Bell - John Deere315sk Training Manual PDF

315SK Backhoe Loader
Diagnostic
OPERATION AND TEST MANUAL
Backhoe Loaders (T3/S3A) models 315SK (PIN: 1T0315SK**D229820-;

1T0315SK**C219607-)
TM12471 27 DEC 15 (ENGLISH)
For complete service information also see:

315SK Backhoe Loader (PIN: 1T0315SK_ _D229820-) (PIN:
TM12472
1T0315SK_ _C219607-)
JDLink (MTG) Technical Manual TM114519
PowerTech E 4.5 and 6.8L Diesel Engines Level 16 Electronic Fuel
CTM502
System With Denso HPCR
PowerTech 4.5L & 6.8L Diesel Engines Level 12 Electronic Fuel
CTM331
System With Stanadyne DE10 Pump
Super Caddy Oil Cleanup Procedure CTM310
120 Series Hydraulic Cylinders CTM120519
PowerTech 4.5L & 6.8L Diesel Engines Tier 1/Stage I, Tier 2/Stage II,
CTM104
Tier 3/Stage IIIA, Tier 3/Stage IIA Tier 3/Stage III, (Base Engine)
COOLANT HEATER SERVICE MANUAL CTM10090X19
John Deere Construction and Forestry

Pinted by Belgreen
315SK Backhoe Loader Diagnostic (g) by Belgreen v2.1
Table of contents
FOREWORD
MANUAL IDENTIFICATION—READ THIS FIRST!
Section 9000 - GENERAL INFORMATION
Group 01 - Safety
Section 9001 - DIAGNOSTICS
Group 10 - Engine Control Unit (ECU) Diagnostic Trouble Codes
Group 20 - Standard Display Monitor (SDM) Diagnostic Trouble Codes
Group 30 - Transmission Control Unit (TCU) Diagnostic Trouble Codes
Group 40 - Vehicle Control Unit (VCU) Diagnostic Trouble Codes
Group 50 - Auxiliary Valve Control (AVC) Diagnostic Trouble Codes
Group 60 - Sealed Switch Module (SSM) Diagnostic Trouble Codes
Section 9005 - OPERATIONAL CHECKOUT PROCEDURE
Group 10 - Operational Checkout Procedure
Section 9010 - ENGINE
Group 05 - Theory of Operation
Group 15 - Diagnostic Information
Group 20 - Adjustments
Group 25 - Tests
Section 9015 - ELECTRICAL SYSTEM
Group 05 - System Information
Group 10 - System Diagrams
Group 15 - Sub-System Diagnostics
Group 16 - Monitor Operation
Group 20 - References
Section 9020 - POWER TRAIN
Group 25 - Tests
Section 9025 - HYDRAULIC SYSTEM
Group 25 - Tests
Section 9031 - HEATING AND AIR CONDITIONING
Group 25 - Tests
<- Go to Global Table of contents 315SK Backhoe Loader Diagnostic

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.
CAUTION:
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 failures quickly.
Information is organized in groups for the various components requiring service instruction. At the beginning of each group are
summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service
parts kits, specifications, wear tolerances, and torque values.
Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information
needed for diagnosis, analysis, testing, and repair.
Fundamental service information is available from other sources covering basic theory of operation, fundamentals of
troubleshooting, general maintenance, and basic type of failures and their causes.

Manual Identification—READ THIS FIRST!

IMPORTANT:
Use only supporting manuals designated for your specific machine. If incorrect manual is chosen,
improper service may occur. Verify product identification number (PIN) when choosing the correct
manual.
Choosing the Correct Supporting Manuals

John Deere backhoe loaders are available in different machine configurations based on the various markets into which they are
sold. Different supporting manuals exist for different machine configurations.
When necessary, product identification numbers are listed on the front covers of backhoe loader manuals. These numbers are
used to identify the correct supporting manual for your machine.
Product Identification Number
PIN Plate Location
Example of PIN Plate

LEGEND:
1 PIN Plate
2 17 Digit PIN
The product identification number (PIN) plate (1) is located on the left-side of machine on the loader frame. Each machine has
a 17 digit PIN (2) shown on PIN plate.

GENERAL INFORMATION (g) by Belgreen v2.0
The PIN identifies the producing factory, machine model number, machine option, year of manufacture, engine emission level,
and machine serial number.
PIN Identification Table
17 Digit PIN Example
(3) (4) (5) (4) (6) (7) (8) (9)
1 T 0 3 1 5 S K C 2 1 9 6 0 7
(3)—World Code —Identifies location where machine is manufactured.

(4)—Machine Model Identifier —Identifies model number.
(5)—Machine Option Code —Identifies which major machine option is equipped. This digit will change from one
machine to another.
(6)—Check Letter —This is a random character assigned by the factory. This is not used in machine identification.
(7)—Manufacturing Year Code —Identifies year of machine manufacture.
(8)—Engine Emission Code —Represents engine emission certification.
(9)—Machine Serial Number —Identifies machine serial number. This digit will change from one machine to another.
The following is an example for a 315SK machine that meets Tier 2 and Stage II emission levels:
PIN Identification
1T0315SK_ _C219607
1T0 .......... World Code (manufacturing location)
1DW .......... Davenport Works
1T8 .......... Thibodaux Works
1T0 .......... Dubuque Works
315_K .......... Machine Model Identifier
S .......... Machine Option Code
X .......... Base Machine
S .......... Super Duty
E .......... Easy Power (EP)
T .......... Total Machine Control (TMC) Configuration
_ .......... Check Letter (variable)
_ .......... Manufacturing Year Code (variable)
C .......... 2012
D .......... 2013
E .......... 2014
F .......... 2015
G .......... 2016
C .......... Engine Emission Code
C .......... Tier 2 and Stage II
D .......... Tier 3 and Stage III A
E .......... Interim Tier 4 and Stage III B
F .......... Tier 4
G .......... Interim Tier 4 and Stage III A (19-56 kW)
219607 .......... Machine Serial Number
<- Go to Section TOC Section 9000 page 2 315SK Backhoe Loader Diagnostic
Section 9000 - GENERAL INFORMATION

