mA/6.89 kPa

1 mA/0.069 bar
1 mA/1 psi

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

D01182AA 20-Ton Floor Stand

JDG10013 750J/850J Floor Stand Kit

XPD361 Quick Coupler (9/16-20UN M ORB) (2 used)

JT03448 Test Hose (2 used)

JT05753 Hydrostatic Test Switch Box

JT02156A Digital Pressure/Temperature Analyzer

JT02161 350 kPa (35 bar) (500 PSI) Transducer

This procedure will test pump PCP's in neutral and also in operational mode.

1. CAUTION:
Prevent possible injury from unexpected track movement. Raise the machine off
the ground and support with 20-Ton Floor Stands. Tracks MUST be clear of tools
and objects before rotating.

1125
 Pressure Control Pilot (PCP) Test

T205099A-UN: 750J/850J Floor Stand Kit

LEGEND:
1 - 20-Ton Floor Stand (4 used)
2 - Floor Stand Adapter (2 used)
3 - Floor Stand Rod
4 - Washer (2 used)
5 - Cap Screw (2 used)

Raise machine off the ground and support with 20-Ton Floor Stands. See Machine Supporting
Procedure . (Group 9026-25.)

Lower blade to ground. Tracks MUST be free to rotate in either direction.

2. Tilt cab or ROPS up. See Cab or ROPS Tilting Procedure . (Operators Manual.)

3.

T206311A-UN: Hydrostatic Pump Test Ports

LEGEND:
1 - Pump Displacement Control Valve (PDCV) Test Port (two shown)
2 - Pump Servo Test Port Port (two shown)
3 - Pump Pressure Control Pilot (PCP) Connector

Install fittings and test hoses in ports (1).

4. NOTE:

A switching valve and gauge or some type of differential pressure gauge or reader must
1126
 Pressure Control Pilot (PCP) Test
be used to obtain an accurate differential pressure reading. Two separate pressure
gauges cannot be used.

Connect switching valve, digital pressure/temperature analyzer and transducer or a gauge.

5. Lower cab or ROPS to normal operating position.

6. Start engine and heat hydrostatic oil to specified temperature. See Transmission Oil Warm-Up
Procedure . (Group 9026-25.)

Item Measurement Specification

Transmission Oil Temperature 57—66°C
135—150°F

7. Check neutral PCP differential pressure.

Item Measurement Specification

Neutral PCP Differential Pressure 0—34 kPa
0—0.34 bar
0—5 psi
If neutral PCP differential pressure is greater than specification but less than 103 kPa (1.03 bar) (15 psi),
PCP must be adjusted. See Pressure Control Pilot (PCP) Internal Adjustment . (9026-25.)

If differential pressure is over 103 kPa (1.03 bar) (15 psi), PCP must be replaced.

8. Set transmission Speed-In-Grip (SIG) to specification.

Item Measurement Specification

Transmission Speed-In-Grip (SIG) Position 1.0

9. NOTE:

Output currents are located in the service menu. To enter the service menu, press the
MENU button and hold it down for 5 seconds.

Access the Output Info menu.

1. Access Service Menu on monitor.

2. Select Diagnostics.

3. Select Live Values.

4. Select Output Info.

10. Set front dash Decelerator Mode Switch to transmission mode, Decel Function icon will come on.

11. Record Left Pump PCP and Right Pump PCP mA values.

12. Depress decelerator pedal to floor.

13. Set engine speed control to specification.

1127
 Pressure Control Pilot (PCP) Test

Item Measurement Specification

Engine Speed Fast Idle

14. CAUTION:
Tracks will rotate when Transmission Control Lever (TCL) is moved to forward or
reverse.

Move Transmission Control Lever (TCL) to forward. Slowly release decelerator pedal. Carefully monitor
the mA as the decelerator is released. The reading will suddenly go from 0 to some low reading (e.g.,
15.9 mA). This is the threshold or initial reading.

15. With the decelerator fully released, slowly increase SIG to maximum speed position to continue
increasing the mA.

16. Record the milliamp and differential readings as follows:

-: Single Lever Steer Machine

Front Pump Rear Pump Calculated Pressure

Control Pressure Control Pressure Differential

Transmission Speed Control Forward Reverse Forward Reverse Front Rear

Milliamp Pump Pump

Neutral Reading at (1.0). 0

Initial Reading at (1.0) (record __mA

actual mA).

Increase speed to get— 35 mA

Increase speed to get— 50 mA

Increase speed to get— 75 mA

Maximum Reading at (3.0) __mA

(record actual mA).

17. Repeat the procedure for reverse.

18. Analyze test results as follows:

The initial reading when coming out of neutral is the threshold of movement value (point tracks begin to
move).

The relationship between control milliamps and differential control pressure is approximately 7 kPa (0.07
bar) (1 psi) differential OUT of the Pressure Control Pilot (PCP) for each milliamp IN.

The operation of the PCP can be considered acceptable if pressure reading is reasonably close to the
theoretical value and linear to the milliamp values.

Item Measurement Specification

Input Current-to-Control Pressure 1 mA/6.89 kPa
1 mA/0.069 bar
1 mA/1 psi

1128
Pressure Control Pilot (PCP) Test

Go to Section_9026:Group_25

TE14778,0000065-19-20090527

1129
 Pressure Control Pilot (PCP) Internal Adjustment

Pressure Control Pilot (PCP) Internal Adjustment

-: Specifications

SPECIFICATIONS

Transmission Oil Temperature 57—66°C

135—150°F

Engine Speed Fast Idle

Transmission Speed Position 1.0

Differential Pressure 0—34.5 kPa

0—0.34 bar
0—5 psi

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

D01182AA 20-Ton Floor Stand

JDG10013 750J/850J Floor Stand Kit

XPD361 Quick Coupler (9/16-20UN M ORB) (2 used)

JT03448 Test Hose (2 used)

JT05753 Hydrostatic Test Switch Box

JT02156A Digital Pressure/Temperature Analyzer

JT02161 350 kPa (35 bar) (500 PSI) Transducer

3/32 Hex Key Wrench

The purpose of this test is to adjust the internal flapper valve in the pressure control pilot (PCP).

1. CAUTION:
Prevent possible injury from unexpected track movement. Raise the machine off
the ground and support with 20-Ton Floor Stands. Tracks MUST be clear of tools
and objects before rotating.

1130
 Pressure Control Pilot (PCP) Internal Adjustment

T205099A-UN: 750J/850J Floor Stand Kit

LEGEND:
1 - 20-Ton Floor Stand (4 used)
2 - Floor Stand Adapter (2 used)
3 - Floor Stand Rod
4 - Washer (2 used)
5 - Cap Screw (2 used)

Raise machine off the ground and support with 20-Ton Floor Stands. See Machine Supporting
Procedure . (Group 9026-25.)

Lower blade to ground. Tracks MUST be free to rotate in either direction.

2. Start engine and heat hydrostatic oil to normal operating temperature. See Transmission Oil Warm-Up
Procedure. (Group 9026-25.)

Item Measurement Specification

Transmission Oil Temperature 57—66°C
135—150°F

3. Tilt cab or ROPS up. See Cab or ROPS Tilting Procedure . (Operators Manual.)

4.

T206311A-UN: Hydrostatic Pump Test Ports

LEGEND:

1131
 Pressure Control Pilot (PCP) Internal Adjustment
1 - Pump Displacement Control Valve (PDCV) Test Ports
2 - Pump Servo Test Port Ports
3 - Pump Pressure Control Pilot (PCP) Connector

Thoroughly clean area around PCP and pump displacement control valve (PDCV) test ports.

5. Install fittings and test hoses in ports (1).

6. NOTE:

A switching valve and gauge or some type of differential pressure gauge or reader must
be used to obtain an accurate differential pressure reading. Two separate pressure
gauges cannot be used.

Connect switching valve, digital pressure/temperature analyzer and transducer or a gauge.

7. Disconnect PCP wire connector (3).

8. Run engine at fast idle, set transmission speed at 1.0.

With park lock lever in up position, record differential pressure.

Item Measurement Specification

Engine Speed Fast Idle
Transmission Speed Position 1.0

9. Read or calculate differential pressure and compare to specifications.

Item Measurement Specification

Differential Pressure 0—34.5 kPa
0—0.34 bar
0—5 psi
If differential pressure is within specifications, test is complete.
If differential pressure is too high, go to next step to adjust.

10. IMPORTANT:

The coil and flapper valve area of the PCP MUST be kept clean for proper operation. Always use clean
wrenches and keep entire area clear of any dirt.

NOTE:

Some silicone oil will leak from port when screw is removed.

1132
 Pressure Control Pilot (PCP) Internal Adjustment

T118613A-UN: Pressure Control Pilot (PCP)

LEGEND:
4 - Slotted Screw

Remove slotted screw (4) with O-ring on side of PCP.

11. Adjust internal allen screw as necessary to get differential pressure to specification.

Item Measurement Specification

Differential Pressure 0—34.5 kPa
0—0.34 bar
0—5 psi
12. IMPORTANT:

DO NOT overtighten PCP screw (4).

Install screw (4) by hand until O-ring contacts housing. Turn screw an additional 1/8 turn.

13. Remove test equipment and connect wire lead to PCP.

14. Route all wiring harnesses back to their original location and replace all tie bands that were removed.

15. Return cab or ROPS to operating position.

16. Calibrate machine. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Go to Section_9026:Group_25

TE14778,0000064-19-20080221

1133
 Multi-Function Relief Valve Test

Multi-Function Relief Valve Test

-: Specifications

SPECIFICATIONS

Transmission Oil Temperature 57—66°C

135—150°F

Engine Speed Fast Idle

Transmission Speed Setting 1.6

Multi-Function Valve

Relief Valve Pressure 44 128—46 884 kPa

441—468 bar
6400—6800 psi

Relief Valve Pressure Change 7000 kPa per 1/2 Turn

70 bar per 1/2 Turn
1000 psi per 1/2 Turn

Lock Nut Torque 16.3 N·m

144 lb.-in.

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

D01182AA 20-Ton Floor Stand (4 used)

JDG10013 750J/850J Floor Stand Kit

The purpose of this test is to check and adjust multi-function valve relief settings. For more information, see Multi-
Function Valve Operation . (Group 9026-05.)

For this test, multi-function valve relief pressures are viewed using the CAN monitor unit (CMU) and the
hydrostatic pressure sensors connected to the diagnostic test ports.

TX1158214A-UN: Diagnostic Test Ports

LEGEND:
5 - Diagnostic Test Port Left Forward and Reverse
6 - Diagnostic Test Port Right Forward and Reverse

1134
 Multi-Function Relief Valve Test
The test could also be performed by removing the pressure sensors and connecting a digital temperature and
pressure analyzer or gauge to the diagnostic test ports.

Use test port (5) to check rear pump (left track) multi-function valve relief settings.
Use test port (6) to check front pump (right track) multi-function valve relief settings.

1. CAUTION:
Prevent possible injury from unexpected track movement. Raise the machine off
the ground and support with appropriate stands. Tracks must be free to rotate in
either direction. Check for objects on tracks before rotating tracks.

T205099A-UN: 750J/850J Floor Stand Kit

LEGEND:
1 - 20-Ton Floor Stand (4 used)
2 - Floor Stand Adapter (2 used)
3 - Floor Stand Rod
4 - Washer (2 used)
5 - Cap Screw (2 used)

Raise machine off the ground and support with appropriate stands. See Machine Supporting Procedure .
(Group 9026-25.)

Lower blade to ground. Tracks must be free to rotate in either direction.

2. Stop engine.

3. CAUTION:
To avoid injury from escaping fluid under pressure, stop engine and relieve the
pressure in the system before disconnecting or connecting hydraulic or other
lines. Tighten all connections before applying pressure. Pressure spikes in the
transmission closed loop can approach 68 950 kPa (690 bar) (10 000 psi). Use
hoses and fittings rated for these pressures when checking transmission system
pressures.

1135
 Multi-Function Relief Valve Test
Start engine and heat oil to specification. See Transmission Oil Warm-Up Procedure . (Group 9026-25.)

Item Measurement Specification

Transmission Oil Temperature 57—66°C
135—150°F

4. Set brake mode to TEST:

1. Enter service mode on the CAN monitor unit (CMU). Press and hold MENU for approximately 5
seconds until monitor alarm is heard and SERVICE MODE is temporarily displayed on CMU.

2. Select MACHINE SETTINGS from CMU main menu.

3. Press NEXT until BRAKE CTRL appears and then press SELECT. Set brake mode to TEST.

For more information on using CMU, see CAN Monitor Unit (CMU) Menu Structure—Service
Mode . (Group 9015-20.)

5. Set decelerator mode switch to transmission mode.

6. Depress decelerator/brake pedal to floor and set engine speed to specification.

Item Measurement Specification

Engine Speed Fast Idle

7. With park lock lever in UP (locked) position, set transmission speed to specification.

Item Measurement Specification

Transmission Speed Setting 1.6

8. Access the Efficiency and Relief monitor screen to display hydrostatic system pressures:

1. With CMU in service mode, select TCU DIAGNOSTICS from CMU main menu.

2. Press NEXT until PROCEDURES appears and then press SELECT.

3. Select EFFICIENCY AND RELIEF VALVE TEST.

9. IMPORTANT:

To prevent damage to multi-function valves, the test software limits the test function to 20 seconds
before returning transmission to neutral. The tracks must be operated between test functions to prevent
localized overheating of multi-function valves. Rotating the tracks will circulate some hot oil out of
closed-loop circuit to the hydrostatic oil reservoir for cooling.

Carefully monitor transmission temperature during this test. Temperature will rise very quickly when
operating in an over-relief condition. Do not exceed 71°C (160°F).

Check multi-function valve relief pressure:

1. Place transmission control lever (TCL) in appropriate detent corresponding with test being
performed. Hold TCL to stop track on opposite side. (Test multi-function valve relief pressure
one side at a time to obtain accurate results.)

2. NOTE:
1136
 Multi-Function Relief Valve Test

In order to obtain an accurate pressure reading it is important not to flood the

relief valve with excessive oil flow. Do not continue increasing engine speed
after pressure levels out.

Slowly release decelerator/brake pedal and record highest pressure reading.

3. NOTE:

Pressure should rise as the engine speed is slowly increased and then levels
out. The point at which the pressure levels out is the relief valve setting.

If high-pressure reading is erratic (very unstable), rotate tracks slightly to reposition motor
speed ring and sensor. Repeat test. If pressures remain erratic, turn TRACKER CONTROL off
in CMU and perform test.

4. Compare reading to specification. If the relief setting cannot be reached at fast idle, then slowly
increase transmission speed until pressure levels out.

Item Measurement Specification

Multi-Function Valve
Multi-Function Relief Valve Pressure 44 128—46 884 kPa
441—468 bar
6400—6800 psi

10. Repeat procedure to test other relief valve settings and record pressures.

11. NOTE:

The top multi-function valve on each pump controls pressure in forward and the bottom
valve in reverse.

1137
 Multi-Function Relief Valve Test

T158857B-UN: Multi-Function Valves

LEGEND:
1 - Outer Lock Nut

If multi-function valve setting does not meet test specification:

1. Remove hex cover, if installed. (Later version machines do not have covers on relief valves.)

2. Loosen the outer lock nut.

3. Insert hex wrench in center of valve.

4. Turn hex wrench in to increase pressure, out to decrease pressure.

Item Measurement Specification

Multi-Function Valve
Relief Valve Pressure Change 7000 kPa per 1/2 Turn
70 bar per 1/2 Turn
1000 psi per 1/2 Turn

5. Hold hex wrench and tighten lock nut to specification.

Item Measurement Specification

Multi-Function Valve
Lock Nut Torque 16.3 N·m
144 lb.-in.

6. Repeat test to verify pressure, adjust as required.

7. Install hex cover.

1138
 Multi-Function Relief Valve Test
12. NOTE:

Do not leave brake mode set to TEST for machine normal operation.

Turn key switch OFF to reset brake mode to NORMAL.

13. Remove test equipment.

Go to Section_9026:Group_25

KV70328,00001F7-19-20140430

1139
 Transmission Efficiency Test

Transmission Efficiency Test

-: Specifications

SPECIFICATIONS

Transmission Oil Temperature 57—66°C

135—150°F

Transmission Speed-In-Grip (SIG) Position 1.6

Engine Speed Fast Idle

Multi-Function Relief Valve Pressure 44 128—46 884 kPa

441—468 bar
6400—6800 psi

Amperage 0—11 mA above 1000 psi reading Good

Amperage 11—16 mA above 1000 psi reading Marginal

Amperage Over 16 mA above 1000 psi reading Bad

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

D01182AA 20-Ton Floor Stands

JDG10013 750J/850J Floor Stand Kit

The purpose of this test is to determine the amount of transmission internal leakage in the closed-loop
components.

This is accomplished by determining the amount of oil the transmission pump must deliver to maintain a specified
system pressure in the closed loop. This pressure is below the relief valve setting. Therefore, the amount of pump
flow indicates the amount of internal leakage in the closed loop.

The transmission controller sends a current signal to the Pressure Control Pilot (PCP) on each pump. The PCP
produces a hydraulic pressure differential to the servo piston relative to the amount of current. By monitoring the
current signal being sent to the PCP, the amount of leakage in the closed loop can be determined.

A small current signal to maintain system pressure means there is very little leakage.

A large current signal reading means higher internal leakage.

1. CAUTION:
Prevent possible injury from unexpected track movement. Raise the machine off
the ground and support with 20-Ton Floor Stands. Tracks MUST be clear of tools
and objects before rotating.

1140
 Transmission Efficiency Test

T205099A-UN: 750J/850J Floor Stand Kit

LEGEND:
1 - 20-Ton Floor Stand (4 used)
2 - Floor Stand Adapter (2 used)
3 - Floor Stand Rod
4 - Washer (2 used)
5 - Cap Screw (2 used)

Raise machine off the ground and support with 20-Ton Floor Stands. See Machine Supporting
Procedure . (Group 9026-25.)

Lower blade to ground. Tracks MUST be free to rotate in either direction.

2. CAUTION:
To avoid injury from escaping fluid under pressure, stop engine and relieve the
pressure in the system before disconnecting or connecting hydraulic or other
lines. Tighten all connections before applying pressure.

Pressure spikes in the transmission closed loop can approach 68 950 kPa (690
bar) (10 000 psi). Use hoses and fittings rated for these pressures when checking
transmission system pressures.

TX1021508A-UN: Diagnostic Test Ports

1141
 Transmission Efficiency Test
LEGEND:
5 - Diagnostic Test Port Left Forward and Reverse
6 - Diagnostic Test Port Right Forward and Reverse

Each test port senses closed-loop pressure.

Use test port (5) to check left motor (rear pump) relief setting.
Use test ports (6) to check right motor (front pump) relief setting.

3. IMPORTANT:

Carefully monitor transmission temperature during this test. Temperature will rise very quickly when
operating in an over-relief condition. Do not exceed 71°C (160°F).

Start engine and heat transmission oil to specification. See Transmission Oil Warm-Up Procedure .
(Group 9026-25.)

Item Measurement Specification

Transmission Oil Temperature 57—66°C
135—150°F
4. IMPORTANT:

There is a feature built in to the brake test mode that allows you to remain out of neutral for 20 seconds,
after which, the TCU will kick out to neutral.

To prevent damage to multi-function valves. The tracks must be operated between test function to
prevent localized overheating of multi-function valves. Rotating the tracks will circulate some hot oil out
of closed loop circuit to the hydrostatic oil reservoir for cooling.

With park lock lever in UP position, set transmission Speed-In-Grip (SIG) to specification.

Item Measurement Specification

Transmission Speed-In-Grip (SIG) Position 1.6

5. NOTE:

The TEST setting is located in the service menu. To enter the service menu, press the
MENU button and hold it down for 5 seconds.

Set brake control setting to TEST.

1. Access Service Menu on monitor.

2. Select Machine Settings.

3. Select Brake Mode.

4. Select Test.

6. NOTE:

Output currents and pressures are located in the service menu. To enter the service
menu, press the MENU button and hold it down for 5 seconds.

Access the Efficiency and Relief menu.

1142
 Transmission Efficiency Test
1. Access Service Menu on monitor.

2. Select TCU Diagnostics.

3. Select Procedures.

4. Press Select.

5. Access Eff and Relief to observe readings.

7. Set front dash Decelerator Mode Switch to transmission mode, Decel Function icon will come on.

8. Fully depress decelerator pedal, park lock lever in up position.

9. Set engine speed to specification.

Item Measurement Specification

Engine Speed Fast Idle
10. IMPORTANT:

Carefully monitor transmission temperature during this test. Temperature will rise very quickly when
operating in an over-relief condition. Do not exceed 71°C (160°F).

Move Transmission Control Lever (TCL) to forward and hold steering lever to stop track on opposite
side. System pressure will increase rapidly to maximum value. this value must be at minimum
specification. If not Perform Multi-Function Relief Valve Test . (Group 9026-25.)

Item Measurement Specification

Multi-Function Relief Valve Pressure 44 128—46 884 kPa
441—468 bar
6400—6800 psi

11. NOTE:

If high pressure reading is erratic (very unstable), rotate tracks slightly to reposition
motor speed ring and sensor. If pressures remain erratic, turn tracker (Trkr) off in TCU
and perform test.

SLOWLY release the decelerator pedal until SYS PSI reads 6895 kPa (68.9 bar) (1000 psi). Record
Pump mA.

12. Continue releasing decelerator pedal until SYS PSI reads 34 474 kPa (345 bar) (5000 psi). Record
Pump mA.

13. Move Transmission Control Lever (TCL) to neutral. Return engine speed to slow idle.

14. Subtract mA reading at 1000 psi from mA reading at 5000 psi. Refer to specifications to determine
closed-loop condition.

Item Measurement Specification

Amperage 0—11 mA above 1000 psi reading Good
Amperage 11—16 mA above 1000 psi reading Marginal
Amperage Over 16 mA above 1000 psi reading Bad

1143
 Transmission Efficiency Test

15. Repeat procedure for other track in forward.

16. Move transducers to Left Reverse (LR ) test port (2) and Right Reverse (RR) test port (3) to check
reverse efficiency settings.

17. If any of the four readings are not within spec, continue to next step.

18. NOTE:

The hydrostatic pump does not have test ports to record closed loop pressure. By
setting mA the same as first part of test, we can now monitor engine rpm to isolate if
leakage is in pump or motor.

Remove the high pressure hoses from pump. Cap and plug open lines and ports.

19. Run test as before and set to the same mA reading at 5000 psi on monitor. Record engine RPM.

If engine RPM decreases, internal leakage is indicated in the motor.

If engine RPM stays the same, leakage is indicated in the pump.

20. Change test connections and repeat test procedure for opposite side.

Go to Section_9026:Group_25

AA95132,0000386-19-20090527

1144
 Neutral Charge Relief and Operating Charge Relief Pressure Test

Neutral Charge Relief and Operating Charge Relief Pressure Test

-: Specifications

SPECIFICATIONS

Transmission Oil Temperature 57—66°C

135—150°F

Engine Speed 1780—1820 rpm

Neutral Delta Pressure 2482—2620 kPa

24.8—26.2 bar
360—380 psi

Neutral Charge Relief Valve Pressure Change 580 kPa per turn
5.8 bar per turn
84 psi per turn

Minimum Operating Delta Pressure 2275 kPa

22.8 bar
330 psi

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

D01182AA 20-Ton Floor Stand

JDG10013 750J/850J Floor Stand Kit

JT02156A Digital Pressure/Temperature Analyzer

JT02161 34 000 kPa (350 bar) (5000 psi) Transducer (2 used)

1. CAUTION:
Prevent possible injury from unexpected track movement. Raise the machine off
the ground and support with 20-ton floor stands. Tracks must be clear of tools
and objects before rotating.

1145
 Neutral Charge Relief and Operating Charge Relief Pressure Test

T205099A-UN: 750J/850J Floor Stand Kit

LEGEND:
1 - 20-Ton Floor Stand (4 used)
2 - Floor Stand Adapter (2 used)
3 - Floor Stand Rod
4 - Washer (2 used)
5 - Cap Screw (2 used)

Raise machine off the ground and support with D01182AA 20-Ton Floor Stand and JDG10013 Floor
Stand Kit. See Machine Supporting Procedure . (Group 9026-25.)

Lower blade to ground. Tracks must be free to rotate in either direction.

2.

TX1078914A-UN: Hydraulic Integrated Circuit (HIC) Valve

LEGEND:
1 - Neutral Charge Relief Valve
2 - Test Port 2
4 - Test Port 4

Open left rear access door, and install JT02156A temperature pressure analyzer and JT02161 34 000
kPa (350 bar) (5000 psi) transducers to test port 2 (2) and test port 4 (4) in the hydraulic integrated
circuit (HIC) valve.

3. Warm transmission oil to specification. See Transmission

1146 Oil Warm-Up Procedure . (Group 9026-25.)
 Neutral Charge Relief and Operating Charge Relief Pressure Test
3. Warm transmission oil to specification. See Transmission Oil Warm-Up Procedure . (Group 9026-25.)

Item Measurement Specification

Transmission Oil Temperature 57—66°C
135—150°F

4. Move park lock lever to the UP position and the transmission control lever (TCL) to neutral.

5. Start engine.

6. Set engine speed to specification.

Item Measurement Specification

Engine Speed 1780—1820 rpm

7. Record delta pressure between test ports 2 and 4.

Item Measurement Specification

Neutral Delta Pressure 2482—2620 kPa
24.8—26.2 bar
360—380 psi

8. NOTE:

The neutral charge relief valve (1) is located on front of the hydraulic integrated circuit
(HIC) valve.

If delta pressure is not within specification, adjust pressure by turning neutral charge relief valve
adjusting screw IN to increase pressure or OUT to decrease pressure.

Item Measurement Specification

Neutral Charge Relief Valve Pressure Change 580 kPa per turn
5.8 bar per turn
84 psi per turn

9. If specification is not obtainable with adjustment, remove valve and inspect seals. Replace if necessary.

10. Move park lock lever to the DOWN position.

11. CAUTION:
Tracks will rotate when transmission control lever (TCL) is moved to forward or
reverse.

IMPORTANT:

If operating charge pressure drops below 1310 kPa (13.1 bar) (190 psi) brakes will start to engage.
Adjust neutral charge pressure to the high end of specification.

Move TCL into forward or reverse. Record delta pressure.

Delta pressure must drop approximately 207 kPa (2.07 bar) (30 psi) as TCL is moved to forward or

1147
 Neutral Charge Relief and Operating Charge Relief Pressure Test
reverse.

Delta pressure must not drop below specification.

Item Measurement Specification

Minimum Operating Delta Pressure 2275 kPa
22.8 bar
330 psi

12. Remove transducers from test ports in HIC valve and install plugs.

Go to Section_9026:Group_25

OUO1020,0001628-19-20100616

1148
 Pump Displacement Control Valve (PDCV) Neutral (Null) Adjustment

Pump Displacement Control Valve (PDCV) Neutral (Null) Adjustment

-: Specifications

SPECIFICATIONS

Transmission Oil Temperature 57—66°C

135—150°F

Engine Speed Slow Idle

PDCV Neutral Adjustment 1/2 total number of turns as marked (from fwd pressure rise-to-rev pressure
Turns rise)

Adjusting Screw Nut Torque 7 N·m

62 lb.-in.

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

D01182AA 20-Ton Floor Stand

JDG10013 750J/850J Floor Stand Kit

JT05598 0—400 psi Gauge

This procedure will adjust the hydrostatic pump neutral between forward and reverse. Repeat procedure for left
and right track.

This procedure must be performed anytime a pump is serviced and reinstalled on machine.

Diagnostic trouble codes will be recorded during this test and must be cleared when completed.

1. CAUTION:
Prevent possible injury from unexpected track movement. Raise the machine off
the ground and support with 20-ton floor stands. Tracks must be clear of tools
and objects before rotating.

1149
 Pump Displacement Control Valve (PDCV) Neutral (Null) Adjustment

T205099A-UN: 750J/850J Floor Stand Kit

LEGEND:
1 - 20-Ton Floor Stand (4 used)
2 - Floor Stand Adapter (2 used)
3 - Floor Stand Rod
4 - Washer (2 used)
5 - Cap Screw (2 used)

Raise machine off the ground and support with D01182AA 20-Ton Floor Stands (1) and JDG10013 Floor
Stand Kit. See Machine Supporting Procedure . (Group 9026-25.)

Lower blade to ground. Tracks must be free to rotate in either direction.

2. Tilt cab or ROPS. Install operator's station tilt cylinder lock. See Cab or ROPS Tilting Procedure .
(Operator’s Manual.)

3.

T206311A-UN: Hydrostatic Pump Test Ports

LEGEND:
1 - Pump Displacement Control Valve (PDCV) Test Port (2 used)
2 - Pump Servo Test Port (2 used)
3 - Pump Pressure Control Pilot (PCP) Connector (2 used)

Install test gauge in one of the servo test ports (2).

4. Heat transmission oil to normal operating temperature. See Transmission Oil Warm-Up Procedure .
(Group 9026-25.)

Item Measurement Specification

Transmission Oil Temperature 57—66°C
135—150°F

5. Turn machine OFF and disconnect front and rear pump pressure control pilot (PCP) connectors (3).

6. Start machine and set engine speed to specification.

Item Measurement Specification

Engine Speed Slow Idle

7. Ensure that park lock lever is in the UP (locked) position.

1150
 Pump Displacement Control Valve (PDCV) Neutral (Null) Adjustment

8.

T118976B-UN: Neutral Adjustment Screw Lock Nut

LEGEND:
4 - Neutral Adjustment Screw Lock Nut

Loosen pump neutral adjustment screw lock nut (4).

9. Slowly turn adjusting screw, noting direction of turn, until pressure on gauge just rises. Stop and mark
location of adjusting screw.

10. Turn machine OFF and move gauge to opposite servo test port.

11. Start machine and set engine speed to specification.

Item Measurement Specification

Engine Speed Slow Idle

12. Ensure that park lock lever is in the UP (locked) position.

13. Slowly turn the screw in the opposite direction, counting the number of turns until pressure on gauge just
rises. Stop and mark location of adjusting screw.

NOTE:

Leveling swash plate would only be considered if pump was just reinstalled on
machine after servicing.

If total number of turns is 1/2 turn or less, disassemble pump and level swash plate again. See
Hydrostatic Pump Disassemble . (Group 0360.)

1151
 Pump Displacement Control Valve (PDCV) Neutral (Null) Adjustment
If total number of turns is more than 2 turns, disassemble pump displacement control valve and
check for a worn feedback link. See Pump Displacement Control Valve (PDCV) Disassemble
and Assemble . (Group 0360.)
If total number of turns is more than 1/2 but less than 2 turns, continue with next step.

14. Turn the screw back 1/2 the total number turns and tighten locking nut.

Item Measurement Specification

PDCV Neutral Turns 1/2 total number of turns as marked (from fwd pressure rise-to-
Adjustment rev pressure rise)
Adjusting Screw Nut Torque 7 N·m
62 lb.-in.

15. Repeat procedure on the other track pump.

16. Disconnect test equipment and return cab or ROPS to operating position.

17. Calibrate transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration . (Group
9015-20.)

Go to Section_9026:Group_25

OUO1020,000162E-19-20111201

1152
 Pump Servo Pressure Test

Pump Servo Pressure Test

-: Specifications

SPECIFICATIONS

Engine Speed Fast Idle

Speed-In-Grip (SIG) Position 3.0

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

D01182AA 20-Ton Floor Stand

JDG10013 750J/850J Floor Stand Kit

XPD361 Quick Coupler

JT02156A Digital Pressure/Temperature Analyzer

JT02161 3446 kPa (35 bar) (500 psi) Transducer

JDG1932 Motor Flushing Test Harness

The purpose of this test is to check proper operation of the pump servo control circuit and pump displacement
control valve (PDCV).

Diagnostic Trouble Codes will be recorded during this test and must be cleared when completed.

1. CAUTION:
Prevent possible injury from unexpected track movement. Raise the machine off
the ground and support with 20-Ton Floor Stands. Tracks MUST be clear of tools
and objects before rotating.

T205099A-UN: 750J/850J Floor Stand Kit

LEGEND:
1 - 20-Ton Floor Stand (4 used)
1153
 Pump Servo Pressure Test
2 - Floor Stand Adapter (2 used)
3 - Floor Stand Rod
4 - Washer (2 used)
5 - Cap Screw (2 used)

Raise machine off the ground and support with 20-Ton Floor Stands. See Machine Supporting
Procedure . (Group 9026-25.)

Lower blade to ground. Tracks MUST be free to rotate in either direction.

2. Tilt cab or ROPS up. See Cab or ROPS Tilting Procedure . (Operator’s Manual.)

3.

T206311A-UN: Hydrostatic Pump Test Ports

LEGEND:
1 - Pump Displacement Control Valve (PDCV) Test Ports
2 - Pump Servo Test Port Ports
3 - Pump Pressure Control Pilot (PCP) Connector

Install quick couplers in servo test ports (2). Connect digital pressure/temperature analyzer and
transducer or a gauge.

4. Return cab or ROPS to operating position.

5. Set monitor display to CHARGE (transmission charge pressure).

6. Start engine and check that forward and reverse pressures on both pumps are equal, and less than
charge pressure in neutral.

If pressures are not OK, check neutral (null) adjustment or go to Mistrack/Indexes flow chart. See Pump
Displacement Control Valve (PDCV) Neutral (Null) Adjustment . (Group 9026-25.) See Mistrack/Index
Malfunctions . (Group 9026-15.)

7. Set engine speed control to specification.

Item Measurement Specification

Engine Speed Fast Idle

8. Set transmission Speed-In-Grip (SIG) to specification.

Item Measurement Specification

Speed-In-Grip (SIG) Position 3.0

1154
 Pump Servo Pressure Test
9. Set front dash Decelerator Mode Switch to transmission mode, Decel Function icon will come on.

CAUTION:
Tracks will rotate when TCL is moved to forward or reverse.

1. Push decel pedal to floor.

2. Put park lock lever in DOWN position.

3. Put TCL lever in forward.

4. Slowly release decel pedal.

5. Record forward servo pressure and charge pressure.

10. Repeat test using reverse servo pressure and charge pressure.

Servo pressures must be approximately equal and will be less than charge pressure.
If servo pressures are not approximately equal, a problem exists in the pump displacement
control valve (PDCV) such that the PDCV cannot fully activate or a leak in the servo is
indicated.
If servo pressure is equal to charge pressure, a mechanical problem is indicated in the pump or
pump servo. Remove displacement control valve and inspect pump servo or repair pump. See
Pump Displacement Control Valve (PDCV) Disassemble and Assemble . (Group 0360.)
If pressures are still not OK, See Mistrack/Index Malfunctions . (Group 9026-15.)

11. NOTE:

During normal operation, the transmission controller regulates the mA to the PCP which
will not allow the swash plate to contact the mechanical stop. When the JDG1932 test
harness is installed, 5 volts are supplied directly to the PCP forcing the swash plate to
the mechanical stops.

It may be necessary to use JDG1886 test harness for additional length when connecting
JDG1932 test harness to machine.

Install JDG1932 test harness with switch between pump PCP and left or right motor speed sensor.