Table of contents
Group 01 - Safety ..................................................................................................................................... 1
Recognize Safety Information ............................................................................................................... 1
Follow Safety Instructions ..................................................................................................................... 1
Operate Only If Qualified ...................................................................................................................... 2
Wear Protective Equipment .................................................................................................................. 3
Avoid Unauthorized Machine Modifications .......................................................................................... 3
Inspect Machine ................................................................................................................................... 3
Stay Clear of Moving Parts ................................................................................................................... 4
Avoid High-Pressure Oils ...................................................................................................................... 4
Avoid High-Pressure Fluids ................................................................................................................... 5
Work In Ventilated Area ........................................................................................................................ 5
Prevent Fires ........................................................................................................................................ 6
Prevent Battery Explosions ................................................................................................................... 7
Handle Chemical Products Safely ......................................................................................................... 7
Decommissioning: Proper Recycling and Disposal of Fluids and Components ..................................... 7
Prepare for Emergencies ...................................................................................................................... 8
Use Steps and Handholds Correctly ..................................................................................................... 9
Start Only From Operator′s Seat ........................................................................................................... 9
Use and Maintain Seat Belt .................................................................................................................. 9
Prevent Unintended Machine Movement .............................................................................................. 9
Prevent Unintended Machine Movement—If Equipped With Pilot Controls ......................................... 10
Avoid Work Site Hazards .................................................................................................................... 10
Keep Riders Off Machine .................................................................................................................... 11
Avoid Backover Accidents .................................................................................................................. 12
Avoid Machine Tipover ....................................................................................................................... 13
Add and Operate Attachments Safely ................................................................................................ 13
Use Special Care When Operating ...................................................................................................... 13
Operating or Traveling On Public Roads ............................................................................................. 14
Inspect and Maintain ROPS ................................................................................................................. 15
Park and Prepare for Service Safely ................................................................................................... 15
Service Cooling System Safely ........................................................................................................... 16
Remove Paint Before Welding or Heating ........................................................................................... 16
Make Welding Repairs Safely ............................................................................................................. 17
Drive Metal Pins Safely ....................................................................................................................... 17
Service Tires Safely ............................................................................................................................ 18

Section 9000 - GENERAL INFORMATION Group 01: Safety
Group 01 - Safety
Recognize Safety Information
Safety alert Symbols
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.
Follow Safety Instructions
Safety Messages
Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition.
Replace missing or damaged safety signs. Use this operator’s manual for correct safety sign placement. Be sure that new
equipment components and repair parts include the current safety signs. Replacement safety signs are available from your
John Deere dealer.
There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in
this operator′s manual.
Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction.
Keep your machine in proper working condition. Unauthorized modifications to the machine could impair the function or safety
and affect machine life.
If you do not understand any part of this manual and need assistance, contact your John Deere dealer.
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.
Wear Protective Equipment
Protective Clothing
Guard against injury from flying pieces or metal or debris; wear goggles or safety glasses.
Wear close fitting clothing and safety equipment appropriate to the job.
Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating
machine.
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. Radio or music headphones are not suitable to use
for hearing protection.
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 malfunctions 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 dealer before making machine modifications that change the intended use, weight or balance of
the machine, or that alter machine controls, performance, or reliability.
Inspect Machine
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.
Stay Clear of Moving Parts
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.
Avoid High-Pressure Oils
Avoid High Pressure Oils
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 could result. Contact a knowledgeable medical source or the Deere & Company Medical Department in
Moline, Illinois, U.S.A.
Avoid High-Pressure Fluids
High Pressure
Inspect hydraulic hoses periodically – at least once per year – for leakage, kinking, cuts, cracks, abrasion, blisters, corrosion,
exposed wire braid or any other signs of wear or damage.
Replace worn or damaged hose assemblies immediately with John Deere approved replacement parts.
Escaping fluid under pressure can penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying
pressure.
Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours
or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such
information is available in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling
1-800-822-8262 or +1 309-748-5636.
Work In Ventilated Area
Engine exhaust fumes
Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust
fumes from the area with an exhaust pipe extension.
If you do not have an exhaust pipe extension, open the doors and get outside air into the area.
Prevent Fires
Handle Fuel Safely
Clean Machine Regularly
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 multipurpose fire extinguisher on or near the machine. Know how to use
extinguisher properly.
Prevent Battery Explosions
Battery Explosions
Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.
Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).
Handle Chemical Products Safely
Material Safety Data Sheet
Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere
equipment include such items as lubricants, coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety
procedures, and emergency response techniques.
Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and
how to do the job safely. Then follow procedures and recommended equipment.
(See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment.)
Decommissioning: Proper Recycling and Disposal of Fluids and

Components
Recycle Waste
Safety and environmental stewardship measures must be taken into account when decommissioning a machine and/or
component. These measures include the following:
Use appropriate tools and personal protective equipment such as clothing, gloves, face shields or glasses, during the
removal or handling of objects and materials.
Follow instructions for specialized components.
Release stored energy by lowering suspended machine elements, relaxing springs, disconnecting the battery or other
electrical power, and releasing pressure in hydraulic components, accumulators, and other similar systems.
Minimize exposure to components which may have residue from agricultural chemicals, such as fertilizers and pesticides.
Handle and dispose of these components appropriately.
Carefully drain engines, fuel tanks, radiators, hydraulic cylinders, reservoirs, and lines before recycling components. Use
leak-proof containers when draining fluids. Do not use food or beverage containers.
Do not pour waste fluids onto the ground, down a drain, or into any water source.
Observe all national, state, and local laws, regulations, or ordinances governing the handling or disposal of waste fluids
(example: oil, fuel, coolant, brake fluid); filters; batteries; and, other substances or parts. Burning of flammable fluids or
components in other than specially designed incinerators may be prohibited by law and could result in exposure to
harmful fumes or ashes.
Service and dispose of air conditioning systems appropriately. Government regulations may require a certified service
center to recover and recycle air conditioning refrigerants which could damage the atmosphere if allowed to escape.
Evaluate recycling options for tires, metal, plastic, glass, rubber, and electronic components which may be recyclable, in
part or completely.
Contact your local environmental or recycling center, or your John Deere dealer for information on the proper way to
recycle or dispose of waste.
Prepare for Emergencies
First Aid Kit
Be prepared if 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.
Use Steps and Handholds Correctly
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.
Start Only From Operator′s Seat
Operate Only From Operators Seat
Avoid unexpected machine movement. Start engine only while sitting in operator′s seat. Ensure that 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.
Use and Maintain Seat Belt
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 that 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.
Prevent Unintended Machine Movement

LEGEND:
1 Park Brake Switch
SSM
Always press park brake switch (1) on the sealed switch module (SSM) to engage park brake before leaving the
operator′s seat for any reason .
Be careful not to accidentally actuate steering, travel or other controls. Engage park brake and lower work equipment to the
ground during work interruptions. Stop the engine before allowing anyone to approach the machine. Follow proper parking
procedures before leaving the operator′s station.
Prevent Unintended Machine Movement—If Equipped With Pilot

Controls
Pilot Enable Switch
Be careful not to accidentally actuate control levers when co-workers are present. Always lock hydraulics on backhoe during
work interruptions. Lock hydraulics before allowing anyone to approach machine.
Avoid Work Site Hazards
Avoid contact with gas lines
Avoid collapsing banks
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 any part of
machine or load 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 over-hanging embankments or stockpiles that could collapse 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) can cause a sudden
stop. Always wear your seat belt.
Keep Riders Off Machine
Keep Riders Off
Only allow the operator on the machine. Keep riders off.