12. NOTE:

The TEST setting is located in the service menu. To enter the service menu, press the
MENU button and hold it down for 5 seconds.

Set brake control setting to TEST.

1. Access Service Menu on monitor.

2. Select Machine Settings.

3. Select Brake Ctrl.

1155
 Pump Servo Pressure Test
4. Select Test.

13. NOTE:

Do not leave machine in brake Test setting during normal operation.

Repeat servo pressure test using switch to activate track in forward and reverse. Servo pressure must
now equal charge pressure.

14. Clear any diagnostic trouble codes that may have appeared during procedure. See Diagnostic Trouble
Codes (DTC) Quick Reference List . (Group 9015-20.)

15. Turn machine OFF to reset brake to normal mode.

Go to Section_9026:Group_25

AA95132,0000387-19-20120801

1156
 Motor Displacement Control Valve (MDCV) Adjustment

Motor Displacement Control Valve (MDCV) Adjustment

-: Specifications

SPECIFICATIONS

Transmission Oil Temperature 57—66°C

135—150°F

Speed-In-Grip (SIG) Position 1.6

Transmission Control Unit (TCU) Amperage 238—242 mA

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

D01182AA 20-Ton Floor Stand

JDG10013 750J/850J Floor Stand Kit

XPD361 Quick Coupler (9/16-20UN M ORB)

JT02156A Digital Pressure/Temperature Analyzer

JT02162 35 000 kPa (350 bar) (5000 PSI) Transducer

This procedure is used to establish the point where the hydrostatic circuit goes from pump phase to motor phase.

NOTE:

Do this procedure for front pump and right motor or rear pump and left motor.

Both front and rear pump null adjustment MUST be accurate (and machine recalibrate, if it was
adjusted) before doing this threshold adjustment.

1. CAUTION:
Prevent possible injury from unexpected track movement. Raise the machine off
the ground and support with 20-Ton Floor Stands. Tracks MUST be clear of tools
and objects before rotating.

1157
 Motor Displacement Control Valve (MDCV) Adjustment

T205099A-UN: 750J/850J Floor Stand Kit

LEGEND:
1 - 20-Ton Floor Stand (4 used)
2 - Floor Stand Adapter (2 used)
3 - Floor Stand Rod
4 - Washer (2 used)
5 - Cap Screw (2 used)

Raise machine off the ground and support with 20-Ton Floor Stands. See Machine Supporting
Procedure . (Group 9026-25.)

Lower blade to ground. Tracks MUST be free to rotate in either direction.

2. NOTE:

Test port (2) on each motor senses pressure to the max. angle control piston. Test port
(1) on each motor senses min. angle control pressure.

Install quick couplers in servo test ports (1 and 2). Connect digital pressure/temperature analyzer and
transducer or a gauge.

T205134A-UN: Min. Angle Test Port

1158
 Motor Displacement Control Valve (MDCV) Adjustment

T205135A-UN: Max. Angle Test Port

LEGEND:
1 - Min. Angle Servo Piston Pressure Test Port
2 - Max. Angle Servo Piston Pressure Test Port

3. Start engine and heat hydrostatic oil to specified temperature. See Transmission Oil Warm-Up
Procedure . (Group 9026-25.)

Item Measurement Specification

Transmission Oil Temperature 57—66°C
135—150°F

4. With park lock lever in UP (locked) position, set transmission Speed-In-Grip (SIG) to specification.

Item Measurement Specification

Speed-In-Grip (SIG) Position 1.6

5. Access the Output Info menu.

1. Access Main Menu on monitor.

2. Select Diagnostics.

3. Select Live Values.

4. Select Output Info.

6. Record Left Motor and Right Motor mA values.

7. Set front dash Decelerator Mode Switch to transmission mode, Decel Function icon will come on.

CAUTION:
Tracks will rotate when TCL is moved out of neutral.

1. Push decel pedal to floor.

2. Put park lock lever in DOWN position.

3. Put TCL lever in forward.

1159
 Motor Displacement Control Valve (MDCV) Adjustment
4. Slowly release decel pedal.

5. Slowly increase engine RPM until amperage reaches specification.

Item Measurement Specification

Transmission Control Unit (TCU) Amperage 238—242 mA

8.

T205765A-UN: Threshold Adjusting Screw

LEGEND:
3 - Threshold Control Spring Adjusting Screw

Loosen lock nut and adjust motor displacement control valve (MDCV) (3) until max servo pressure
begins to drop (turning the screw OUT will cause the motor servo pressure to drop sooner).

This sudden drop in motor servo pressure indicates that the motor is starting to de-swash (increase
speed).

9. CAUTION:
To avoid injury from escaping fluid under pressure, stop engine and relieve the
pressure in the system before disconnecting or connecting hydraulic or other
lines. Tighten all connections before applying pressure.

Repeat procedure on other side.

10. Calibrate machine. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)

Go to Section_9026:Group_25

AA95132,0000388-19-20080220

1160
 Hydrostatic Motor Min./Max. Angle Servo Piston Pressure Test

Hydrostatic Motor Min./Max. Angle Servo Piston Pressure Test

-: Specifications

SPECIFICATIONS

Transmission Oil Temperature 57—66°C

135—150°F

Engine Speed Fast Idle

Speed-In-Grip (SIG) Position 1.0—3.0

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

D01182AA 20-Ton Floor Stand

JDG10013 750J/850J Floor Stand Kit

XPD361 Quick Coupler (9/16-20UN M ORB)

JT02156A Digital Pressure/Temperature Analyzer

JT02162 35 000 kPa (350 bar) (5000 PSI) Transducer

The purpose of this test is to verify that the motor shift solenoid has shifted allowing control pressure to the servo
piston, swashing the motor to minimum or maximum displacement.

IMPORTANT:

Carefully monitor transmission temperature during this test. Temperature will rise very quickly when operating in
an over-relief condition. Do not exceed 71°C (160°F).

1. CAUTION:
Prevent possible injury from unexpected track movement. Raise the machine off
the ground and support with 20-ton floor stands. Tracks must be clear of tools
and objects before rotating.

1161
 Hydrostatic Motor Min./Max. Angle Servo Piston Pressure Test

T205099A-UN: 750J/850J Floor Stand Kit

LEGEND:
1 - 20-Ton Floor Stand (4 used)
2 - Floor Stand Adapter (2 used)
3 - Floor Stand Rod
4 - Washer (2 used)
5 - Cap Screw (2 used)

Raise machine off the ground and support with D01182AA 20-Ton Floor Stands (1). See Machine
Supporting Procedure . (Group 9026-25.)

Lower blade to ground. Tracks must be free to rotate in either direction.

2. NOTE:

Test port (2) on each motor senses pressure to the max. angle control piston. Test port
(1) on each motor senses min. angle control pressure.

Install quick couplers in servo piston pressure test ports (1 and 2). Connect digital pressure/temperature
analyzer and transducer or a gauge.

T205134A-UN: Angle Test Port (minimum)

T205135A-UN: Angle Test Port (maximum)

LEGEND:
1 - Angle Servo Piston Pressure Test Port (minimum)
2 - Angle Servo Piston Pressure Test Port (maximum)

3. Heat oil to specification. See Transmission Oil Warm-Up Procedure . (Group 9026-25.)

1162
 Hydrostatic Motor Min./Max. Angle Servo Piston Pressure Test

Item Measurement Specification

Transmission Oil Temperature 57—66°C
135—150°F

4. Set transmission speed-in-grip (SIG) to specification.

Item Measurement Specification

Speed-In-Grip (SIG) Position 1.0

5. Set front dash decelerator mode switch to transmission mode, decel mode indicator will come on.

6. Push decelerator/brake to floor.

7. Set engine speed to specification.

Item Measurement Specification

Engine Speed Fast Idle

8. Put park lock lever in DOWN position.

9. Put transmission control lever (TCL) in forward and slowly release decelerator/brake.

CAUTION:
Tracks will rotate when TCL is moved out of neutral.

10. Slowly increase transmission speed to maximum.

11. Compare test port pressures to table. Track speeds MUST increase evenly.

-: Servo Piston Pressures Comparison Chart

Transmission Control Lever Minimum Angle Test Port Maximum Angle Test Port
Position/Speed

Neutral / Speed (1.0) Return Pressure Charge Pressure

Forward / Speed (1.0) Return Pressure Reduced Closed-Loop

Pressure

Forward / Speed (3.0) Reduced Closed-Loop Reduced Closed-Loop

Pressure Pressure

Go to Section_9026:Group_25

AA95137,0000817-19-20111130

1163
 Charge Pump Flow Test

Charge Pump Flow Test

-: Specifications

SPECIFICATIONS

Transmission Oil Temperature 57—66°C

135—150°F

Engine Speed 1800 rpm

Typical Single Flow Rate 45—53 L/min.

12—14 gpm

Minimum Single Flow Rate 43.5 L/min.

11.5 gpm

Typical Combined Flow Rate 91—106 L/min.

24—28 gpm

Minimum Combined Flow Rate 87 L/min.

23 gpm

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JT07148 Digital Hydraulic Tester

JT03448 Test Hose (2 used)

This procedure is used to determine hydrostatic pump flow and to isolate front and rear pump flow, if necessary.
Charge pressures must be to specification prior to performing this test. See Neutral Charge Relief and Operating
Charge Relief Pressure Test . (Group 9026-25.)

1. Single Charge Pump Flow— Tilt cab or ROPS up. See Cab or ROPS Tilting Procedure . (Operator’s
Manual.)

2. IMPORTANT:

Flow control valve on flow meter MUST be fully open. Damage to charge pumps will result if valve is not
fully open.

T206596A-UN: Charge Pump Flow Test

1164
 Charge Pump Flow Test
LEGEND:
1 - Front Hydrostatic Charge Pump Pressure Hose
2 - Rear Hydrostatic Charge Pump Pressure Hose
3 - Hydraulic Integrated Circuit (HIC) Valve

Connect JT07148 Digital Hydraulic Tester flow meter in line between front hydrostatic charge pump
(right track) pressure hose (1) and Hydraulic Integrated Circuit (HIC) valve (3). Flow control valve must
be fully open.

3. Lower cab or ROPS to normal operating position.

4. Heat oil to specification. See Transmission Oil Warm-Up Procedure . (Group 9026-25.)

Item Measurement Specification

Transmission Oil Temperature 57—66°C
135—150°F

5. With park lock lever UP, run engine at specified RPM. Record flow meter reading. If charge pump flow is
below specification, replace or repair charge pump.

Item Measurement Specification

Engine Speed 1800 rpm
Typical Single Flow Rate 45—53 L/min.
12—14 gpm
Minimum Single Flow Rate 43.5 L/min.
11.5 gpm

6. Repeat procedure for testing flow from rear hydrostatic charge pump (left track).

7. Remove test equipment.

8. Combined Charge Pump Flow— Add front and rear pump flows together to determine combined flow.

Item Measurement Specification

Typical Combined Flow Rate 91—106 L/min.
24—28 gpm
Minimum Combined Flow Rate 87 L/min.
23 gpm

Go to Section_9026:Group_25

OUO1020,0001629-19-20120801

1165
 Charge Pressure Sensor Test

Charge Pressure Sensor Test

TX1024040-UN: Hydraulic Integrated Control (HIC) Valve (top view)

LEGEND:
1 - Charge pressure port (port 2)

This procedure is used to test charge pressure sensor on later serial numbered machines. These machines do
not have a quick disconnect on the Hydraulic Integrated Control (HIC) valve. This procedure is used to confirm
that the charge pressure sensor is reading properly.

1. Park machine on level surface, engine running.

2. Using monitor, display transmission charge pressure.

1. Select Diagnostics.

2. Select Live Values.

3. Select Pressures.

4. Select Trans. Pressures.

5. Select Trans Charge.

6. Record reading.

3. Using monitor, display brake pressure.

1. Select Diagnostics.

2. Select Live Values.

3. Select Pressures.

4. Select Trans. Pressures.

1166
 Charge Pressure Sensor Test
5. Select Brake Pres.

6. Release park brake and record reading.

4. Compare trans. charge pressure with brake pressure. If there is less than 69 N·m (10 psi) (0.69 bar) the
sensor is reading properly, if the difference is more than 69 kPa (10 psi) (0.69 bar) the sensor is not
reading properly.

5.

TX1024040-UN: Hydraulic Integrated Control (HIC) Valve (top view)

LEGEND:
1 - Charge pressure port (port 2)

To confirm this conclusion a quick disconnect can be installed in the charge pressure port (1). This port
has a “2” stamped in the HIC valve body next to it.

Go to Section_9026:Group_25

MR50960,000000E-19-20090527

1167
 Hydrostatic Oil Cooler Bypass Test

Hydrostatic Oil Cooler Bypass Test

-: Specifications

SPECIFICATIONS

Engine Speed Fast Idle

Hydrostatic Oil Cooler Bypass Solenoid Coil Resistance at 20°C (68°F) 23.5—33.5 ohms

Hydrostatic Oil Cooler Bypass Solenoid Voltage 24 V

Oil Cooler Inlet (bypass off ) Pressure 414—552 kPa

4.14—5.52 bar
60—80 psi

Oil Cooler Bypass Valve Torque 88—102 N˙m

65—75 lb.- ft

-: Essential Tools

ESSENTIAL TOOLS

JDG10006 Test Harness

JT07237-1 Single Pin Test Harness

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

XPD341 Quick Coupler (7/16-20UN M ORB)

JT02156A Digital Pressure/Temperature Analyzer

JT02162 34 000 kPa (350 bar) (5000 psi) Transducer

Multimeter

The purpose of this test is to determine if the cooler bypass solenoid and valves are opening and closing.

Diagnostic Trouble Codes will be recorded during this test and must be cleared when completed.

NOTE:

Before performing diagnostic procedures, check diagnostic trouble codes and stored diagnostic
trouble codes. See Diagnostic Trouble Codes (DTC) Quick Reference List . (Group 9015-20.) See
CAN Monitor Unit (CMU) Circuit Theory of Operation . (Group 9015-15.)

1168
 Hydrostatic Oil Cooler Bypass Test

T206645-UN: Oil Cooler and Reservoir Bypass Test

LEGEND:
1 - Test Port 6
2 - Test Port 14
11 - Hydrostatic Oil Cooler Bypass Solenoid
12 - Hydrostatic Oil Cooler Bypass Valve
39 - Hydraulic Integrated Circuit (HIC) Valve

1. Heat transmission oil to operating temperature. See Transmission Oil Warm-Up Procedure . (Group
9026-25.)

Oil Cooler Bypass Solenoid Test

1. Install quick coupler in test port 6 (1) on top of hydraulic integrated circuit (HIC) valve. Connect
digital pressure/temperature analyzer and transducer or a gauge.

2. Start engine.

3. NOTE:

The Cooler Bypass Control setting is located in the service menu. To enter the
service menu, press the MENU button and hold it down for 5 seconds.

Set cooler bypass control to OFF.

Access Service Menu on monitor.

Select TCU Diagnostics.
Select Settings.
Select Cooler Byp Ctrl.
Select Off.

4. Set engine speed to specification.

1169
 Hydrostatic Oil Cooler Bypass Test

Item Measurement Specification

Engine Speed Fast Idle

5. Record pressures in test port 6:

With cooler bypass control turned OFF, pressure should be at zero.

Set cooler bypass control to ON.
Set monitor display to CHARGE (transmission charge pressure).
With cooler bypass control turned ON, pressure should equal Neutral Charge
pressure.
If either of these conditions is not true, test Hydrostatic Oil Cooler Bypass Solenoid.

1. Disconnect harness to Hydrostatic Oil Cooler Bypass Solenoid.

2. Connect test harness JDG10006 to Hydrostatic Oil Cooler Bypass Solenoid (11) only.
Do not connect other connector to transmission harness.
3. Connect Multimeter using JT07237-1 Single Pin Test Harness.

4. NOTE:

Machine wire harness must be disconnected for correct

measurement.

Measure resistance of solenoid coil.

Item Measurement Specification
Hydrostatic Oil Cooler Bypass Solenoid Resistance at 20°C 23.5—33.5
Coil (68°F) ohms
If resistance is not to specification, remove and replace Hydrostatic Oil Cooler Bypass
Solenoid.
5. Disconnect test harness from solenoid and connect to machine harness.
6. Turn key switch to ON.
7. Set cooler bypass control to ON. Measure DC voltage at harness. Voltage should be
zero.
8. Set cooler bypass control to OFF. Measure DC voltage at harness. If voltage is not to
specification, check wiring.
Item Measurement Specification
Hydrostatic Oil Cooler Bypass Solenoid Voltage 24 V
9. Record pressure in test port 6. If pressure is not zero, remove Oil Cooler Bypass
Solenoid Valve.
10. Inspect O-rings and movement of spool, if spool does not move freely replace valve or
O-rings.

2. Oil Cooler Bypass Valve Test

1. Install quick coupler in test port 14 (2) on top of hydraulic integrated circuit (HIC) valve. Connect
digital pressure/temperature analyzer and transducer or a gauge.

2. Unplug Hydrostatic Oil Reservoir Bypass Solenoid Connector.

3. Start engine.

4. Set engine speed to specification.

1170
 Hydrostatic Oil Cooler Bypass Test

Item Measurement Specification

Engine Speed Fast Idle

5. Set cooler bypass control to ON.

Access Service Menu on monitor.

Select TCU Diagnostics.
Select Settings.
Select Cooler Byp Ctrl.
Select On.

6. Record pressure in test port 14. If pressure is not zero, remove Oil Cooler Bypass Valve.
Inspect O-rings and movement of spool. Spool should move freely. If necessary, replace valve
or O-rings.