Riders on machine are subject to injury such as being struck by foreign objects and being thrown off of the machine. Riders
also obstruct the operator’s view resulting in the machine being operated in an unsafe manner.
Avoid Backover Accidents
Avoid Backover Accidents
Before moving machine, be sure that all persons are clear of machine path. Turn around and look directly for best
visibility. Use mirrors to assist in checking all around machine. Keep windows and mirrors clean, adjusted, and in good repair.
Be certain reverse 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.
Do not rely on the rear camera and radar object detection systems to determine if personnel are behind the machine. The
system has limitations due to maintenance practices, environmental conditions, and operating range.
Avoid Machine Tipover
Avoid Machine Tipover
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.
Be careful on slopes. Use extra care on soft, rocky or frozen ground because machine may slip sideways in these conditions.
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.
Add and Operate Attachments Safely

Always verify compatibility of attachments by contacting your authorized dealer. Adding unapproved attachments could affect
machine stability or reliability and could 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.
Use Special Care When Operating
Man Falling From Bucket
Tipover
Never use the loader to lift people. Do not allow anyone to ride in the bucket or use the bucket as a work platform.
Operate carefully with raised loads. Raising the load reduces machine stability, especially on side slopes on soft terrain.
Drive and turn slowly with a raised load.
Ensure that objects in the bucket are secure. Do not attempt to lift or carry objects that are too big or too long to fit
inside the bucket unless secured with an adequate chain or other device. Keep bystanders away from raised loads.
Be careful when lifting objects. Never attempt to lift objects too heavy for your machine. Assure machine stability and
hydraulic capability with a test lift before attempting other maneuvers. Use an adequate chain or sling and proper rigging
techniques to attach and stabilize loads.
Never lift an object above or near another person.
Operating or Traveling On Public Roads
Operating or Traveling On Public Roads
Machines that work near vehicle traffic or travel slower than normal highway speeds must have proper lighting and markings to
assure they are visible to other drivers.

Install additional lights, beacon lights, slow moving vehicle (SMV) emblems, or other devices and use as required to make the
machine visible and identify it as a work machine. Check state and local regulations to assure compliance. Keep these devices
clean and in working condition.
Inspect and Maintain ROPS

A damaged rollover protective structure (ROPS) should be replaced, not reused.
The protection offered by ROPS could be impaired if ROPS is subjected to structural damage, is involved in an overturn
incident, or is in any way altered by welding, bending, drilling, or cutting.
If ROPS was loosened or removed for any reason, inspect it carefully before operating the machine again.
To maintain the ROPS:
Replace missing hardware using correct grade hardware.

Check hardware torque.
Check isolation mounts for damage, looseness, or wear; replace them if necessary.
Check ROPS for cracks or physical damage.
Park and Prepare for Service Safely
Do Not Operate Tag
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 equipment to the ground.

Engage park brake.
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 any hydraulically actuated tools 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.
Always install boom lock before working on or around this machine with the loader boom raised.
Understand service procedures before beginning repairs. Keep service area clean and dry. Use two people whenever the
engine must be running for service work.
Service Cooling System Safely
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.
Remove Paint Before Welding or Heating
Toxic Fumes
Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.
Remove paint before heating:
Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an
approved respirator before heating or welding.
If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.
If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper
containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or
heating.
Do not use a chlorinated solvent in areas where welding will take place.
Do all work in an area that is well ventilated to carry toxic fumes and dust away.
Dispose of paint and solvent properly.
Make Welding Repairs Safely
Heating Near Pressurized Fluid Lines
IMPORTANT:
Disable electrical power before welding. Turn off main battery switch and disconnect positive (+) and
negative (-) battery cables.
Do not weld or apply heat on any part of a reservoir or tank that has contained oil or fuel. Heat from welding and cutting can
cause oil, fuel, or cleaning solution to create gases which are explosive, flammable, or toxic.
Avoid welding or heating near pressurized fluid lines. Flammable spray may result and cause severe burns if pressurized lines
malfunction 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.
Drive Metal Pins Safely
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 could dislodge chips at high velocity.
Use a soft hammer or a brass bar between hammer and object to prevent chipping.
DIAGNOSTICS (g) by Belgreen v2.0
Service Tires Safely
Explosive Tire and Rim Parts
Explosive separation of a tire and rim parts can cause serious injury or death.
Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a
wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally
weaken or deform the wheel.
When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of
or over the tire assembly. Use a safety cage if available.
Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.
Section 9001 - DIAGNOSTICS

Table of contents
Group 10 - Engine Control Unit (ECU) Diagnostic Trouble Codes .................................................... 1
Engine Control Unit (ECU) Diagnostic Trouble Codes ........................................................................... 1
Engine Speed Control Short Circuit Diagnostic Procedure .................................................................... 2
Engine Speed Control Open Circuit Diagnostic Procedure .................................................................... 4
Engine Speed Control Out of Range Diagnostic Procedure ................................................................... 5
Engine Speed Control Pedal Short Circuit Diagnostic Procedure .......................................................... 7
Engine Speed Control Pedal Open Circuit Diagnostic Procedure .......................................................... 9
Engine Speed Control Pedal Out of Range Diagnostic Procedure ....................................................... 10
Air Filter Restriction Switch Malfunction Diagnostic Procedure .......................................................... 12
Engine Overspeed Severely High Diagnostic Procedure ..................................................................... 14
Engine Overspeed Moderately High Diagnostic Procedure ................................................................. 14
Invalid VIN Diagnostic Procedure ........................................................................................................ 16
Memory Error Diagnostic Procedure ................................................................................................... 16
Fuel Lift Pump Relay Diagnostic Procedure ........................................................................................ 18
Fuel Lift Pump Relay is Above Normal Operating Voltage Diagnostic Procedure ................................ 21
Starter Relay Open Circuit Diagnostic Procedure ............................................................................... 23
Starter Relay Short Circuit Diagnostic Procedure ............................................................................... 25
Power Shutdown Check ...................................................................................................................... 26
Controller Area Network (CAN) Communication Lost For Vehicle Control Unit (VCU) Diagnostic
Procedure .................................................................................................................................... 27
Can Communication Lost with VCU Diagnostic Procedure .................................................................. 28
Procedure .................................................................................................................................... 29
Procedure .................................................................................................................................... 29
Group 20 - Standard Display Monitor (SDM) Diagnostic Trouble Codes ....................................... 31
Standard Display Monitor (SDM) Diagnostic Trouble Codes ............................................................... 31
Fuel Level Sensor Open or Short Diagnostic Procedure ...................................................................... 32
Fuel Level Sensor Short to Ground Diagnostic Procedure ................................................................... 35
Battery Voltage Diagnostic Procedure ................................................................................................ 36
Battery Voltage Diagnostic Procedure ................................................................................................ 38
Software Revision Mismatch Diagnostic Procedure ............................................................................ 40
VIN Mismatch Diagnostic Procedure ................................................................................................... 40
VIN Missing Diagnostic Procedure ...................................................................................................... 41
VIN Missing Diagnostic Procedure ...................................................................................................... 42
Memory Error Diagnostic Procedure ................................................................................................... 43
000629.12 - Controller Fault ............................................................................................................... 43
Monitor Alarm Output Voltage Low Diagnostic Procedure .................................................................. 44
NO CAN From ECU Diagnostic Procedure ........................................................................................... 45
No CAN From ECU Diagnostic Procedure—Tier 3 Engine .................................................................... 47
NO CAN From TCU Diagnostic Procedure ........................................................................................... 54
NO CAN From VCU Diagnostic Procedure ........................................................................................... 54
NO CAN From SSM Diagnostic Procedure ........................................................................................... 55
NO CAN From HVC Diagnostic Procedure ........................................................................................... 56
NO CAN From MTG Diagnostic Procedure ........................................................................................... 57
Fuel Level Sensor Open or Short Diagnostic Procedure ...................................................................... 58
Fuel Level Sensor Short to Ground Diagnostic Procedure ................................................................... 61
Monitor Button Stuck Diagnostic Procedure ....................................................................................... 62
Group 30 - Transmission Control Unit (TCU) Diagnostic Trouble Codes ....................................... 64
Transmission Control Unit (TCU) Diagnostic Trouble Codes ............................................................... 64