7. Set cooler bypass control to OFF.

8. Record pressure in test port 14. If pressure is not to specification, remove Oil Cooler Bypass
Valve. Inspect O-rings and movement of spool. Spool should move freely. If necessary, replace
valve or O-rings.

Item Measurement Specification

Oil Cooler Inlet (Bypass OFF) Pressure 414—552 kPa
4.14—5.52 bar
60—80 psi

Install valve and tighten to specification.

Item Measurement Specification

Oil Cooler Bypass Valve Torque 88—102 N˙m
65—75 lb.- ft

9. Clear any diagnostic trouble codes that may have appeared during procedure. See Diagnostic
Trouble Codes (DTC) Quick Reference List . (Group 9015-20.)

Go to Section_9026:Group_25

JW40272,00000F2-19-20120816

1171
 Hydrostatic Oil Reservoir Bypass Test

Hydrostatic Oil Reservoir Bypass Test

-: Specifications

SPECIFICATIONS

Engine Speed Fast Idle

Hydrostatic Oil Reservoir Bypass Solenoid

Case Return (Bypass ON) Pressure 69—172 kPa

0.69—1.72 bar
10—25 psi

Case Return (Bypass ON) Voltage 24 V

Case Return (Bypass OFF) Pressure 345—172 kPa

3.45—1.72 bar
50—80 psi

Case Return (Bypass OFF) Voltage 0V

Hydrostatic Oil Cooler Reservoir Solenoid Coil Resistance at 20°C (68°F) 27.75—39.75 ohms

Hydrostatic Oil Reservoir Bypass Valve

Case Return (Bypass ON) Pressure 241—345 kPa

2.41—3.45 bar
35—50 psi

Case Return (Bypass ON) Voltage 24 V

Case Return (Bypass OFF) Pressure 414—621 kPa

4.14—6.21 bar
60—90 psi

Case Return (Bypass OFF) Voltage 0V

-: Essential Tools

ESSENTIAL TOOLS

JDG10006 2-Pin Test Harness

JT07237-1 Single Pin Test Harness

JDG1886 Test Harness

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

XPD341 Quick Coupler (7/16-20UN M ORB)

JT02156A Digital Pressure/Temperature Analyzer

JT02162 34 000 kPa (350 bar) (5000 psi) Transducer

Multimeter

The purpose of this test is to determine if the reservoir bypass valves are opening and closing.

1172
 Hydrostatic Oil Reservoir Bypass Test
Diagnostic Trouble Codes will be recorded during this test and must be cleared when completed.

NOTE:

Before performing diagnostic procedures, check diagnostic trouble codes and stored diagnostic
trouble codes. See Diagnostic Trouble Codes (DTCs) Quick Reference List . (Group 9015-20.)
See CAN Monitor Unit (CMU) Circuit Theory of Operation . (Group 9015-15.)

T206680-UN: Hydrostatic Oil Reservoir Bypass Test

LEGEND:
1 - Test Port 11
2 - Test Port 8
13 - Hydrostatic Oil Reservoir Bypass Solenoid
14 - Hydrostatic Oil Reservoir Bypass Valve
39 - Hydraulic Integrated Circuit (HIC) Valve

1. Heat transmission oil to operating temperature. See Transmission Oil Warm-Up Procedure . (Group
9026-25.)

Hydrostatic Oil Reservoir Bypass Solenoid Test

1. Install quick coupler in test port 11 (1) on top of hydraulic integrated circuit (HIC) valve. Connect
digital pressure/temperature analyzer and transducer or a gauge.

2. Connect JDG10006 2-Pin Test Harness between Hydrostatic Oil Reservoir Bypass Solenoid
and transmission harness.

3. Connect Multimeter using JT07237-1 Single Pin Test Harness.

4. Start engine.

5. Set engine speed to specification.

Item Measurement Specification

Engine Speed Fast Idle

1173
 Hydrostatic Oil Reservoir Bypass Test

6. NOTE:

The Cooler Bypass Control and Tank Bypass Control settings are located in
the service menu. To enter the service menu, press the MENU button and hold
it down for 5 seconds.

Set cooler bypass control to ON (Cooler Closed).

Access Service Menu on monitor.

Select TCU Diagnostics.
Select Settings.
Select Cool Byp Ctrl.
Select Off.

7. Set tank bypass control to ON (Tank Open).

Access Service Menu on monitor.

Select TCU Diagnostics.
Select Settings.
Select Tank Byp Ctrl.
Select ON.

8. Record pressure in test port 11. Record DC voltage. Set tank bypass control to OFF (tank
closed). Record pressure and voltage.

Item Measurement Specification

Hydrostatic Oil Reservoir Bypass Solenoid
Case Return (bypass on) Pressure 69—172 kPa
0.69—1.72 bar
10—25 psi
Voltage 24 V
Case Return (bypass off) Pressure 345—172 kPa
3.45—1.72 bar
50—80 psi
Voltage 0V

If pressure or voltage is not to specification, test Hydrostatic Oil Reservoir Bypass Solenoid Coil
(13).

1. NOTE:

Machine wire harness must be disconnected for correct

measurement.

Disconnect test JDG1886 Test Harness from transmission harness.

2. Measure resistance of solenoid coil.
Item Measurement Specification
Hydrostatic Oil Cooler Reservoir Resistance at 20°C 27.75—39.75
Solenoid Coil (68°F) ohms
If resistance is not to specification, remove and replace Hydrostatic Oil Reservoir
Bypass Solenoid Coil.
1174
 Hydrostatic Oil Reservoir Bypass Test
3. If pressure is still not to specification, remove Hydrostatic Oil Reservoir Bypass
Solenoid Valve. Inspect O-rings and movement of spool. Spool should move freely. If
necessary, replace valve or O-rings.
1. Turn key switch to ON.
2. Have someone cycle tank bypass control ON and OFF.
3. If solenoid is working correctly, you should feel the solenoid vibrate in your
hand.

2. Hydrostatic Oil Reservoir Bypass Valve Test

1. Install quick coupler in test port 8 (2) on top of hydraulic integrated circuit (HIC) valve. Connect
digital pressure/temperature analyzer and transducer or a gauge.

2. Connect JDG1886 Test Harness between Hydrostatic Oil Reservoir Bypass Solenoid and
transmission harness.

3. Connect Multimeter using JT07237-1 Single Pin Test Harness.

4. Start engine.

5. Set engine speed to specification.

Item Measurement Specification

Fast Idle Speed 2255—2360 rpm

6. Set cooler bypass control to ON (Cooler Closed).

7. Set tank bypass control to ON (Tank Open).

8. Record pressure in test port 8. Record DC voltage. Set tank bypass control to OFF (tank
closed). Record pressure and voltage.

Item Measurement Specification

Hydrostatic Oil Reservoir Bypass Valve
Case Return (bypass ON) Pressure 241—345 kPa
2.41—3.45 bar
35—50 psi
Voltage 24 V
Case Return (bypass off) Pressure 414—621 kPa
4.14—6.21 bar
60—90 psi
Voltage 0V
1. If pressures are not changing according to specification, remove Oil Reservoir Bypass
Valve. Inspect O-rings and movement of spool. Spool should compress spring when
pushed. If necessary, replace valve or O-rings.

Go to Section_9026:Group_25

TE14778,0000073-19-20120816

1175
 Park Brake Test

Park Brake Test

-: Specifications

SPECIFICATIONS

Engine Speed Fast Idle

Speed-in-Grip (SIG) Position 1.6

Multi-Function Relief Valve Pressure 44 128—46 884 kPa

440—468 bar
6400—6800 psi

Brake On Pressure 0—207 kPa

0—2.1 bar
0—30 psi

Brake Off Pressure 2482—2620 kPa

24.8—26.2 bar
360—380 psi

Park Brake Solenoids

Park Brake Solenoid Coil Resistance at 20°C (68°F) 22.5—34.5 ohms

Park Brake Voltage 24 V

Park Brake Solenoid Coil Nut Torque 6.8—9.5 N·m

5—7 lb.- ft

Park Brake Solenoid 1 Torque 34—36.7 N·m

25—27 lb.- ft

Park Brake Solenoid 2 Torque 44.9—50.3 N·m

33—37 lb.- ft

-: Essential Tools

ESSENTIAL TOOLS

JDG1886 Test Harness

JT07237-1 Single Pin Test Harness

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

D01182AA 20-Ton Floor Stands

JDG10013 750J/850J Floor Stand Kit

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

XPD341 Quick Coupler (7/16-20UN M ORB)

JT02156A Digital Pressure/Temperature Analyzer

1176
 Park Brake Test

SERVICE EQUIPMENT AND TOOLS

JT02162 34 000 kPa (350 bar) (5000 PSI) Transducer

Multimeter

The purpose of this test is to determine if the brake solenoids and valves are working and if the brake disks are
applying and releasing.

Diagnostic trouble codes will be generated during this test and must be cleared when completed.

NOTE:

Before performing diagnostic procedures:

Check diagnostic trouble codes and stored diagnostic trouble codes. See Diagnostic
Trouble Codes (DTCs) Quick Reference List . (Group 9015-20.) See CAN Monitor Unit
(CMU) Circuit Theory of Operation . (Group 9015-15.)
Turn key switch to ON position. Cycle park lock lever while checking for corresponding
N or P on monitor. If N or P is not displayed See Transmission Control Unit (TCU)
Circuit Theory of Operation . (Group 9015-15.)

Machine Preparation

1. CAUTION:
Prevent possible injury from unexpected track movement. Raise the machine off
the ground and support with appropriate stands. Tracks must be free to rotate in
either direction, check for objects on tracks before rotating tracks.

T205099A-UN: Floor Stand with Floor Stand Kit

LEGEND:
1 - 20-Ton Floor Stand (4 used)
2 - Floor Stand Adapter (2 used)
3 - Floor Stand Rod
4 - Washer (2 used)

1177
 Park Brake Test
5 - Cap Screw (2 used)

Raise machine off the ground and support with D01182AA stands. See Machine Supporting Procedure .
(Group 9026-25.)

2. Lower blade to ground. Tracks MUST be free to rotate in either direction.

Brake Operation Test

1.

TX1036917-UN: Park Brake Test

LEGEND:
1 - Brake Pressure Sensor
2 - Ball Shuttle Valve
9 - Park Brake Solenoid 1
10 - Park Brake Solenoid 2
39 - Hydraulic Integrated Circuit (HIC) Valve

Start engine.

2. Display brake pressure on monitor:

1. Select Diagnostics

2. Select Live Values

3. Select Pressures

4. Select Trans. Pressures

5. Select Brake Pressure

3. With park lock lever in UP position, record brake pressure. Brake On pressure must not be higher than
specifications.

1178
 Park Brake Test

Item Measurement Specification

Brake On Pressure 0—207 kPa
0—2.1 bar
0—30 psi

4. Move park lock lever to DOWN position. Pressure should equal neutral charge pressure.

Item Measurement Specification

Brake Off Pressure 2482—2620 kPa
24.8—26.2 bar
360—380 psi

5. If pressures do not meet the Brake ON or Brake Off specifications, test Park Brake Solenoids 1 and 2 (9
and 10). Otherwise, proceed to next step.

Park Brake Solenoid Test:

1. Disconnect harness to park brake solenoid 1.

2. Connect JDG1886 Test Harness to park brake solenoid 1 only. Do not connect other connector
to transmission harness.

3. Connect multimeter using JT07237-1 Single Pin Test Harness.

4. NOTE:

Machine wire harness must be disconnected for correct measurement.

Measure resistance of solenoid coil.

Item Measurement Specification

Park Brake Solenoid Coil Resistance at 20°C (68°F) 22.5—34.5 ohms

5. If resistance is not to specification, remove and replace coil. Tighten nut on coil to specification.

Item Measurement Specification

Park Brake Solenoid Coil Nut Torque 6.8—9.5 N.m
5—7 lb.- ft

6. Start engine and measure DC voltage at harness. Voltage should be zero.

7. Place park lock lever in DOWN position. Measure DC voltage at harness. If voltage is not to
specification, check wiring.

Item Measurement Specification

Park Brake Voltage 24 V

8. Perform same test on park brake solenoid 2 (10).

1179
 Park Brake Test
9. Stop engine, disconnect test harness from solenoid and connect to machine harness.

6. If Brake On pressure is higher than specifications, remove and inspect park brake solenoids 1 and 2.
Replace if necessary.

Item Measurement Specification

Brake On Pressure 0—207 kPa
0—2.1 bar
0—30 psi

1. Remove solenoid from hydraulic integrated circuit (HIC) valve.

2. Connect solenoid to transmission harness.

3. Turn key switch to ON.

4. While holding solenoid in your hand, have someone cycle park lock lever to UP and DOWN
position.

5. If solenoid piston is moving freely, you should feel and hear an audible click.

6. Install and tighten solenoids to specification.

Item Measurement Specification

Park Brake Solenoids
Park Brake Solenoid 1 Torque 34—36.7 N.m
25—27 lb ft
Park Brake Solenoid 2 Torque 44.9—50.3 N.m
33—37 lb.- ft

7. If Brake On pressure is higher than specifications, inspect ball shuttle valve (2). Replace if necessary.

Item Measurement Specification

Brake On Pressure 0—207 kPa
0—2.1 bar
0—30 psi

Park Brake Slippage Test

1. Warm transmission oil to operating temperature. See Transmission Oil Warm-Up Procedure . (Group
9026-25)

2. Start engine.

3. NOTE:

The TEST setting is located in the service menu. To enter the service menu, press the
MENU button and hold it down for 5 seconds.

Set brake control setting to TEST:

1. Access service menu on monitor.

1180
 Park Brake Test
2. Select MACHINE SETTINGS.

3. Select BRAKE CTRL.

4. Select TEST.

4. Set engine speed to specification.

Item Measurement Specification

Engine Speed Fast Idle

5. Push decel pedal to floor.

6. Put park lock lever in UP position.

7. Set front dash decelerator mode switch to transmission mode, decel function icon on.

8. Set hydrostatic transmission speed-in-grip (SIG) to specification.

Item Measurement Specification

Speed-in-Grip (SIG) Position 1.6

9. NOTE:

Output currents and pressures are located in the service menu. To enter the service
menu, press the MENU button and hold it down for 5 seconds.

Access the efficiency and relief menu:

1. Access service menu on monitor.

2. Select TCU DIAGNOSTICS.

3. Select PROCEDURES.

4. Press SELECT.

5. Access EFF AND RELIEF to observe readings.

10. Put transmission control lever (TCL) in forward.

11. Slowly release decel pedal.

12. NOTE:

There is a feature built in to the brake test mode that allows you to remain out of neutral
for 20 seconds, after which, the TCU will kick out to neutral. Then you have to shift the
trans lever to neutral and leave it there for 13 more seconds before going back in range.
Then the cycle starts again

Compare brake slippage test results to following criteria:

If motion is detected by either motor speed sensor, the transmission will default to neutral and

1181
 Park Brake Test
closed loop pressure will go to near charge pressure.

If you can build closed loop pressure to multi-function relief valve pressure specifications, the
brakes have held and are in good condition.
Item Measurement Specification
Multi-Function Relief Valve Pressure 44 128—46 884 kPa
440—468 bar
6400—6800 psi
If track movement occurs, the brakes are have slipping and need repair. See Park Brake
Remove and Install . (Group 1100.)

13. Turn machine OFF to reset brake to normal operation setting.

Clear any diagnostic trouble codes that may have appeared during procedure. See Diagnostic Trouble
Codes (DTCs) Quick Reference List . (Group 9015-20.)

Go to Section_9026:Group_25

OUO1020,000162D-19-20120816

1182
 Park Brake Relief Valve Test

Park Brake Relief Valve Test

-: Specifications

SPECIFICATIONS

Park Brake Relief Valve Pressure 2275—2550 kPa

22.7—25.5 bar
330—370 psi

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

XPD341 Quick Coupler

JT02156A Digital Pressure/Temperature Analyzer

JT02161 3446 kPa (35 bar) (500 psi) Transducer

This procedure will check hand pump relief valve setting.

IMPORTANT:

Incorrect relief setting could cause damage to brake seals when brakes are manually released.

1.

T206573A-UN: Park Brake Relief Valve Test

LEGEND:
1 - Brake Pressure Test Port
2 - Hand Pump

Position hand pump selector lever (red handle) OUT.

2. Insert handle in hand pump (2) and begin stroking pump. During initial operation, monitor will indicate
pressure required to release brakes. When brake pistons bottom, pressure will rise rapidly to the setting
of hand pump park brake relief valve.

Item Measurement Specification

Park Brake Relief Valve Pressure 2275—2550 kPa
22.7—25.5 bar
330—370 psi
If relief pressure is not within specification, adjust pressure by turning screw in or out.

1183
Park Brake Relief Valve Test

Go to Section_9026:Group_25

TE14778,0000078-19-20111130

1184
 Cab Tilt Relief Valve Test

Cab Tilt Relief Valve Test

-: Specifications

SPECIFICATIONS

Cab Tilt Relief Valve Pressure 10 000—21 374 kPa

200—214 bar
2900—3100 psi

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

XPD341 Quick Coupler

JT02156A Digital Pressure/Temperature Analyzer

JT02162 5000 PSI Tranducer

This procedure will check hand pump relief valve setting.

IMPORTANT:

Incorrect relief setting could cause damage to cylinder when cab is tilted.

1.

T214859A-UN: Cab Tilt Relief Valve Test

LEGEND:
1 - Brake Pressure Sensor
2 - Hand Pump
3 - Hand Pump Selector Lever (black)
4 - Hand Pump Selector Lever (red)

Install quick coupler in test port (1). Connect JT02156A Digital Pressure/Temperature Analyzer and
JT02162 5000 psi transducer.

2. Position hand pump selector lever (red handle) IN.

3. Insert handle in hand pump (2) and begin stroking pump. When cylinder is bottomed out, pressure will
rise rapidly to the setting of hand pump cab tilt relief valve.