Park Brake Diagnostic Procedure ....................................................................................................... 65

Trans Oil Temp Diagnostics Procedure ............................................................................................... 67
Trans Oil Temp Diagnostic Procedure ................................................................................................. 68
Transmission Speed Diagnostic Procedure ......................................................................................... 69
Requested Gear Diagnostic Procedure ............................................................................................... 76
TCL Neutral SW Diagnostic Procedure ................................................................................................ 84
Park Brake Circuit Diagnostic Procedure ............................................................................................ 86
Park Brake Circuit Diagnostic Procedure ............................................................................................ 89
000629.12 - Controller Fault ............................................................................................................... 91
Y1 Solenoid Diagnostic Procedure ...................................................................................................... 92
Y2 Solenoid Diagnostic Procedure .................................................................................................... 100
Differential Lock Diagnostic Procedure ............................................................................................. 132
Requested Gear Diagnostic Procedure ............................................................................................. 139
Brake Lights Diagnostic Procedure ................................................................................................... 141
Brake Light Switch Diagnostic Procedure ......................................................................................... 149
No CAN From ECU Diagnostic Procedure—Tier 3 Engine .................................................................. 151
NO CAN From SDM Diagnostic Procedure ......................................................................................... 158
No CAN From AVC Diagnostic Procedure .......................................................................................... 158
No CAN From ECU Diagnostic Procedure .......................................................................................... 159
NO CAN From JSR Diagnostic Procedure ........................................................................................... 160
Backup Lights Diagnostic Procedure ................................................................................................ 163
Backup Lights Diagnostic Procedure ................................................................................................ 165

MFWD Solenoid Diagnostic Procedure .............................................................................................. 167

MWFD Solenoid Diagnostic Procedure .............................................................................................. 169
MFWD Solenoid Diagnostic Procedure .............................................................................................. 171
TCL Selector Diagnostic Procedure ................................................................................................... 173
Park Brake Diagnostic Procedure ..................................................................................................... 181
Reverse Alarm Diagnostic Procedure ............................................................................................... 190
Reverse Alarm Diagnostic Procedure ............................................................................................... 192
Park Brake Pressure Switch Diagnostic Procedure ........................................................................... 194
Diff Lock Switch Diagnostic Procedure ............................................................................................. 196
Diff Lock Switch Diagnostic Procedure ............................................................................................. 198
Flexpower Diagnostic Procedure ...................................................................................................... 199
MFWD Switch Diagnostic Procedure ................................................................................................. 202
Clutch Disconnect Diagnostic Procedure .......................................................................................... 204
Group 40 - Vehicle Control Unit (VCU) Diagnostic Trouble Codes ............................................... 211
Vehicle Control Unit (VCU) Diagnostic Trouble Codes ...................................................................... 211
Battery Voltage Diagnostic Procedure .............................................................................................. 211
Software Incorrect Diagnostic Procedure ......................................................................................... 215
VIN Mismatch Diagnostic Procedure ................................................................................................. 215
VIN Missing Diagnostic Procedure .................................................................................................... 216
Memory Error Diagnostic Procedure ................................................................................................. 217
Controller Fault Diagnostic Procedure .............................................................................................. 218
Starter Relay Diagnostic Procedure .................................................................................................. 219
Starter Relay Open Circuit Diagnostic Procedure ............................................................................. 221
Engine Shutdown Diagnostic Procedure ........................................................................................... 224
Hydraulic Temperature Sensor Diagnostic Procedure ...................................................................... 228
Hydraulic Oil Restriction Diagnostic Procedure ................................................................................ 233
Hydraulic Pressure Diagnostic Procedure ......................................................................................... 235
No CAN from SSM Diagnostic Procedure .......................................................................................... 244
No CAN from SSM Diagnostic Procedure .......................................................................................... 246
No CAN from HVC Diagnostic Procedure .......................................................................................... 248
EH Watchdog Diagnostic Procedure ................................................................................................. 250
Drive Lights Diagnostic Procedure .................................................................................................... 251


Front Work Lights Diagnostic Procedure ........................................................................................... 258
Rear Work Lights Diagnostic Procedure ............................................................................................ 273
Side Work Lights Diagnostic Procedure ............................................................................................ 289
Side Work Lights Diagnostic Procedure ............................................................................................ 292
Left Flasher Diagnostic Procedure .................................................................................................... 294
Right Flasher Diagnostic Procedure .................................................................................................. 301
Marker Light Diagnostic Procedure ................................................................................................... 308
EH Horn Diagnostic Procedure .......................................................................................................... 317
Hazard Wakeup Diagnostic Procedure .............................................................................................. 323
Turn Signal Switch Diagnostic Procedure ......................................................................................... 325
Right Door Switch Diagnostic Procedure .......................................................................................... 327
Right Door Switch Diagnostic Procedure .......................................................................................... 329
Sensor Supply 1 Diagnostic Procedure ............................................................................................. 331
Accessory Relay Diagnostic Procedure ............................................................................................. 343
Valve Power Diagnostic Procedure ................................................................................................... 349
Pilot Enable Switch Diagnostic Procedure ......................................................................................... 355
Pilot Enable Switch Diagnostic Procedure ......................................................................................... 357
Pilot Enable Driver Diagnostic Procedure ......................................................................................... 361
Pattern Select Driver Diagnostic Procedure ...................................................................................... 367

Loader Coupler Press Diagnostic Procedure ..................................................................................... 374