1185
 Cab Tilt Relief Valve Test

Item Measurement Specification

Cab Tilt Relief Valve Pressure 10 000—21 400 kPa
200—214 bar
2900—3100 psi

If relief pressure is not within specification, adjust pressure by removing cap on end of valve and turning
adjustment screw in or out.

Go to Section_9026:Group_25

KV70328,0000001-19-20111130

1186
 Fan Pump Pressure Test

Fan Pump Pressure Test

-: Specifications

SPECIFICATIONS

Transmission Oil Temperature 57—66°C

135—150°F

Engine Speed Fast Idle

Fan Pump Pressure 17 582—18 961 kPa

176—190 bar
2550—2750 psi

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JT02156A Digital Pressure and Temperature Analyzer

JT02162 Pressure Transducer 34 474 kPa (345 bar) (5000 psi)

JT05719 Digital Hand Held Tachometer

This test checks hydraulic fan pump output pressure. If digital hand held tachometer JT05719 is available,
perform Fan Motor Speed Test in this group in place of this test.

The purpose of this test is to determine fan pump outlet pressure. Pressure not within specification can indicate
excessive wear on internal components.

NOTE:

Deactivate proportional fan drive before performing test. Set fan speed to Maximum by accessing
Settings under TCU Diagnostics in the standard display monitor (CMU).

See CAN Monitor Unit (CMU) Circuit Theory of Operation . (Group 9015-15.)

1.

T205157A-UN: Fan Pump Pressure Test Connections (750J shown)

LEGEND:
1 - Fan Pump
2 - Quick Coupler
3 - Pump Outlet Hose

1187
 Fan Pump Pressure Test
Make test connections as shown using existing pump outlet hose (3). Pump is located on left side rear of
engine.

2. Perform Transmission Oil Warm-Up Procedure . (Group 9026-25.)

Item Measurement Specification

Transmission Oil Temperature 57—66°C
135—150°F

3. Install JT02156A Digital Pressure Analyzer with JT02162 Pressure Transducer to quick coupler (2).
Perform JT02156A Digital Pressure/Temperature Analyzer Installation . (Group 9026-25.)

4. NOTE:

The fan valve set setting is located in the service menu. To enter the service menu,
press the menu button and hold it down for 5 seconds.

Set fan speed to maximum as follows:

1. Access Service Menu on monitor.

2. Select TCU Diagnostics.

3. Select Settings.

4. Select Fan Valve Set.

5. Select Maximum.

5. Operate engine at specification and record pressure. Pressure must be within specification.

Item Measurement Specification

Engine Speed Fast Idle
Fan Pump Pressure 17 582—18 961 kPa
176—190 bar
2550—2750 psi

6. If fan pump pressure is not within specification:

Perform Fan Pump Flow Test . (Group 9026-25.)

Inspect proportional fan solenoid for contamination or seal leakage. Replace if necessary.

7. After performing this test, cycle key switch to restart engine. This will activate proportional fan drive.

Go to Section_9026:Group_25

JW40272,00000F3-19-20120816

1188
 Fan Pump Flow Test

Fan Pump Flow Test

-: Specifications

SPECIFICATIONS

Transmission Oil Temperature 57—66°C

135—150°F

Engine Speed 2330—2360 rpm

Fan Pump Pressure 17 926 kPa

179 bar
2600 psi

New Fan Pump Flow (Minimum) 54.1 L/min.

14.3 gpm

Used Fan Pump Flow (Minimum) 51.9 L/min.

13.7 gpm

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JT07148 Digital Hydraulic Tester

JT03448 Test Hose (2 used)

The purpose of this test is to determine fan pump flow. Flow not within specification can indicate excessive wear
on internal components.

Perform this test only if Fan Pump Pressure Test or Fan Motor Speed Test procedures have failed to meet
specification.

1189
 Fan Pump Flow Test
T202967-UN: Hydraulic Fan Drive (S.N. —178462)
LEGEND:
41 - Hydraulic Fan Pump
42 - Hydraulic Fan Motor
43 - Hydraulic Fan Reversing Valve
44 - Hydraulic Fan Reversing Solenoid
45 - Hydraulic Fan Directional Valve
46 - Hydraulic Fan Proportional Solenoid
48 - Hydraulic Fan Oil Filter Bypass Valve
49 - Hydraulic Fan Oil Filter Restriction Switch
50 - Hydraulic Fan Oil Filter
54 - Suction Line (hydrostatic reservoir through bulkhead to hydraulic fan pump)
55 - High Pressure Line (hydraulic fan pump to hydraulic fan reversing valve)
56 - Forward Pressure Line (hydraulic fan reversing valve through bulkhead to hydraulic fan motor)
57 - Reverse Pressure Line (hydraulic fan reversing valve through bulkhead to hydraulic fan motor)
58 - Return Line (hydraulic fan reversing valve to hydraulic fan oil filter)
59 - Case Drain Line (hydraulic fan motor to hydraulic fan oil filter)
96 - High Pressure Oil
98 - Return Oil

TX1201813-UN: Hydraulic Fan Drive (S.N. 178463— )

LEGEND:
41 - Hydraulic Fan Pump
42 - Hydraulic Fan Motor
43 - Hydraulic Fan Reversing Valve
44 - Hydraulic Fan Reversing Solenoid
45 - Hydraulic Fan Directional Valve
46 - Hydraulic Fan Proportional Solenoid
48 - Hydraulic Fan Oil Filter Bypass Valve
49 - Hydraulic Fan Oil Filter Restriction Switch
50 - Hydraulic Fan Oil Filter
54 - Suction Line (hydrostatic reservoir through bulkhead to hydraulic fan pump)
1190
 Fan Pump Flow Test
55 - High Pressure Line (hydraulic fan pump to hydraulic fan reversing valve)
56 - Forward Pressure Line (hydraulic fan reversing valve through bulkhead to hydraulic fan motor)
57 - Reverse Pressure Line (hydraulic fan reversing valve through bulkhead to hydraulic fan motor)
58 - Return Line (hydraulic fan reversing valve to hydraulic fan oil filter)
62 - Case Drain Line (hydraulic fan motor to hydrostatic reservoir)
96 - High Pressure Oil
98 - Return Oil

1. IMPORTANT:

Flow control valve on flow meter MUST be fully open. Damage to charge pumps will result if valve is not
fully open.

Disconnect hose (55) from fan drive pump and install to JT07148 Digital Hydraulic Tester flow meter.
Assemble JT03448 Test Hose from flow meter to fan pump outlet. Flow control valve must be fully open.

2. Perform Transmission Oil Warm-Up Procedure . (Group 9026-25.)

Item Measurement Specification

Transmission Oil Temperature 57—66°C
135—150°F

3. NOTE:

The Fan Valve Set setting is located in the service menu. To enter the service menu,
press the MENU button and hold it down for 5 seconds.

Set fan speed to maximum.

1. Access Service Menu on monitor.

2. Select TCU Diagnostics.

3. Select Settings.

4. Select Fan Valve Set.

5. Select Maximum.

4. Set engine speed to specification.

Item Measurement Specification

Engine Speed 2330—2360 rpm

5. Record pump flow. Pump flow must be within specification.

1191
 Fan Pump Flow Test

Item Measurement Specification

Fan Pump Pressure 17 926 kPa
179 bar
2600 psi
New Fan Pump Flow (Minimum) 54.1 L/min.
14.3 gpm
Used Fan Pump Flow (Minimum) 51.9 L/min.
13.7 gpm

6. If fan pump flow is not within specification, remove and inspect fan pump. Replace if necessary.

7. After performing this test, cycle key switch to restart engine. This will activate proportional fan drive.

Go to Section_9026:Group_25

OUO1020,000162B-19-20150917

1192
 Fan Motor Speed Test

Fan Motor Speed Test

-: Specifications

SPECIFICATIONS

Transmission Oil Temperature 57—66°C

135—150°F

Fan Motor Minimum Speed at 100% setting 1700 rpm

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

JT05709 Reflective Tape

JT05719 Handheld Digital Tachometer

The purpose of this test is to determine fan motor speed. Motor speed not within specification can indicate
improper fan pump flow or excessive wear on internal components.

1. NOTE:

It will require two people to perform this test. One operates machine while other obtains
reading from digital handheld tachometer.

T207357A-UN: Fan Motor Speed Test

LEGEND:
1 - Reflective Tape

Place piece of JT05709 Reflective Tape (1) on fan hub.

2. NOTE:

The fan valve set setting is located in the service menu. To enter the service menu,
press the MENU button and hold it down for 5 seconds.

Set fan speed to maximum.

1. Access Service Menu on monitor.

2. Select TCU Diagnostics.

1193
 Fan Motor Speed Test

3. Select Settings.

4. Select Fan Valve Set.

5. Select Maximum.

3. Perform Transmission Oil Warm-Up Procedure . (Group 9026-25.)

Item Measurement Specification

Transmission Oil Temperature 57—66°C
135—150°F

4. Operate engine at fast idle and record rpm using JT05719 Handheld Digital Tachometer. Fan motor rpm
must be within specification.

Item Measurement Specification

Fan Motor Minimum Speed at 100% setting 1700 rpm

5. If fan motor rpm is not within specification:

Perform Fan Pump Flow Test . (Group 9026-25.)

Inspect proportional fan solenoid for contamination or seal leakage. Replace if necessary.
Inspect fan motor. Repair or replace if necessary.

Go to Section_9026:Group_25

OUO1020,000162C-19-20070214

1194
 Fan Motor Case Drain Test

Fan Motor Case Drain Test

-: Specifications

SPECIFICATIONS

Transmission Oil Temperature 57—66°C

135—150°F

Fan Motor Case Drain Leakage (maximum per minute) 1.2 L/min.
0.317 gpm

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

38H1415 (-6 F ORFS) Cap

Calibrated Container

The purpose of this test is to determine if case drain leakage is within specification. Accelerated case drain can
indicate excessive wear on internal components.

1. Heat transmission oil to specification. See Transmission Oil Warm-Up Procedure . (Group 9026-25.)

Item Measurement Specification

Transmission Oil Temperature 57—66°C
135—150°F

2. Stop the engine.

3.

T207021A-UN: Fan Motor Case Drain Test

LEGEND:
1 - Case Drain Line (hydraulic fan motor to hydraulic fan oil filter)
2 - Calibrated Container

Disconnect case drain line (1) from hydraulic fan oil filter head. Close all openings with plugs and caps.
Put line in a calibrated container (2).

4. Operate engine at slow idle and fast idle. Record case drain flow. Case drain flow must be within
specification.

1195
 Fan Motor Case Drain Test

Item Measurement Specification

Fan Motor Case Drain Leakage (maximum per minute) 1.2 L/min
0.317 gpm

5. If case drain flow is not within specification, replace motor. Fan motor is not serviceable.

Go to Section_9026:Group_25

TE14778,0000061-19-20120417

1196
 Table of Contents

Section 9031: Heating and Air Conditioning

Group 05: Theory of Operation

Air Conditioning System Cycle Of Operation

Group 15: Diagnostic Information

Air Conditioning System Diagnose Malfunctions

Heater System Diagnose Malfunctions

Group 25: Tests

Proper Refrigerant Handling

R134a Refrigerant Cautions

R134a Oil Charge Capacity

R134a Refrigerant Charge Capacity

Refrigerant Hoses And Tubing Inspection

R134a Air Conditioning System Test

Operating Pressure Diagnostic Chart

Air Conditioner High/Low Pressure (Binary) Switch Test

Freeze Control Switch Test

Leak Testing

1197
 Air Conditioning System Cycle Of Operation

Air Conditioning System Cycle Of Operation

T142307-UN: Refrigerant System Cycle Of Operation

LEGEND:
1 - Evaporator Core
2 - Compressor
3 - Condenser Core
4 - Circulation Blower Motor
5 - Expansion Valve
6 - Receiver-Dryer
7 - High Pressure Liquid
8 - High Pressure Gas
9 - Low Pressure Liquid
10 - Low Pressure Gas
11 - Air Flow

The compressor is belt driven and engaged by an electromagnetic clutch. The air conditioning circuit
automatically controls compressor engagement or disengagement when system is in operation. See System
Functional Schematic and Section Legend . (Group 9015-10.)

Compressor draws low pressure gas from evaporator and compresses it into high pressure gas. This causes
temperature of refrigerant to rise higher than that of outside air.

High pressure gas leaves compressor and flows through condenser where heat is removed and transferred to
outside air being drawn through condenser core by fan. Cooling refrigerant causes it to condense and refrigerant
leaves condenser as high pressure liquid.

1198
 Air Conditioning System Cycle Of Operation
High pressure liquid flows into receiver-dryer where moisture and contaminants (acid, solids, etc.) are removed.
Receiver-dryer may contain a color moisture indicator. (Blue) indicates no moisture is present. (Pink) indicates
moisture is present. Should moisture be combined with refrigerant, hydrofluoric and hydrochloric acids are
formed. These acids are very corrosive to metal surfaces and leakage will eventually develop. Receiver-dryer also
stores refrigerant allowing a longer period of time before additional refrigerant is needed. Refrigerant hoses allow
a small amount of refrigerant to migrate through their walls.

Refrigerant flows from receiver-dryer through expansion valve to evaporator. Expansion valve senses refrigerant
temperature and pressure to modulate refrigerant flow. Expansion valve changes refrigerant to low pressure liquid
entering evaporator. Actual cooling and drying of cab air takes place at evaporator. Heat absorbed by evaporator
and transferred to refrigerant causes refrigerant to vaporize into low pressure gas. Low pressure gas is drawn
from evaporator by compressor and cycle is repeated.

A freeze control switch senses temperature of evaporator coil through a capillary tube. This prevents the
evaporator from becoming cold enough to freeze moisture that condenses on evaporator coil. Condensed
moisture is drained away through drain tubes connected to drain pan under evaporator.

System pressure is monitored by high and low pressure switch, located on high pressure side of expansion valve.
If pressure becomes too high or too low the switch opens and stops compressor, interrupting the cycle.

Accumulator is located between evaporator and compressor in low pressure gas hose to retain a quantity of oil to
protect compressor from a dry start after long periods of not being used.

See Air Conditioning Harness (W14) Component Location (Group 9015-10) for location of machine heater and air
conditioning components.

Go to Section_9031:Group_05

AA95137,0000818-19-20070226

1199
 Air Conditioning System Cycle Of Operation

Air Conditioning System Cycle Of Operation

T142307-UN: Refrigerant System Cycle Of Operation

LEGEND:
1 - Evaporator Core
2 - Compressor
3 - Condenser Core
4 - Circulation Blower Motor
5 - Expansion Valve
6 - Receiver-Dryer
7 - High Pressure Liquid
8 - High Pressure Gas
9 - Low Pressure Liquid
10 - Low Pressure Gas
11 - Air Flow

The compressor is belt driven and engaged by an electromagnetic clutch. The air conditioning circuit
automatically controls compressor engagement or disengagement when system is in operation. See System
Functional Schematic and Section Legend . (Group 9015-10.)

Compressor draws low pressure gas from evaporator and compresses it into high pressure gas. This causes
temperature of refrigerant to rise higher than that of outside air.

High pressure gas leaves compressor and flows through condenser where heat is removed and transferred to
outside air being drawn through condenser core by fan. Cooling refrigerant causes it to condense and refrigerant
leaves condenser as high pressure liquid.

1200
 Air Conditioning System Cycle Of Operation
High pressure liquid flows into receiver-dryer where moisture and contaminants (acid, solids, etc.) are removed.
Receiver-dryer may contain a color moisture indicator. (Blue) indicates no moisture is present. (Pink) indicates
moisture is present. Should moisture be combined with refrigerant, hydrofluoric and hydrochloric acids are
formed. These acids are very corrosive to metal surfaces and leakage will eventually develop. Receiver-dryer also
stores refrigerant allowing a longer period of time before additional refrigerant is needed. Refrigerant hoses allow
a small amount of refrigerant to migrate through their walls.

Refrigerant flows from receiver-dryer through expansion valve to evaporator. Expansion valve senses refrigerant
temperature and pressure to modulate refrigerant flow. Expansion valve changes refrigerant to low pressure liquid
entering evaporator. Actual cooling and drying of cab air takes place at evaporator. Heat absorbed by evaporator
and transferred to refrigerant causes refrigerant to vaporize into low pressure gas. Low pressure gas is drawn
from evaporator by compressor and cycle is repeated.

A freeze control switch senses temperature of evaporator coil through a capillary tube. This prevents the
evaporator from becoming cold enough to freeze moisture that condenses on evaporator coil. Condensed
moisture is drained away through drain tubes connected to drain pan under evaporator.

System pressure is monitored by high and low pressure switch, located on high pressure side of expansion valve.
If pressure becomes too high or too low the switch opens and stops compressor, interrupting the cycle.

Accumulator is located between evaporator and compressor in low pressure gas hose to retain a quantity of oil to
protect compressor from a dry start after long periods of not being used.

See Air Conditioning Harness (W14) Component Location (Group 9015-10) for location of machine heater and air
conditioning components.

Go to Section_9031:Group_05

AA95137,0000818-19-20070226

1201
 Air Conditioning System Diagnose Malfunctions

Air Conditioning System Does Not Operate Diagnostic Procedure

Launch Close Expand List Collapse List

1 Heater Blower 15-Amp Fuse (F12) Check

Action:

Check heater blower 15-amp fuse (F12).

Is fuse blown?

NOTE:

If the heater blower switch and all work lights do not operate, check accessory relay #2
(K12). See Accessory Relay #2 Check .

Record of Actual Results:

Result:
YES:
Replace fuse. See Fuse and Relay Specifications . (Group 9015-10.)
NO:
Go to Heater Blower Switch Check.