HVC Valve Power Diagnostic procedure ........................................................................................... 380
HVC Valve Power Diagnostic procedure ........................................................................................... 382
Seat Position Diagnostic Procedure .................................................................................................. 384
Bucket Level Indicator Diagnostic Procedure ................................................................................... 397
Rear Wiper Park Diagnostic Procedure ............................................................................................. 399
Rear Wiper Park Diagnostic Procedure ............................................................................................. 401
Front Wiper Park Diagnostic Procedure ............................................................................................ 403
Front Wiper Park Diagnostic Procedure ............................................................................................ 405
Rear Wiper Diagnostic Procedure ..................................................................................................... 407
Front Wiper Low Diagnostic Procedure ............................................................................................. 413
Front Wiper Hi Diagnostic Procedure ................................................................................................ 419
Front Wiper High Speed Diagnostic Procedure ................................................................................. 421
Front Wiper High Speed Diagnostic Procedure ................................................................................. 422
Loader Coupler Diagnostic Procedure .............................................................................................. 424
Front Washer Pump Diagnostic Procedure ....................................................................................... 430
Beacon Light Driver Diagnostic Procedure ....................................................................................... 436
Pump Control Diagnostic Procedure ................................................................................................. 442
Hydraulic Pump Control Diagnostic Procedure ................................................................................. 448
Ride Control Diagnostic Procedure ................................................................................................... 452
Group 50 - Auxiliary Valve Control (AVC) Diagnostic Trouble Codes .......................................... 458
Auxiliary Valve Controller (AVC) Diagnostic Trouble Codes .............................................................. 458
Software Incorrect Diagnostic Procedure ......................................................................................... 463
000629.12 - Controller Fault ............................................................................................................. 467
Loader Auxiliary Roller Diagnostic Procedure ................................................................................... 468


Left Joystick Diagnostic Procedure ................................................................................................... 475
CAN Bus Diagnostic Procedure ......................................................................................................... 481
CAN Bus Diagnostic Procedure ......................................................................................................... 482
Loader Auxiliary Pressure Drop Diagnostic Procedure ...................................................................... 483
Loader Auxiliary Pressure Drop Diagnostic Procedure ...................................................................... 485
Valve Power 2 Diagnostic Procedure ................................................................................................ 488
Loader Auxiliary Solenoid Diagnostic Procedure .............................................................................. 494
Selective Flow Diagnostic Procedure ................................................................................................ 510
524204.03 - Loader Aux Switch ........................................................................................................ 517
524204.05 - Loader Aux Switch ........................................................................................................ 518
Group 60 - Sealed Switch Module (SSM) Diagnostic Trouble Codes ........................................... 519
Sealed Switch Module (SSM) Diagnostic Trouble Codes ................................................................... 519
Watchdog Timeout Diagnostic Procedure ......................................................................................... 519
Ignition Relay Out Voltage Low Diagnostic Procedure ...................................................................... 520
Ignition Relay Out Current Low Diagnostic Procedure ...................................................................... 522
Switch Stuck Diagnostic Procedure .................................................................................................. 523
No LED Response Diagnostic Procedure ........................................................................................... 523



Section 9001 - DIAGNOSTICS Group 10: Engine Control Unit (ECU) Diagnostic Trouble Codes
Group 10 - 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 002047.09 , 002047 is the SPN and 09 is the FMI number.
Diagnostic trouble codes can be displayed using the standard display monitor (SDM) or by using Service ADVISOR ™ .
See Standard Display Monitor (SDM)—Main Menu—Diagnostics—Codes . (Operator′s Manual.)
See Reading Diagnostic Trouble Codes (DTCs) . (Group 9015-20.)
Note: For in-depth diagnostics on all ECU diagnostic trouble codes, see specific code diagnostic procedure in this group.
000029.03- Hand Throttle

17
Engine speed control dial (B21) is above normal operating voltage.
Alarm Level:
Amber Check Service Code Indicator
Additional References: See Engine Control Unit (ECU) Circuit Theory of Operation . (Group 9015-15.)
Engine Speed Control Short Circuit Diagnostic Procedure

( 1 ) Intermittent Check
Action:
Does diagnostic trouble code (DTC) periodically “go away”?
Result:
YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.)
NO:Go to Connector Check.
( 2 ) Connector Check
Action:
Switched power OFF.

Check the following connectors for damage, corrosion, or debris. Use JDG10466 Flex Probe Kit to check for pin fit and
continuity.
Engine speed control dial (B21). See Cab Harness (W14) Component Location or see Canopy Harness (W15) Component
Location . (Group 9015-15.)
Engine harness-to-cab/canopy harness connector (X20). See Cab Harness (W14) Component Location or see Canopy
Harness (W15) Component Location . (Group 9015-15.)
ECU 48-pin connector (X42). See Engine Harness (W10) Component Location . (Group 9015-15.) Are connectors in good
condition and free of corrosion and debris?
Result:
YES:Go to Component Check.

NO:Repair or replace connector.
( 3 ) Component Check
Action:
Switched power OFF.

Disconnect engine speed control dial (B21).
Measure resistance between pins A and B on speed control dial (B21).
Does resistance meet specification? See Electrical Component Specifications . (Group 9015-20.)
Result:
YES:Go to Voltage Check.

NO:Engine speed control dial (B21) malfunction. Replace engine speed control dial.
( 4 ) Voltage Check
Action:
Switched power OFF.

Engine speed control dial (B21) disconnected.
Switched power ON.
Check for voltage at:
Pin A wire R051 BLK of engine speed dial connector for 0.0 V.
Pin B wire E021 WHT of engine speed dial connector for 0.0 V.
Pin C wire P051 RED of engine speed dial connector for 5 V.
Is correct voltage indicated?
Result:
YES:Go to Short to Power Check.

NO:Repair or replace harness. See appropriate wiring diagram or schematic.
( 5 ) Short to Power Check
Action:
Switched power OFF.

Disconnect engine speed control pedal (B20).
Disconnect ECU 48-pin connector (X42).
Switched power ON.
Pin A wire R051 BLK of engine speed dial connector for 0.0 V.
Pin B wire E021 WHT of engine speed dial connector for 0.0 V.
Pin C wire P051 RED of engine speed dial connector for 0.0 V.
Is voltage indicated?
Result:
YES:Repair or replace harness. See appropriate wiring diagram or schematic.

NO:Go to Harness Check.
( 6 ) Harness Check
Action:
Switched power OFF.

Engine speed control pedal (B20) disconnected.
ECU 48-pin connector (X42) disconnected.
Disconnect the following connectors:
Disconnect engine harness to cab/canopy harness connector (X20).

Check for continuity between:
Pin A3 wire P051 RED of ECU 48-pin connector and all other pins on ECU connectors (X41 and X42).
Pin C3 wire R051 BLK of ECU 48-pin connector and all other pins on ECU connectors (X41 and X42).
Pin F3 wire E021 WHT of ECU 48-pin connector and all other pins on ECU connectors (X41 and X42).
Is continuity indicated?
Result:

NO:Program ECU.

17
Engine speed control dial (B21) circuit is open.
Alarm Level:
Engine Speed Control Open Circuit Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Engine speed control dial (B21). See Cab Harness (W14) Component Location or see Canopy Harness (W15) Component
Result:

Action:
Switched power OFF.

Measure resistance between pins A and B on speed control dial (B21).
Does resistance meet specification? See Electrical Component Specifications . (Group 9015-20.)
Result:

NO:Engine speed control dial (B21) malfunction. Replace engine speed control dial.
( 4 ) Voltage Check
Action:
Switched power OFF.

Switched power ON.
Check pin C wire P051 RED of engine speed control dial (B21) connector for 5 V.
Result:
YES:Go to Continuity Check.

( 5 ) Continuity Check
Action:
Switched power OFF.

Pin A wire R051 BLK of engine speed dial connector and pin C3 of ECU 48-pin connector (X42).
Pin B wire E021 WHT of engine speed dial connector and pin F3 of ECU 48-pin connector (X42).
Result:
YES:Go to Short to Ground Check.

( 6 ) Short to Ground Check
Action:
Switched power OFF.

Check for continuity between pin B wire E021 WHT and machine ground.
Result:

NO:Program ECU.
17
Engine speed control dial is out of range high or low.
Alarm Level:
Engine Speed Control Out of Range Diagnostic Procedure

( 1 ) Engine Speed Control Dial (B21) Reset
Action:
Switched power ON.

Reset the engine speed control dial (B21) by:
Turning switch to the minimum throttle value and then back to full throttle value.
Setting throttle to mid-position and turning ignition switch OFF for 60 seconds and then back ON.
Is ECU code 000029.14 present?
Result:
YES:Go to Code Check.

NO:Checks complete.
( 2 ) Code Check
Action:
Check for active diagnostic trouble codes. See Reading Diagnostic Trouble Codes (DTCs) . (Group 9015-20.)
Check for the following engine control unit (ECU) codes: 000029.03—Hand Throttle or 000029.04—Hand Throttle.
Are either of these codes active?
Result:
YES:Correct active ECU codes first. See 000029.03—Hand Throttle or see 000029.04—Hand Throttle . (Group 9001-10.)
NO:Program ECU.
000091.03- Foot Throttle

17
Engine speed control pedal (B20) is out of range high.
Alarm Level:
Engine Speed Control Pedal Short Circuit Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Engine speed control pedal connector (B20). See Cab Harness (W14) Component Location or see Canopy Harness (W15)
Component Location . (Group 9015-15.)
Result:

Action:
Test engine speed control pedal (B20). See Engine Speed Control Pedal Test . (Group 9015-20.)
Result:

NO:Engine speed control pedal (B20) malfunction. Replace engine speed control pedal.
( 4 ) Voltage Check
Action:
Switched power OFF.

Switched power ON.
Pin A wire E020 WHT of engine speed control pedal connector for 0.0 V.
Pin B wire R051 BLK of engine speed control pedal connector for 0.0 V.
Pin C wire P051 RED of engine speed control pedal connector for 5 V.
Result:

Action:
Switched power OFF.

Switched power ON.
Pin A wire E020 WHT of engine speed control pedal connector for 0.0 V.
Pin B wire R051 BLK of engine speed control pedal connector for 0.0 V.
Pin C wire P051 RED of engine speed control pedal connector for 0.0 V.
Result:
YES:Go to Harness Check.

( 6 ) Harness Check
Action:
Switched power OFF.

Disconnect engine harness to cab/canopy harness connector (X20).

Pin A3 wire P051 RED of ECU 48-pin connector and all other pins on ECU connectors (X41 and X42).
Pin A4 wire E021 WHT of ECU 48-pin connector and all other pins on ECU connectors (X41 and X42).
Pin C3 wire R051 BLK of ECU 48-pin connector and all other pins on ECU connectors (X41 and X42).
Result:

NO:Program ECU.

17
Engine speed control pedal (B20) circuit is open.
Alarm Level:
Engine Speed Control Pedal Open Circuit Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Engine speed control pedal (B20). See Cab Harness (W14) Component Location or see Canopy Harness (W15) Component
Result:

Action:
Test engine speed control pedal (B20). See Engine Speed Control Pedal Test . (Group 9015-20.)
Result:

NO:Engine speed control pedal (B20) malfunction. Replace engine speed control pedal.
( 4 ) Voltage Check
Action:
Switched power OFF.

Switched power ON.
Check pin C wire P051 RED of engine speed control pedal (B20) connector for 5 V.
Result:

Action:
Switched power OFF.

Pin A wire R051 BLK of engine speed dial connector and pin C3 of ECU 48-pin connector (X42).
Pin B wire E020 WHT of engine speed dial connector and pin A4 of ECU 48-pin connector (X42).
Result:

Action:
Switched power OFF.

Check for continuity between pin B wire E020 WHT and machine ground.
Result:

NO:Program ECU.
17
Engine speed control pedal (B20) is out of range high or low.
Alarm Level:
No Warning Lamp
Engine Speed Control Pedal Out of Range Diagnostic Procedure

( 1 ) Engine Speed Control Pedal (B20) Reset
Action:
Reset the engine speed control pedal (B20) by depressing pedal to maximum and then releasing pedal back to the minimum
value, or setting pedal to mid-position and turning ignition switch OFF for 60 seconds and then back ON.
Result:
YES:Go to Code Check.

NO:Checks complete.
( 2 ) Code Check
Action:
Check for active diagnostic trouble codes. See Reading Diagnostic Trouble Codes (DTCs) . (Group 9015-20.)
Check for the following engine control unit (ECU) codes: 000091.03—Foot Throttle or 000091.04—Foot Throttle.
Are either of these codes active?
Result:
YES:Correct active ECU codes first. See 000091.03—Foot Throttle or see 000091.04—Foot Throttle . (Group 9001-10.)
NO:Program ECU.
000107.00- Engine Air Filter

213
Air filter restriction switch (B109) indicates a blockage in the air inlet system.
Alarm Level:
Red Stop Lamp
Air Filter Restriction Switch Malfunction Diagnostic Procedure

Action:
Result:
NO:Go to Air Filter Check.
( 2 ) Air Filter Check
Action:
Check air filter. See Clean or Replace Air Cleaner Elements . (Operator’s Manual.)
Is air filter restricted with debris?
Result:
YES:Replace air filter. See Clean or Replace Air Cleaner Elements . (Operator’s Manual.)
NO:Go to Air Inlet System Check.
( 3 ) Air Inlet System Check
Action:
Check air inlet system for debris. See Engine Intake and Exhaust Component Location . (Group 9010-15.)
Is air inlet system restricted?
Result:
YES:Remove restriction from air intake system. See Engine Intake and Exhaust Component Location . (Group 9010-15.)
Action:
Switched power OFF.

continuity.
Air restriction switch (B109). See Engine Harness (W10) Component Location . (Group 9015-15.)
ECU 48-pin connector (X42). See Engine Harness (W10) Component Location . (Group 9015-15.)
Are connectors in good condition and free of corrosion and debris?
Result:

Action:
Switched power OFF.