2 Heater Blower Switch Check

Action:

Check heater blower switch (S10). See Cab Roof Harness (W9) Component Location . (Group 9015-10.)

-: Heater Blower Switch Continuity

Switch Position Continuity Between Pins

Off No Continuity

Low 1 and Battery Power

Medium 1, 2 and Battery Power

High 1, 2, 3 and Battery Power

Maximum 1, 2, 3, 4 and Battery Power

Is switch functioning properly?

Record of Actual Results:

Result:
YES:
Go to Cab Heater Blower Resistor Check.

1202
 Air Conditioning System Diagnose Malfunctions

NO:
Switch malfunction. Replace heater blower switch (S10).

3 Cab Heater Blower Resistor Check

Action:

Check cab heater blower resistor (R4). See Air Conditioning Harness (W14) Component Location . (Group
9015-10.)

Is resistor within specifications?

Item Measurement Specification

R4—Cab Heater Blower Resistor Low Speed Resistance (X12 pins 2 and 6) 2.2—2.7 ohms
Medium Low Speed Resistance (X12 pins 3 and 6) 1.3—1.9 ohms
Medium Speed Resistance (X12 pins 5 and 6) 0.5—0.9 ohms

Record of Actual Results:

Result:
YES:
Go to Heater Blower Motor Check.
NO:
Resistor malfunction. Replace cab heater blower resistor (R4).

4 Heater Blower Motor Check

Action:

Disconnect heater blower motor (M3) and supply 24 volts to motor. See Air Conditioning Harness (W14)
Component Location . (Group 9015-10.)

Does motor run?

Record of Actual Results:

Result:
YES:
Go to Accessory Relay Check.
NO:
Motor malfunction. Replace heater blower motor (M3).

5 Accessory Relay Check

Action:

Remove accessory relay #2 (K11). See Operator's Station Harness (W7) Component Location . (Group
9015-10.)

1203
 Air Conditioning System Diagnose Malfunctions
Install accessory relay #1 (K12) in place of accessory relay #2.

Does A/C system operate?

Record of Actual Results:

Result:
YES:
Relay malfunction. Replace accessory relay #2.
NO:
Go to Air Conditioning On/Off Switch Check.

6 Air Conditioning On/Off Switch Check

Action:

Put switch in both ON positions and measure continuity between pins 2B and 3 or in other ON position
between pins 2B and 1. See Cab Roof Harness (W9) Component Location . (Group 9015-20.)

Is there continuity in both switch ON positions?

Record of Actual Results:

Result:
YES:
Go to Air Conditioning Freeze Switch Check.
NO:
Switch malfunction. Replace air conditioning on/off switch (S11).

7 Air Conditioning Freeze Switch Check

Action:

Check air conditioning freeze switch (B27). Perform Freeze Control Switch Test . (Group 9031-25.)

Is switch functioning properly?

Record of Actual Results:

Result:
YES:
Go to A/C Binary Pressure Switch Check.
NO:
Switch malfunction. Replace air conditioning freeze switch (B27).

8 A/C Binary Pressure Switch Check

Action:
1204
 Air Conditioning System Diagnose Malfunctions
Check A/C binary pressure switch (B50). Perform Air Conditioner High/Low Pressure (Binary) Switch Test .
(Group 9031-25.)

Is switch functioning properly?

Record of Actual Results:

Result:
YES:
Go to Air Conditioning Compressor Clutch Solenoid Check.
NO:
Pressure switch malfunction. Replace A/C binary pressure switch (B50).

9 Air Conditioning Compressor Clutch Solenoid Check

Action:

Check resistance of air conditioning compressor clutch solenoid (Y16). See Engine Harness (W10)
Component Location . (Group 9015-10.)

Is solenoid within specifications?

Item Measurement Specification

Y16—Air Conditioning Compressor Clutch Solenoid Resistance 3.5—6 ohms

Record of Actual Results:

Result:
YES:
Go to Air Conditioning Compressor Clutch 5-Amp Diode Check.
NO:
Solenoid malfunction. Repair or replace air conditioning compressor clutch solenoid (Y16).

10 Air Conditioning Compressor Clutch 5-Amp Diode Check

Action:

Check air conditioning compressor clutch diode (V4). See Engine Harness (W10) Component Location .
(Group 9015-10.)

Is diode functioning properly?

Record of Actual Results:

Result:
YES:
Go to Air Conditioning Harness Check.
NO:
1205
 Air Conditioning System Diagnose Malfunctions
Diode malfunction. Replace diode.

11 Air Conditioning Harness Check

Action:

Check wiring and connections to components. See Air Conditioning Harness (W14) Wiring Diagram and see
Cab Roof Harness (W9) Wiring Diagram . (Group 9015-10.)

Check for open and short circuits.

Do any shorts or opens exist?

Record of Actual Results:

Result:
YES:
Harness malfunction. Repair or replace harness. See Air Conditioning Harness (W14) Wiring Diagram and
see Cab Roof Harness (W9) Wiring Diagram . (Group 9015-10.)
NO:
Checks complete.

Air Conditioner Does Not Cool Interior of Cab Diagnostic Procedure

Launch Close Expand List Collapse List

1 Fresh Air Filter Component Check

Action:

Check fresh air filter for debris or air flow restrictions.

Is fresh air filter clogged?

Record of Actual Results:

Result:
YES:
Replace fresh air filter.
NO:
Go to Condenser Restriction Check.

2 Condenser Restriction Check

Action:

Check condenser fins for air flow restrictions.

Are condenser fins clogged with debris?

Record of Actual Results:

1206
 Air Conditioning System Diagnose Malfunctions

Result:
YES:
Clean condenser fins.
NO:
Go to Recirculating Air Filter Restriction Check.

3 Recirculating Air Filter Restriction Check

Action:

Check recirculating air filter for flow restrictions.

Is recirculating air filter dirty or clogged with debris?

Record of Actual Results:

Result:
YES:
Clean or replace recirculating air filter.
NO:
Go to Refrigerant Hose Restriction Check.

4 Refrigerant Hose Restriction Check

Action:

Check refrigerant hoses.

Are any hoses kinked, pinched, or collapsed?

Record of Actual Results:

Result:
YES:
Reroute or re-index hoses. Replace kinked or collapsed hoses.
NO:
Go to Condenser Core and Evaporator Core Air Flow Restriction Check.

5 Condenser Core and Evaporator Core Air Flow Restriction Check

Action:

Check condenser core and evaporator core fins for debris.

Are the condenser core or evaporator core fins clogged with debris?

Record of Actual Results:

1207
 Air Conditioning System Diagnose Malfunctions

Result:
YES:
Clean condenser core and evaporator core fins.
NO:
Go to Heater Blower Motor and Cab Heater Blower Resistor Check.

6 Heater Blower Motor and Cab Heater Blower Resistor Check

Action:

Check heater blower motor (M3) by applying 24 volts to the motor. Check to see if motor is running when
voltage is applied. See Air Conditioning Harness (W14) Component Location . (Group 9015-10.)

Check cab heater blower resistor (R4). See Air Conditioning Harness (W14) Wiring Diagram . (Group 9015-
10.) For specifications, see Electrical Component Specifications . (Group 9015-20.)

Are heater blower motor and cab heater blower resistor both functioning properly?

Record of Actual Results:

Result:
YES:
Go to Compressor Belt Check.
NO:
Replace heater blower motor and/or resistor.

7 Compressor Belt Check

Action:

Check engine serpentine belt. See Check Alternator Belt Tension . (Operator's Manual.)

Is belt tension ok?

Record of Actual Results:

Result:
YES:
Go to Operator's Station Seals Check.
NO:
Adjust or replace belt.

8 Operator's Station Seals Check

Action:

Check windows and doors to make sure seals are good.

1208
 Air Conditioning System Diagnose Malfunctions
Are seals on all windows and doors functioning properly?

Record of Actual Results:

Result:
YES:
Go to Condenser Fan Motor 1 Relay Check.
NO:
Repair or replace malfunctioning seals.

9 Condenser Fan Motor 1 Relay Check

Action:

Check condenser fan motor 1 relay (K2). See Fuse and Relay Specifications . (Group 9015-10.)

Is relay functioning properly?

Record of Actual Results:

Result:
YES:
Go to Condenser Fan Motor 2 Relay Check.
NO:
Relay malfunction. Replace condenser fan motor 1 relay (K2). See Fuse and Relay Specifications . (Group
9015-10.)

10 Condenser Fan Motor 2 Relay Check

Action:

Check condenser fan motor 2 relay (K1). See Fuse and Relay Specifications . (Group 9015-10.)

Is relay functioning properly?

Record of Actual Results:

Result:
YES:
Go to Condenser Fan Motor 1 15-Amp Fuse Check.
NO:
Relay malfunction. Replace condenser fan motor 2 relay (K1). See Fuse and Relay Specifications . (Group
9015-10.)

11 Condenser Fan Motor 1 15-Amp Fuse Check

Action:

Check condenser fan motor 1 15-amp fuse (F2). See Fuse and Relay Specifications . (Group 9015-10.)
1209
 Air Conditioning System Diagnose Malfunctions
Check condenser fan motor 1 15-amp fuse (F2). See Fuse and Relay Specifications . (Group 9015-10.)

Is fuse blown?

Record of Actual Results:

Result:
YES:
Replace condenser fan motor 1 15-amp fuse (F2). See Fuse and Relay Specifications . (Group 9015-10.)
NO:
Go to Condenser Fan Motor 2 15-Amp Fuse Check.

12 Condenser Fan Motor 2 15-Amp Fuse Check

Action:

Check condenser fan motor 2 15-amp fuse (F1). See Fuse and Relay Specifications . (Group 9015-10.)

Is fuse blown?

Record of Actual Results:

Result:
YES:
Replace condenser fan motor 2 15-Amp fuse (F1). See Fuse and Relay Specifications . (Group 9015-10.)
NO:
Go to Heater Valve Motor Check.

13 Heater Valve Motor Check

Action:

Check heater valve motor (M2) to make sure heater valve is not staying open.

Is heater valve motor functioning properly?

Record of Actual Results:

Result:
YES:
Go to System Refrigerant (R134a) Charge Low Check.
NO:
Heater valve motor (M2) malfunction. Replace motor.

14 System Refrigerant (R134a) Charge Low Check

Action:

Check for leaks in refrigerant system and recharge. See Charge R134a System . (Group 1830.)
1210
 Air Conditioning System Diagnose Malfunctions
Check for leaks in refrigerant system and recharge. See Charge R134a System . (Group 1830.)

Does refrigerant system have any leaks?

Record of Actual Results:

Result:
YES:
Repair or replace hoses and recharge system.
NO:
Go to Evaporator Core Fins Check.

15 Evaporator Core Fins Check

Action:

Check evaporator core fins for frosting or freezing.

Is there any ice or frost on evaporator fins?

Record of Actual Results:

Result:
YES:
Thermostat switch not positioned correctly in evaporator core. Reposition switch.
NO:
Checks complete.

Air Conditioner Runs Constantly, Too Cold Diagnostic Procedure

Launch Close Expand List Collapse List

1 Evaporator Core Component Check

Action:

Check evaporator core fins for frosting or freezing.

Is there any ice or frost on evaporator fins?

Record of Actual Results:

Result:
YES:
Thermostat switch not positioned correctly in evaporator core. Reposition switch in evaporator core.
NO:
Compressor clutch running constantly. Go to Freeze Control Switch Check.

2 Freeze Control Switch Check

1211
 Air Conditioning System Diagnose Malfunctions

Action:

Check freeze control switch (B27). See Air Conditioning Harness (W14) Component Location . (Group 9015-
10.) See Freeze Control Switch Test . (Group 9031-25.)

Is freeze control switch functioning properly?

Record of Actual Results:

Result:
YES:
Checks complete.
NO:
Switch malfunction. Replace air conditioning freeze switch (B27).

Interior Windows Continue To Fog Diagnostic Procedure

Launch Close Expand List Collapse List

1 Fresh Air Filter Check

Action:

Check fresh air filter for debris or air flow restrictions.

Is fresh air filter clogged?

Record of Actual Results:

Result:
YES:
Replace fresh air filter.
NO:
Go to Air Conditioning On/Off Switch Check.

2 Air Conditioning On/Off Switch Check

Action:

Check status of air conditioning on/off switch (S11). See Cab Roof Harness (W9) Component Location .
(Group 9015-10.)

Is switch in the on position?

Record of Actual Results:

Result:
YES:
Replace air conditioning on/off switch (S11).
1212
 Air Conditioning System Diagnose Malfunctions

NO:
Turn switch on.

Go to Section_9031:Group_15

AA95137,00007EE-19-20070222

1213
 Air Conditioning System Diagnose Malfunctions

Air Conditioning System Does Not Operate Diagnostic Procedure

Launch Close Expand List Collapse List

1 Heater Blower 15-Amp Fuse (F12) Check

Action:

Check heater blower 15-amp fuse (F12).

Is fuse blown?

NOTE:

If the heater blower switch and all work lights do not operate, check accessory relay #2
(K12). See Accessory Relay #2 Check .

Record of Actual Results:

Result:
YES:
Replace fuse. See Fuse and Relay Specifications . (Group 9015-10.)
NO:
Go to Heater Blower Switch Check.

2 Heater Blower Switch Check

Action:

Check heater blower switch (S10). See Cab Roof Harness (W9) Component Location . (Group 9015-10.)

-: Heater Blower Switch Continuity

Switch Position Continuity Between Pins

Off No Continuity

Low 1 and Battery Power

Medium 1, 2 and Battery Power

High 1, 2, 3 and Battery Power

Maximum 1, 2, 3, 4 and Battery Power

Is switch functioning properly?

Record of Actual Results:

Result:
YES:
Go to Cab Heater Blower Resistor Check.

1214
 Air Conditioning System Diagnose Malfunctions

NO:
Switch malfunction. Replace heater blower switch (S10).

3 Cab Heater Blower Resistor Check

Action:

Check cab heater blower resistor (R4). See Air Conditioning Harness (W14) Component Location . (Group
9015-10.)

Is resistor within specifications?

Item Measurement Specification

R4—Cab Heater Blower Resistor Low Speed Resistance (X12 pins 2 and 6) 2.2—2.7 ohms
Medium Low Speed Resistance (X12 pins 3 and 6) 1.3—1.9 ohms
Medium Speed Resistance (X12 pins 5 and 6) 0.5—0.9 ohms

Record of Actual Results:

Result:
YES:
Go to Heater Blower Motor Check.
NO:
Resistor malfunction. Replace cab heater blower resistor (R4).

4 Heater Blower Motor Check

Action:

Disconnect heater blower motor (M3) and supply 24 volts to motor. See Air Conditioning Harness (W14)
Component Location . (Group 9015-10.)

Does motor run?

Record of Actual Results:

Result:
YES:
Go to Accessory Relay Check.
NO:
Motor malfunction. Replace heater blower motor (M3).

5 Accessory Relay Check

Action:

Remove accessory relay #2 (K11). See Operator's Station Harness (W7) Component Location . (Group
9015-10.)

1215
 Air Conditioning System Diagnose Malfunctions
Install accessory relay #1 (K12) in place of accessory relay #2.

Does A/C system operate?

Record of Actual Results:

Result:
YES:
Relay malfunction. Replace accessory relay #2.
NO:
Go to Air Conditioning On/Off Switch Check.

6 Air Conditioning On/Off Switch Check

Action:

Put switch in both ON positions and measure continuity between pins 2B and 3 or in other ON position
between pins 2B and 1. See Cab Roof Harness (W9) Component Location . (Group 9015-20.)

Is there continuity in both switch ON positions?

Record of Actual Results:

Result:
YES:
Go to Air Conditioning Freeze Switch Check.
NO:
Switch malfunction. Replace air conditioning on/off switch (S11).

7 Air Conditioning Freeze Switch Check

Action:

Check air conditioning freeze switch (B27). Perform Freeze Control Switch Test . (Group 9031-25.)

Is switch functioning properly?

Record of Actual Results:

Result:
YES:
Go to A/C Binary Pressure Switch Check.
NO:
Switch malfunction. Replace air conditioning freeze switch (B27).

8 A/C Binary Pressure Switch Check

Action:
1216
 Air Conditioning System Diagnose Malfunctions
Check A/C binary pressure switch (B50). Perform Air Conditioner High/Low Pressure (Binary) Switch Test .
(Group 9031-25.)

Is switch functioning properly?

Record of Actual Results:

Result:
YES:
Go to Air Conditioning Compressor Clutch Solenoid Check.
NO:
Pressure switch malfunction. Replace A/C binary pressure switch (B50).

9 Air Conditioning Compressor Clutch Solenoid Check

Action:

Check resistance of air conditioning compressor clutch solenoid (Y16). See Engine Harness (W10)
Component Location . (Group 9015-10.)

Is solenoid within specifications?

Item Measurement Specification

Y16—Air Conditioning Compressor Clutch Solenoid Resistance 3.5—6 ohms

Record of Actual Results:

Result:
YES:
Go to Air Conditioning Compressor Clutch 5-Amp Diode Check.
NO:
Solenoid malfunction. Repair or replace air conditioning compressor clutch solenoid (Y16).

10 Air Conditioning Compressor Clutch 5-Amp Diode Check

Action:

Check air conditioning compressor clutch diode (V4). See Engine Harness (W10) Component Location .
(Group 9015-10.)

Is diode functioning properly?

Record of Actual Results:

Result:
YES:
Go to Air Conditioning Harness Check.
NO:
1217
 Air Conditioning System Diagnose Malfunctions
Diode malfunction. Replace diode.

11 Air Conditioning Harness Check

Action:

Check wiring and connections to components. See Air Conditioning Harness (W14) Wiring Diagram and see
Cab Roof Harness (W9) Wiring Diagram . (Group 9015-10.)