Disconnect air filter restriction switch (B109).
Start engine.
Check switch for continuity between pins A and B on switch connector.
Result:
YES:Replace air filter restriction switch (B109).

NO:Go to Voltage Check.
( 6 ) Voltage Check
Action:
Switched power OFF.

Air filter restriction switch (B109) disconnected.
Switched power ON.
Pin A wire P031 RED of air filter restriction connector for machine voltage.
Pin B wire M009 PUR of air filter restriction connector for 0.0 V.
Result:

Action:
Switched power OFF.

Disconnect alternator D+ terminal.
Switched power ON.
Pin A wire P031 RED of air filter restriction connector for 0.0 V.
Pin B wire M009 PUR of air filter restriction connector for 0.0 V.
Result:

( 8 ) Harness Check
Action:
Switched power OFF.


Alternator D+ terminal disconnected.
Check for continuity between pin B wire M009 PUR and the remaining pins on connectors (X41 and X42).
Result:

NO:Checks complete.
000190.00- Engine Speed
17
Engine has exceeded overspeed specification of 3000 rpm.
Alarm Level:
Red Stop Lamp
Engine Overspeed Severely High Diagnostic Procedure

Action:
Does DTC periodically “go away”?
Result:
NO:Go to Diagnostic Trouble Code Check.
( 2 ) Diagnostic Trouble Code Check
Action:
See Reading Diagnostic Trouble Codes (DTCs) . (Group 9015-20.) Check for active engine control unit (ECU) diagnostic trouble
codes.
000190.00
000636.02
000636.10
000637.02
000637.07
Are any of the above engine control unit (ECU) codes present?
Result:
YES:Diagnose and repair active ECU trouble codes. See 4045 PowerTech™ OEM Diesel Engines Below 130kW (175hp)—Interim
Tier 4/Stage III B Platform. (CTM104.)
NO:Program ECU.
000190.16- Engine Speed
17
Engine has exceeded overspeed specification of 2600 rpm.
→NOTE:
Diagnostic trouble code will not appear within monitor DIAGNOSTIC menu.
Alarm Level:
Red Stop Lamp
Engine Overspeed Moderately High Diagnostic Procedure

Action:
Result:
NO:Go to Diagnostic Trouble Code Check.
Action:
See Reading Diagnostic Trouble Codes (DTCs) . (Group 9015-20.) Check for active engine control unit (ECU) diagnostic trouble
codes.
000190.00
000636.02
000636.10
000637.02
000637.07
Are any of the above engine control unit (ECU) codes present?
Result:
YES:Diagnose and repair active ECU trouble codes. See 4045 PowerTech™ OEM Diesel Engines Below 130kW (175hp)—Interim
Tier 4/Stage III B Platform. (CTM104.)
NO:Program ECU.
000237.31- Vehicle ID Number

17
VIN number sent over CAN network to vehicle control unit (VCU) does not match the VIN stored in engine control unit (ECU).
Alarm Level:
Additional References:
See Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.)
See Engine Control Unit (ECU) Circuit Theory of Operation . (Group 9015-15.)
Invalid VIN Diagnostic Procedure

Action:
Result:
NO:Go to CAN Circuit Check.
( 2 ) CAN Circuit Check
Action:
Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20.)

Does CAN circuit test good?
Result:
YES:Go to CAN Resistor Check.

NO:Repair CAN circuit.
( 3 ) CAN Resistor Check
Action:
Perform Controller Area Network (CAN) Resistor Test . (Group 9015-20.)

Does CAN resistor test good?
Result:
YES:Go to Software Version Check.

NO:Replace CAN resistor.
( 4 ) Software Version Check
Action:
Using Service ADVISOR ™ , verify proper software versions of all controllers. If new software is available, update all controllers
and install new software.
See Service ADVISOR™ Connection Procedure . (Group 9015-20.)
Is correct software stored?
Result:
YES:Program ECU.
NO:Install compatible version of software.
000628.12- Memory Error
17
The engine control unit (ECU) has detected an internal error.
Alarm Level:
Memory Error Diagnostic Procedure

Action:
Result:
NO:Go to Reset Controller.
( 2 ) Reset Controller
Action:
Switched power OFF.

Wait 20 seconds.
Switched power ON.
Check for active ECU codes.
Result:
YES:Program controller.
NO:Checks complete.
001075.05- Fuel Pump Control

17
The fuel lift pump relay (K17) circuit is open.
Alarm Level:
Additional References: See Start and Charge Theory of Operation . (Group 9015-15.)
Fuel Lift Pump Relay Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Fuel lift pump relay (K17). See Fuel Lift Pump Relay Harness (W22) Component Location . (Group 9015-15.)
Fuel lift pump relay harness connector (X86). See Engine Harness (W10) Component Location . (Group 9015-15.)
Result:

Action:
Switched power OFF.

Disconnect fuel lift pump relay (K17).
Apply machine voltage to pin 86 and machine ground to pin 85.
sss:
Does starter relay click when machine voltage is applied?
Result:
YES:Go to next step in this check.

NO:Fuel lift pump relay (K17) malfunction. Replace relay.
Action:
With machine voltage applied to pin 86 and machine ground to pin 85, check continuity between pin 30 and pin 87.
Result:

NO:Replace fuel lift pump relay (K17).
( 4 ) Voltage Check
Action:
Switched power OFF.

Fuel lift pump relay (K17) disconnected.
Switched power ON.
Check for voltage between pin 85 (wire G040 BLK) and pin 86 (wire E031 WHT).
Is machine voltage indicated?
Result:

NO:Go to Continuity Check.
Action:
Switched power OFF.

Disconnect fuel lift pump (M17).
Pin 85 wire G040 BLK to pin 1 of fuel lift pump (M17).

Pin 86 wire E031 WHT to pin M3 of ECU 48-pin connector (X42).
Result:

Action:
Switched power OFF.

Fuel lift pump (M17) disconnected.
Check for continuity between pin 86 wire E031 WHT and machine ground.
Result:

( 7 ) Harness Check
Action:
Switched power OFF.

Disconnect fuel lift pump (M17).
Check continuity between pim M3 of ECU 48-pin connector (X42) and all other pins on connectors (X41 and X42.)
Result:

NO:Program ECU.
001075.06- Fuel Pump Control

17
The fuel lift pump relay (K17) is above normal operating voltage.
Alarm Level:
Additional References: See Start and Charge Theory of Operation . (Group 9015-15.)
Fuel Lift Pump Relay is Above Normal Operating Voltage Diagnostic

Procedure
Action:
Result:
Action:
Switched power OFF.

continuity.
Fuel lift pump relay (K17). See Fuel Lift Pump Relay Harness (W22) Component Location . (Group 9015-15.)
Fuel lift pump relay harness connector (X86). See Engine Harness (W10) Component Location . (Group 9015-15.)
Result:

Action:
Switched power OFF.