Check for open and short circuits.

Do any shorts or opens exist?

Record of Actual Results:

Result:
YES:
Harness malfunction. Repair or replace harness. See Air Conditioning Harness (W14) Wiring Diagram and
see Cab Roof Harness (W9) Wiring Diagram . (Group 9015-10.)
NO:
Checks complete.

Air Conditioner Does Not Cool Interior of Cab Diagnostic Procedure

Launch Close Expand List Collapse List

1 Fresh Air Filter Component Check

Action:

Check fresh air filter for debris or air flow restrictions.

Is fresh air filter clogged?

Record of Actual Results:

Result:
YES:
Replace fresh air filter.
NO:
Go to Condenser Restriction Check.

2 Condenser Restriction Check

Action:

Check condenser fins for air flow restrictions.

Are condenser fins clogged with debris?

Record of Actual Results:

1218
 Air Conditioning System Diagnose Malfunctions

Result:
YES:
Clean condenser fins.
NO:
Go to Recirculating Air Filter Restriction Check.

3 Recirculating Air Filter Restriction Check

Action:

Check recirculating air filter for flow restrictions.

Is recirculating air filter dirty or clogged with debris?

Record of Actual Results:

Result:
YES:
Clean or replace recirculating air filter.
NO:
Go to Refrigerant Hose Restriction Check.

4 Refrigerant Hose Restriction Check

Action:

Check refrigerant hoses.

Are any hoses kinked, pinched, or collapsed?

Record of Actual Results:

Result:
YES:
Reroute or re-index hoses. Replace kinked or collapsed hoses.
NO:
Go to Condenser Core and Evaporator Core Air Flow Restriction Check.

5 Condenser Core and Evaporator Core Air Flow Restriction Check

Action:

Check condenser core and evaporator core fins for debris.

Are the condenser core or evaporator core fins clogged with debris?

Record of Actual Results:

1219
 Air Conditioning System Diagnose Malfunctions

Result:
YES:
Clean condenser core and evaporator core fins.
NO:
Go to Heater Blower Motor and Cab Heater Blower Resistor Check.

6 Heater Blower Motor and Cab Heater Blower Resistor Check

Action:

Check heater blower motor (M3) by applying 24 volts to the motor. Check to see if motor is running when
voltage is applied. See Air Conditioning Harness (W14) Component Location . (Group 9015-10.)

Check cab heater blower resistor (R4). See Air Conditioning Harness (W14) Wiring Diagram . (Group 9015-
10.) For specifications, see Electrical Component Specifications . (Group 9015-20.)

Are heater blower motor and cab heater blower resistor both functioning properly?

Record of Actual Results:

Result:
YES:
Go to Compressor Belt Check.
NO:
Replace heater blower motor and/or resistor.

7 Compressor Belt Check

Action:

Check engine serpentine belt. See Check Alternator Belt Tension . (Operator's Manual.)

Is belt tension ok?

Record of Actual Results:

Result:
YES:
Go to Operator's Station Seals Check.
NO:
Adjust or replace belt.

8 Operator's Station Seals Check

Action:

Check windows and doors to make sure seals are good.

1220
 Air Conditioning System Diagnose Malfunctions
Are seals on all windows and doors functioning properly?

Record of Actual Results:

Result:
YES:
Go to Condenser Fan Motor 1 Relay Check.
NO:
Repair or replace malfunctioning seals.

9 Condenser Fan Motor 1 Relay Check

Action:

Check condenser fan motor 1 relay (K2). See Fuse and Relay Specifications . (Group 9015-10.)

Is relay functioning properly?

Record of Actual Results:

Result:
YES:
Go to Condenser Fan Motor 2 Relay Check.
NO:
Relay malfunction. Replace condenser fan motor 1 relay (K2). See Fuse and Relay Specifications . (Group
9015-10.)

10 Condenser Fan Motor 2 Relay Check

Action:

Check condenser fan motor 2 relay (K1). See Fuse and Relay Specifications . (Group 9015-10.)

Is relay functioning properly?

Record of Actual Results:

Result:
YES:
Go to Condenser Fan Motor 1 15-Amp Fuse Check.
NO:
Relay malfunction. Replace condenser fan motor 2 relay (K1). See Fuse and Relay Specifications . (Group
9015-10.)

11 Condenser Fan Motor 1 15-Amp Fuse Check

Action:

Check condenser fan motor 1 15-amp fuse (F2). See Fuse and Relay Specifications . (Group 9015-10.)
1221
 Air Conditioning System Diagnose Malfunctions
Check condenser fan motor 1 15-amp fuse (F2). See Fuse and Relay Specifications . (Group 9015-10.)

Is fuse blown?

Record of Actual Results:

Result:
YES:
Replace condenser fan motor 1 15-amp fuse (F2). See Fuse and Relay Specifications . (Group 9015-10.)
NO:
Go to Condenser Fan Motor 2 15-Amp Fuse Check.

12 Condenser Fan Motor 2 15-Amp Fuse Check

Action:

Check condenser fan motor 2 15-amp fuse (F1). See Fuse and Relay Specifications . (Group 9015-10.)

Is fuse blown?

Record of Actual Results:

Result:
YES:
Replace condenser fan motor 2 15-Amp fuse (F1). See Fuse and Relay Specifications . (Group 9015-10.)
NO:
Go to Heater Valve Motor Check.

13 Heater Valve Motor Check

Action:

Check heater valve motor (M2) to make sure heater valve is not staying open.

Is heater valve motor functioning properly?

Record of Actual Results:

Result:
YES:
Go to System Refrigerant (R134a) Charge Low Check.
NO:
Heater valve motor (M2) malfunction. Replace motor.

14 System Refrigerant (R134a) Charge Low Check

Action:

Check for leaks in refrigerant system and recharge. See Charge R134a System . (Group 1830.)
1222
 Air Conditioning System Diagnose Malfunctions
Check for leaks in refrigerant system and recharge. See Charge R134a System . (Group 1830.)

Does refrigerant system have any leaks?

Record of Actual Results:

Result:
YES:
Repair or replace hoses and recharge system.
NO:
Go to Evaporator Core Fins Check.

15 Evaporator Core Fins Check

Action:

Check evaporator core fins for frosting or freezing.

Is there any ice or frost on evaporator fins?

Record of Actual Results:

Result:
YES:
Thermostat switch not positioned correctly in evaporator core. Reposition switch.
NO:
Checks complete.

Air Conditioner Runs Constantly, Too Cold Diagnostic Procedure

Launch Close Expand List Collapse List

1 Evaporator Core Component Check

Action:

Check evaporator core fins for frosting or freezing.

Is there any ice or frost on evaporator fins?

Record of Actual Results:

Result:
YES:
Thermostat switch not positioned correctly in evaporator core. Reposition switch in evaporator core.
NO:
Compressor clutch running constantly. Go to Freeze Control Switch Check.

2 Freeze Control Switch Check

1223
 Air Conditioning System Diagnose Malfunctions

Action:

Check freeze control switch (B27). See Air Conditioning Harness (W14) Component Location . (Group 9015-
10.) See Freeze Control Switch Test . (Group 9031-25.)

Is freeze control switch functioning properly?

Record of Actual Results:

Result:
YES:
Checks complete.
NO:
Switch malfunction. Replace air conditioning freeze switch (B27).

Interior Windows Continue To Fog Diagnostic Procedure

Launch Close Expand List Collapse List

1 Fresh Air Filter Check

Action:

Check fresh air filter for debris or air flow restrictions.

Is fresh air filter clogged?

Record of Actual Results:

Result:
YES:
Replace fresh air filter.
NO:
Go to Air Conditioning On/Off Switch Check.

2 Air Conditioning On/Off Switch Check

Action:

Check status of air conditioning on/off switch (S11). See Cab Roof Harness (W9) Component Location .
(Group 9015-10.)

Is switch in the on position?

Record of Actual Results:

Result:
YES:
Replace air conditioning on/off switch (S11).
1224
 Air Conditioning System Diagnose Malfunctions

NO:
Turn switch on.

Go to Section_9031:Group_15

AA95137,00007EE-19-20070222

1225
 Heater System Diagnose Malfunctions

Heater System Does Not Operate Diagnostic Procedure

Launch Close Expand List Collapse List

1 Under-Seat Heater 10-Amp Fuse Check

Action:

Check under-seat heater 10-amp fuse (F10). See Fuse and Relay Specifications . (Group 9015-10.)

Is fuse blown?

Record of Actual Results:

Result:
YES:
Replace under-seat heater 10-amp fuse (F10). See Fuse and Relay Specifications . (Group 9015-10.)
NO:
Go to Heater Blower 15-Amp Fuse Check.

2 Heater Blower 15-Amp Fuse Check

Action:

Check heater blower 15-amp fuse (F12). See Fuse and Relay Specifications . (Group 9015-10.)

Is fuse blown?

Record of Actual Results:

Result:
YES:
Replace heater blower 15-amp fuse (F12). See Fuse and Relay Specifications . (Group 9015-10.)
NO:
Go to Under Seat Heater Blower Switch Check.

3 Under Seat Heater Blower Switch Check

Action:

Check for continuity between pins 3 and 6 of under-seat heater blower switch (S15), when switch is in ON
position. See Operator's Station Harness (W7) Component Location . (Group 9015-10.)

Is switch functioning properly?

Record of Actual Results:

Result:
YES:

1226
 Heater System Diagnose Malfunctions
Go to Heater Blower Switch Check.
NO:
Switch malfunction. Replace under-seat heater blower switch (S15).

4 Heater Blower Switch Check

Action:

Check heater blower switch (S10). See Cab Roof Harness (W9) Component Location . (Group 9015-10.)

-: Heater Blower Switch Continuity

Switch Position Continuity Between Pins

Off No Continuity

Low 1 and Battery Power

Medium 1, 2 and Battery Power

High 1, 2, 3 and Battery Power

Maximum 1, 2, 3, 4 and Battery Power

Is switch functioning properly?

Record of Actual Results:

Result:
YES:
Go to Accessory Relay #1 Check.
NO:
Switch malfunction. Replace heater blower switch (S10).

5 Accessory Relay #1 Check

Action:

Remove accessory relay #1 (K12). See Operator's Station Harness (W7) Component Location . (Group
9015-10.)

Install accessory relay #2 (K11) in place of accessory relay #1.

Does A/C system operate?

Record of Actual Results:

Result:
YES:
Relay malfunction. Replace accessory relay #1.
NO:
Go to Accessory Relay #2 Check.

1227
 Heater System Diagnose Malfunctions

6 Accessory Relay #2 Check

Action:

Remove accessory relay #2 (K11). See Operator's Station Harness (W7) Component Location . (Group
9015-10.)

Install accessory relay #1 (K12) in place of accessory relay #2.

Does A/C system operate?

Record of Actual Results:

Result:
YES:
Relay malfunction. Replace accessory relay #2.
NO:
Go to Heater Wiring Harness Check.

7 Heater Wiring Harness Check

Action:

Check air conditioning, operator's station and cab roof wiring harnesses for short-circuits and/or open-
circuits. See Operator's Station Harness (W7) Wiring Diagram , see Cab Roof Harness (W9) Wiring Diagram
, and see Air Conditioning Harness (W14) Wiring Diagram . (Group 9015-10.)

Is wiring ok?

Record of Actual Results:

Result:
YES:
Checks complete.
NO:
Harness malfunction. Repair or replace harness. See Operator's Station Harness (W7) Wiring Diagram , see
Cab Roof Harness (W9) Wiring Diagram , and see Air Conditioning Harness (W14) Wiring Diagram . (Group
9015-10.)

Heater Does Not Warm Interior of Cab Diagnostic Procedure

Launch Close Expand List Collapse List

1 Fresh Air Filter Check

Action:

Check fresh air filter for debris or air flow restrictions.

Is fresh air filter clogged?

1228
 Heater System Diagnose Malfunctions

Record of Actual Results:

Result:
YES:
Replace fresh air filter.
NO:
Go to Recirculating Air Filter Check.

2 Recirculating Air Filter Check

Action:

Check recirculating air filter for flow restrictions.

Is recirculating air filter dirty or clogged with debris?

Record of Actual Results:

Result:
YES:
Clean or replace recirculating air filter.
NO:
Go to Heater Hose Restriction Check.

3 Heater Hose Restriction Check

Action:

Check heater hoses.

Are any hoses kinked, pinched, or collapsed?

Record of Actual Results:

Result:
YES:
Reroute or re-index hoses. Replace kinked or collapsed hoses.
NO:
Go to Heater Core Air Flow Restriction Check

4 Heater Core Air Flow Restriction Check

Action:

Check heater core fins for debris.

Are the heater core fins clogged with debris?

1229
 Heater System Diagnose Malfunctions

Record of Actual Results:

Result:
YES:
Clean heater core fins.
NO:
Go to Heater Blower Motor and Cab Heater Blower Resistor Check.

5 Heater Blower Motor and Cab Heater Blower Resistor Check

Action:

Check heater blower motor (M3) and cab heater blower resistor (R4). See Air Conditioning Harness (W14)
Wiring Diagram . (Group 9015-10.) For specifications, see Electrical Component Specifications . (Group
9015-20.)

Are heater blower motor and cab heater blower resistor both functioning properly?

Record of Actual Results:

Result:
YES:
Go to Heater Valve 5-Amp Fuse Check.
NO:
Replace heater blower motor and/or resistor.

6 Heater Valve 5-Amp Fuse Check

Action:

Check heater valve 5-amp fuse (F18). See Fuse and Relay Specifications . (Group 9015-10.)

Is fuse blown?

Record of Actual Results:

Result:
YES:
Replace fuse (F18). See Fuse and Relay Specifications . (Group 9015-10.)
NO:
Go to Heater Valve Check.

7 Heater Valve Check

Action:

Check heater valve for proper operation.

1230
 Heater System Diagnose Malfunctions
Is heater valve operating properly?

Record of Actual Results:

Result:
YES:
Checks complete.
NO:
Replace heater valve.

Interior Windows Continue To Fog Diagnostic Procedure

Launch Close Expand List Collapse List

1 Fresh Air Filter Check

Action:

Check fresh air filter for debris or air flow restrictions.

Is fresh air filter clogged?

Record of Actual Results:

Result:
YES:
Replace fresh air filter.
NO:
Go to Air Conditioning On/Off Switch Check.

2 Air Conditioning On/Off Switch Check

Action:

Check status of air conditioning on/off switch (S11). See Cab Roof Harness (W9) Component Location .
(Group 9015-10.)

Is switch in the ON position?

Record of Actual Results:

Result:
YES:
Replace air conditioning on/off switch (S11).
NO:
Turn switch on.

1231
Heater System Diagnose Malfunctions

Go to Section_9031:Group_15

AA95137,00007EF-19-20081216

1232
 Proper Refrigerant Handling

Proper Refrigerant Handling

The U.S. Environmental Protection Agency prohibits discharge of any refrigerant into the atmosphere, and
requires that refrigerant be recovered using the approved recovery equipment.

IMPORTANT:

Use correct refrigerant recovery, recycling and charging stations. Do not use refrigerant, hoses, fittings,
components or refrigerant oils intended for use with R12 refrigerant.

Recovery, recycling and charging stations for R12 and R134a refrigerants must not be interchanged. Systems
containing R12 refrigerant use a different oil than systems using R134a. Certain seals are not compatible with
both types of refrigerants.

Go to Section_9031:Group_25

MODTX9031QQ2009-19-20040506

1233
 Proper Refrigerant Handling

Proper Refrigerant Handling

The U.S. Environmental Protection Agency prohibits discharge of any refrigerant into the atmosphere, and
requires that refrigerant be recovered using the approved recovery equipment.

IMPORTANT:

Use correct refrigerant recovery, recycling and charging stations. Do not use refrigerant, hoses, fittings,
components or refrigerant oils intended for use with R12 refrigerant.

Recovery, recycling and charging stations for R12 and R134a refrigerants must not be interchanged. Systems
containing R12 refrigerant use a different oil than systems using R134a. Certain seals are not compatible with
both types of refrigerants.

Go to Section_9031:Group_25

MODTX9031QQ2009-19-20040506

1234
 R134a Refrigerant Cautions

R134a Refrigerant Cautions

-: Specifications

SPECIFICATIONS

Maximum Amount To Heat Refrigerant In Closed Container Temperature 52°C

125°F

CAUTION:
Do not allow liquid refrigerant to contact eyes or skin. Liquid refrigerant will freeze eyes or
skin on contact. Wear goggles, gloves and protective clothing.

If liquid refrigerant contacts eyes or skin, do not rub the area. Splash large amounts of
cool water on affected area. Go to a physician or hospital immediately for treatment.

Do not allow refrigerant to contact open flames or very hot surfaces such as electric
welding arc, electric heating element, and lighted smoking materials.

Do not heat refrigerant over 52°C (125°F) in a closed container. Heated refrigerant will
develop high pressure which can burst the container.

Item Measurement Specification

Maximum Amount To Heat Refrigerant In Closed Container Temperature 52°C
125°F

Keep refrigerant containers away from heat sources. Store refrigerant in a cool place.

Do not handle damp refrigerant container with your bare hands. Skin may freeze to
container. Wear gloves.

If skin freezes to container, pour cool water over container to free the skin. Go to a
physician or hospital immediately for treatment.

Go to Section_9031:Group_25

TX,9031,JC1705-19-20120801

1235
 R134a Oil Charge Capacity

R134a Oil Charge Capacity

Item Measurement Specification

System (Total) Capacity 232.2 mL
7.85 fl. oz.
Compressor (Precharge) Capacity 229.8 mL
7.77 fl. oz.

Go to Section_9031:Group_25

TX14826,000009E-19-20120801

1236
 R134a Refrigerant Charge Capacity

R134a Refrigerant Charge Capacity

Item Measurement Specification Item Measurement Specification

Refrigerant Charge Capacity 1.59 kg Refrigerant Charge Capacity 1.47 kg
(Portable Charge 3.5 lb. (Automated Charge 3.25 lb.
Station) Station)

Go to Section_9031:Group_25

TX14826,000009F-19-20120801

1237
 Refrigerant Hoses And Tubing Inspection

Refrigerant Hoses And Tubing Inspection

When a component is disconnected from the system, special care should be given to inspecting hoses and tubing
for moisture, grease, dirt, rust, or other foreign material. If such contamination is present in hoses, tubing, or
fittings and cannot be removed by cleaning, then replace parts.

Fittings that have grease or dirt on them should be wiped clean with a cloth dampened with alcohol. Chlorinated
solvents (such as trichloroethylene) are contaminants, and must not be used for cleaning.

To assist in making leak proof joints, use a small amount of clean correct viscosity refrigerant oil on all hose and
tube connections. Dip O-rings in correct viscosity oil before assembling.

IMPORTANT:

Hose used for air conditioning systems contains special barriers in its walls to prevent migration of refrigerant gas.

Do not use hydraulic hoses as replacement hoses in the air conditioning system. Use only certified hose meeting
SAE J2064 requirements.

Go to Section_9031:Group_25

MODTX9031QQ1882-19-20160229

1238
 R134a Air Conditioning System Test

R134a Air Conditioning System Test

-: Specifications

SPECIFICATIONS

Cab Position Open

Engine rpm 2000 rpm

Temperature Control Switch Position Maximum

Blower Speed High

Run Unit Time At least 5 minutes

-: Essential Tools

ESSENTIAL TOOLS

JT02045 R134a Refrigerant Recovery/Recycling and Charging Station

-: Temperature/Pressure Chart (624J)

Ambient Air Duct Low Pressure Gauge High Pressure Gauge

Temperature Temperature

21.1—26.7°C (70— 8°C (47°F) 68.9—93.1 kPa (0.69—0.93 bar) (10 1110—1386 kPa (11.1—12.9 bar)
80°F) —13 psi) (161—210 psi)

26.7—29.4°C (80— 10.6°C (51°F) 93.1—100 kPa (0.93—1 bar) (13.5— 1358—1476 kPa (13.6—14.8 bar)
85°F) 14.5 psi) (197—214 psi)

29.4—32.2°C (85— 11.1°C (52°F) 96.1—103.4 kPa (0.96—1.03 bar) 1427—1586 kPa (14.3—15.9 bar)
90°F) (14—15 psi) (207—230 psi)

32.2—37.8°C (90— 13.3°C (56°F) 100—131 kPa (1—1.31 bar) (14.5— 1538—2013 kPa (15.4—20.13 bar)
100°F) 19 psi) (223—292 psi)

37.8—43.3°C (100 16.9°C (62.5°F) 135.8—168.9 kPa (1.36—1.69 bar) 1868—2275 kPa (18.7—22.8 bar)
—110°F) (19.7—24.5 psi) (271—330 psi)

43.3—48.9°C (110 22.5°C (72.5°F) 171.7—217.9 kPa (1.72—2.18 bar) 2275—2723 kPa (22.8—27.2 bar)
—120°F) (24.9—31.6 psi) (330-395 psi)

48.9—54.4°C (120 28°C (82.5°F) 217.9—268.9 kPa (2.18—2.69 bar) 2654—3103kPa (25.5—31.0 bar)
—130°F) (31.6—39 psi) (385—450 psi)

NOTE:

JTO2046 and JTO2050 Recovery and Charging Stations can be substituted for the JTO2045
station.

IMPORTANT:

Use correct refrigerant recovery, recycling and charging stations. DO NOT use refrigerant, hoses, fittings,
components or refrigerant oils intended for R12 refrigerant.

1. Connect refrigerant recovery, recycling and charging station. See R134a Refrigerant Recovery,
Recycling and Charging Station Installation Procedure . (Group 1830.)
1239
 R134a Air Conditioning System Test

2. Close both low and high pressure valves on refrigerant recovery, recycling and charging station.

3. Open cab doors and windows. Disconnect hydraulic fan proportional relief solenoid (Y5) and hydraulic
fan reversing solenoid (Y6).

Item Measurement Specification

Cab Position Open

4.

T8118AG-UN: R134a Air Conditioning System Test

LEGEND:
A - High Pressure Hose Charge Port Cap
B - Red Hose (High Pressure)
C - Blue Hose (Low Pressure)
D - High Pressure Relief Valve
E - Refrigerant Recovery/Recycling and Charging System

Start engine and run at rated engine speed.

Item Measurement Specification
Engine Speed 2000 rpm

5. Turn temperature control switch to the maximum cooling position.

1240
 R134a Air Conditioning System Test

Item Measurement Specification

Temperature Control Switch Position Maximum Cooling

6. Turn blower switch to high speed.

Item Measurement Specification

Blower Speed High

7. Check sight glass in receiver-dryer to condenser line.

8. Run unit for at least 5 minutes.

Item Measurement Specification

Run Unit Time At least 5 minutes

9. Measure air temperature at condenser air inlet and at air ducts in air conditioning unit.

10. Compare air duct temperature reading to the temperatures shown in the specifications.

11. Observe low-side pressure (C) and high-side pressure (B) on gauges.

12. Compare pressure readings to the pressure shown in specifications. See Operating Pressure Diagnostic
Chart . (Group 9031-25.)

Go to Section_9031:Group_25

AA95132,0000389-19-20070222

1241
 Operating Pressure Diagnostic Chart

Operating Pressure Diagnostic Chart

NOTE:

Inspection of the sight glass will not give proper indicators of air conditioning concerns on R134a
systems.

-: Operating Pressure Diagnostic Chart

OPERATING PRESSURE DIAGNOSTIC CHART

Low High
Side Side
Pressure Pressure Problem Solution

Low Low or Loss of refrigerant. Leak in system. Do leak test. Add refrigerant. Normal migration
Normal through hoses. Add refrigerant.

Low Low or Loss of refrigerant. Leak in system. Do leak test. Repair leak. Add refrigerant in this
Normal group.

Low Low or Loss of refrigerant. Normal migration through hoses. Add refrigerant in this group
Normal

Low Low or Restriction in system: Inspect for bent, kinked, or dented lines. Feel lines for a temperature
Normal change. Remove refrigerant by recovery method. Inspect and clean
1. Between each component.
compressor
and
condenser.
2. Inside
condenser.
3. Between
condenser
and
receiver-
dryer.
4. Inside
receiver-
dryer.

Low Low or Blower motor running Check for motor shaft binding or defective electrical connections.
Normal too slow.

Low Low or Evaporator core dirty Clean evaporator and straighten fins.
Normal or air flow through
evaporator restricted.

Low Low or Expansion valve Replace expansion valve.

Normal malfunction.

1242
 Operating Pressure Diagnostic Chart

OPERATING PRESSURE DIAGNOSTIC CHART

Low High
Side Side
Pressure Pressure Problem Solution

Low Low or Restriction in system: Inspect for bent, kinked, or dented lines. Feel lines for a temperature
Normal change. Remove refrigerant by recovery method. Inspect and clean
1. Between each component.
receiver-
dryer and
expansion
valve.
2. Between
expansion
valve and
evaporator.
3. Between
evaporator
and
compressor.

Low Low or Moisture in system. Remove refrigerant using recovery method, evacuate and charge the
Normal system. See Recover R134a System See Evacuate R134a System
See Charge R134a System . (Group 1830.)

Low High Restriction in system: Inspect for bent, kinked, or dented lines. Feel lines for a temperature
change. Remove refrigerant by recovery method. Inspect and clean
1. Between each component.
compressor
and
condenser.
2. Inside
condenser.
3. Between
condenser
and
receiver-
dryer.
4. Inside
receiver-
dryer.
5. Between
receiver-
dryer and
expansion
valve.

Normal Normal Heater valve not Close heater shutoff valve on engine block or clamp heater hoses
closing. shut.

Normal Normal Expansion valve Replace expansion valve.

malfunction.

Normal Normal Moisture in system Remove refrigerant using recovery method, evacuate and charge the
(intermittent cooling system. See Recover R134a System See Evacuate R134a System .
below 27°C [80°F] See Charge R134a System . (Group 1830.)
ambient).
1243
 Operating Pressure Diagnostic Chart

OPERATING PRESSURE DIAGNOSTIC CHART

Low High
Side Side
Pressure Pressure Problem Solution

Normal Normal Loss of refrigerant. Leak in system. Do leak test. Repair leak. Add refrigerant.

Normal Normal Loss of refrigerant Normal migration through hoses. Add refrigerant in this group.

Normal Normal Air is system. Remove refrigerant using recovery method, evacuate and charge the
system. See Recover R134a System . See Evacuate R134a System
. See Charge R134a System . (Group 1830.)

Normal High Restricted air flow Inspect for debris. Straighten fins.
through condenser or
radiator.

Normal High Overcharge of Start engine and run at fast idle. Operate air conditioner at maximum
refrigerant. cooling. Remove refrigerant from low-side of system using recovery
operation until bubbles appear in sight glass. Add 0.7 kg (1.5 lb) of
refrigerant through low-side valve.

Normal High Expansion valve Replace expansion valve.

malfunction.

Normal High Restriction in system: Inspect for bent, kinked, or dented lines. Feel lines for a temperature
change. Remove refrigerant by recovery method. Inspect and clean
1. Between each component.
compressor
and
condenser.
2. Inside
condenser.
3. Between
condenser
and
receiver-
dryer.
4. Inside
receiver-
dryer.

1244
 Operating Pressure Diagnostic Chart

OPERATING PRESSURE DIAGNOSTIC CHART

Low High
Side Side
Pressure Pressure Problem Solution

Normal High Restriction in system: Inspect for bent, kinked, or dented lines. Feel lines for a temperature
change. Remove refrigerant by recovery method. Inspect and clean
1. Between each component.
compressor
and
condenser.
2. Inside
condenser.
3. Between
condenser
and
receiver-
dryer.
4. Inside
receiver-
dryer.

High Low Compressor belt Tighten belt.

loose.

High Low Compressor clutch Check for battery voltage at compressor clutch with clutch engaged.
slipping. Clean electrical connections or replace relay.

High Low Compressor clutch Inspect and repair clutch.

slipping.

High Low Compressor failure. Test compressor efficiency. (Group 1830.)

High Normal Expansion valve Replace expansion valve.

malfunction.

High High Restricted air flow Inspect for debris. Straighten fins.
through condenser or
radiator.

High High Expansion valve Replace expansion valve.

malfunction.

High High Overcharge of Start engine and run at fast idle. Operate air conditioner at maximum
refrigerant. cooling. Remove refrigerant from low-side of system using
refrigerant recovery method until bubbles appear in sight glass. Add
0.7 kg (1.5 lb) of refrigerant through low-side valve.

High High Restriction in system: Inspect for bent, kinked, or dented lines. Feel lines for a temperature
change. Remove refrigerant by recovery method. Inspect and clean
each component.

High High Air in system. Remove refrigerant using recovery method, evacuate and charge the
system. See Recover R134a System . See Evacuate R134a System
. See Charge R134a System . (Group 1830.)

1245
 Operating Pressure Diagnostic Chart

OPERATING PRESSURE DIAGNOSTIC CHART

Low High
Side Side
Pressure Pressure Problem Solution

High High Restriction in system: Inspect for bent, kinked, or dented lines. Feel lines for a temperature
change. Remove refrigerant by recovery method. Inspect and clean
1. Between each component.
compressor
and
condenser.
2. Inside
condenser.
3. Between
condenser
and
receiver-
dryer.
4. Inside
receiver-
dryer.

Go to Section_9031:Group_25

CED,OUTX466,1346-19-20120801

1246
 Air Conditioner High/Low Pressure (Binary) Switch Test

Air Conditioner High/Low Pressure (Binary) Switch Test

T8426AD-UN: Pressure Switch

-: Specifications

SPECIFICATIONS

Low Pressure Opening Pressure 138—228 kPa

1.4—2.3 bar
20—33 psi

Low Pressure (Normally Open) Closing Pressure 159—255 kPa

1.6—2.6 bar
23—37 psi

High Pressure Opening Pressure 2620—2895 kPa

26—29 bar
380—420 psi

High Pressure (Normally Closed) Closing Pressure 1379—2068 kPa

13.8—20.7 bar
200—300 psi

-: Essential Tools

ESSENTIAL TOOLS

JT02148 Straight Connector For Switch Testing

-: Service Equipment and Tools

SERVICE EQUIPMENT AND TOOLS

Multimeter

NOTE:

Low pressure switch is normally open when removed from machine. When installed the switch
becomes closed because of normal system pressure.

1247
 Air Conditioner High/Low Pressure (Binary) Switch Test
Turn key switch on but do not start engine. Turn blower switch on. Turn temperature control switch to
the maximum cooling position.
Disconnect and connect low pressure switch at harness connector. Compressor clutch must engage and
disengage (click).

NOTE:

The line that attaches the low pressure switch has a valve to prevent discharging the air
conditioning system when switch is removed.

Disconnect harness from switch and remove switch from line. Connect low pressure switch to harness.
Item Measurement Specification
Low Pressure Opening Pressure 138—228 kPa
1.4—2.3 bar
20—33 psi
Low Pressure (Normally Open) Closing Pressure 159—255 kPa
1.6—2.6 bar
23—37 psi

Compressor clutch must not engage (click).

The actual pressure setting of switch can be checked by connecting it to a pressure source such as a
regulated air supply or dry nitrogen.
Switch must not have continuity between terminals until pressure increases to switch closing pressure
specification. Slowly release pressure. Switch must have continuity until pressure decreases to switch
opening pressure specification.

Connect a portable pressure source, such as dry nitrogen, to switch.

Item Measurement Specification
High Pressure Opening Pressure 2620—2895 kPa
26—29 bar
380—420 psi
High Pressure (Normally Closed) Closing Pressure 1379—2068 kPa
13.8—20.7 bar
200—300 psi
Switch must have continuity between terminals until pressure increases to switch opening pressure
specification.
Slowly release pressure. Switch must not have continuity until pressure decreases to switch closing
pressure specification.
The switch can also be checked when installed in air conditioning system, however, pressure is slow to
increase to test specification.

Connect an air conditioning gauge set to service fittings at compressor. Cover condenser with paper or
plastic to stop air flow. Operate air conditioner on maximum cooling. Note high-side pressure when high
pressure switch opens and then closes.

Go to Section_9031:Group_25

AA95137,00007ED-19-20070214

1248
 Freeze Control Switch Test

Freeze Control Switch Test

T7199EZ-UN: Freeze Control Switch Test

-: Specifications

SPECIFICATIONS

Freeze Control Switch (Normally Closed) Opens As Temperature Drops Opening Temperature -1.4—0.28°C
29.5—32.5°F

Freeze Control Switch (Normally Closed) Closes as Temperature rises Closing Temperature 1.38—3.06°C
34.5—37.5°F

Remove freeze control switch from evaporator.

Connect ohmmeter to switch terminals. Switch must be closed at room temperature.
Put switch into a freezer (temperature must be below -0.56 ± 0.84°C [31 ± 1.5°F]). Switch must open,
and continuity must not be read.
Item Measurement Specification
Freeze Control Switch (Normally Closed) Opens As Temperature Opening -1.4—0.28°C
Drops Temperature 29.5—32.5°F
Remove switch from freezer. Put sensing tube into a glass of warm water. Switch must close, and
continuity must be read.
Item Measurement Specification
Freeze Control Switch (Normally Closed) Closes As Temperature Closing 1.38—3.06°C
Rises Temperature 34.5—37.5°F
If switch does not open and close during testing, install new switch.

Go to Section_9031:Group_25

TX18076,0000016-19-20001114

1249
 Leak Testing

Leak Testing

-: Specifications

SPECIFICATIONS

Move Leak Detector Speed 25 mm per second

1 in. per second

Inspect all lines, fittings, and components for oily or dusty spots. When refrigerant leaks from the system,
a small amount of oil is carried out with it.
A soap and water solution can be sprayed on the components in the system to form bubbles at the
source of the leak.
If a leak detector is used, move the leak detector probe under the hoses and around the connections at a
rate of 25 mm (1 in.) per second.
Item Measurement Specification
Move Leak Detector Speed 25 mm per second
1 in .per second
Some refrigerant manufacturers add dye to refrigerant to aid in leak detection.

Go to Section_9031:Group_25

MODTX9031QQ1881-19-19940819

1250
 tm10293 - 750J Crawler Dozer (S.N. 141344—219962) Technical Manual

tm10293 - 750J Crawler Dozer (S.N. 141344—219962)

Technical Manual

MAIN SECTIONNS

Foreword

Technical Information Feedback Form

General Information
Safety

Diagnostic Trouble Codes (DTC)

CAN Monitor Unit (CMU) Diagnostic Trouble Codes

Engine Control Unit (ECU) Diagnostic Trouble Codes

Transmission Control Unit (TCU) Diagnostic Trouble Codes

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

Blade Control Joystick (BCJ) Diagnostic Trouble Codes

Operational Checkout Procedure

Operational Checkout Procedure

Engine
Theory of Operation

Diagnostic Information

Tests

Electrical System
System Information

System Diagrams

Sub-System Diagnostics

References

1251
tm10293 - 750J Crawler Dozer (S.N. 141344—219962) Technical Manual

Hydraulics
Theory

Diagnostic Information

Tests

Hydrostatic System
Theory of Operation

Diagnostic Information

Tests

Heating and Air Conditioning

Theory of Operation

Diagnostic Information

Tests

1252