Disconnect fuel lift pump relay (K17).
Apply machine voltage to pin 86 and machine ground to pin 85.
sss:
Result:

NO:Fuel lift pump relay (K17) malfunction. Replace relay.
Action:
With machine voltage applied to pin 86 and machine ground to pin 85, check continuity between pin 30 and pin 87.
Result:

NO:Replace fuel lift pump relay (K17).
( 4 ) Voltage Check
Action:
Switched power OFF.

Switched power ON.
Pin 30 wire P021 RED of fuel lift pump relay for machine voltage.
Pin 85 wire G040 BLK of fuel lift pump relay for 0.0 V.
Pin 86 wire E031 WHT of fuel lift pump relay for machine voltage.
Pin 87 wire E030 WHT of fuel lift pump relay for 0.0 V.
Result:

( 5 ) Harness Check
Action:
Switched power OFF.

Pin 86 wire E031 WHT on fuel lift pump relay and all other pins on connectors (X41 and X42).
Pin 85 wire G040 BLK on fuel lift pump relay and all other pins on connectors (X41 and X42).
Result:

NO:Program ECU.
001321.05- Starter Relay

17
Starter relay (K5) circuit is open.
Alarm Level:
Amber Warning Alarm
See Start and Charge Circuit Theory of Operation . (Group 9015-15.)

Starter Relay Open Circuit Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Starter relay (K5). See Engine Harness (W10) Component Location . (Group 9015-15.)
Result:

NO:Repair or replace connectors.
Action:
Switched power OFF.

Disconnect starter relay (K5).
Apply machine voltage to pin C1 and machine ground to pin C2.
sss:
Result:

NO:Starter relay (K5) malfunction. Replace relay.
Action:
With machine voltage applied to pin C1 and machine ground to pin C2, check continuity between pin 1 and pin 2.
Result:
YES:Go to Fuse Check.

NO:Starter relay (K5) malfunction. Replace relay.
( 4 ) Fuse Check
Action:
Switched power OFF.

Remove main 250 A fuse (F1).
Check continuity between both sides of fuse.
Result:

NO:Replace main 250 A fuse (F1).
Action:
Switched power OFF.
Starter relay (K5) diconnected.

Pin C1 wire E005 WHT on starter relay (K5) to pin K4 of ECU 48-pin connector (X42).
Pin C2 wire G005 BLK and machine ground.
Result:
YES:Program ECU.

17
Starter relay (K5) circuit is short to ground.
Alarm Level:
Amber Warning Alarm

Starter Relay Short Circuit Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Disconnect wires G005 BLK and E005 WHT from starter relay (K5).
Apply machine voltage to pin C1 and machine ground to pin C2.
sss:
Result:

NO:Starter relay (K5) malfunction. Replace starter.
Action:
With machine voltage applied to pin C1 and machine ground to pin C2, check continuity between pin 1 and pin 2.
Result:

NO:Replace starter relay (K5).
( 4 ) Fuse Check
Action:
Switched power OFF.

Remove main 250 A fuse (F1).
Check continuity between both sides of fuse.
Result:

Action:
Switched power OFF.

Starter relay (K5) disconnected.
Check for continuity between pin C1 wire E005 WHT and machine ground.
Result:

( 6 ) Harness Check
Action:
Switched power OFF.

Disconnect starter (M1).
Check for continuity on pin K4 wire E005 WHT and all other pins on ECU connectors (X41 and X42).
Result:

NO:Program ECU.
17
Starter motor (M1) was engaged for 30 or more seconds. Starter motor needs to be disengaged for 60 seconds to reset engine
control unit (ECU) internal timer.
Alarm Level:

Power Shutdown Check

Action:
To protect the starter from damage due to overcranking, the engine control unit (ECU) will disengage the starter after 30
seconds of continuous cranking. To reset the ECU and clear this code:
Turn ignition switch OFF for 60 seconds.

Switched power ON.
Result:
YES:Program ECU.
NO:Go to Engine Crank Check.
( 2 ) Engine Crank Check
Action:
Attempt to start engine.

Does engine start?
Result:
YES:Program ECU.
NO: See E1 - Engine Cranks/Won′t Start . (CTM331.)
002003.09- No CAN From TCU
17
CAN communication error; engine control unit (ECU) has lost communication with VCU.
Alarm Level:
Controller Area Network (CAN) Communication Lost For Vehicle Control

Unit (VCU) Diagnostic Procedure
Action:
Result:
Action:

Result:

Action:

Result:
002047.09- Can Communication Lost with VCU
17
The engine control unit (ECU) has lost communication with vehicle control unit (VCU).
Alarm Level:
Can Communication Lost with VCU Diagnostic Procedure

Action:
Result:
Action:

Result:
YES:Go to CAN Resistor Test.

( 3 ) CAN Resistor Test
Action:

Result:
NO:Replace CAN Resistor.
002071.09- No CAN From VCU
17
The engine control unit (ECU) is not receiving the hand throttle message from the vehicle control unit (VCU).
Alarm Level:

Action:
Result:
Action:

Result:

Action:

Result:
523702.09- Flex Power Message Missing
17
The engine control unit (ECU) is not receiving the flex power message from the vehicle control unit (VCU).
Alarm Level:
Section 9001 - DIAGNOSTICS Group 20: Standard Display Monitor (SDM) Diagnostic Trouble Codes

Action:
Result:
Action:

Result:

Action:

Result:
Group 20 - Standard Display Monitor (SDM) Diagnostic Trouble Codes

Standard Display Monitor (SDM) Diagnostic Trouble Codes
number.
Note: For in-depth diagnostics on all SDM diagnostic trouble codes, see specific code diagnostic procedure in this group.
000096.03- Fuel Level Sensor

276
Fuel level sensor (B8) circuit is open or short to power.
Alarm Level:
See Standard Display Monitor (SDM) Circuit Theory of Operation . (Group 9015-15.)
Fuel Level Sensor Open or Short Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Fuel level sensor (B8). See Transmission Harness (W13) Component Location . (Group 9015-10.)
Transmission harness-to cab/canopy harness connector (X21). See Transmission Harness (W13) Component Location .
(Group 9015-10.)
Standard display monitor (SDM) connector (X4). See Cab Harness (W14) Component Location or see Canopy Harness
(W15) Component Location . (Group 9015-10.)
Result:
YES:Go to Switched Power ON/OFF Check.

( 3 ) Switched Power ON/OFF Check
Action:
Switched power OFF.

Switched power ON.
Check for active standard display monitor (SDM) codes.
Is SDM code 000096.03 present?
Result:

NO:Checks complete.
Action:
Switched power OFF.

Disconnect fuel level sensor (B8).
Measure resistance across pins 1 and 2 of fuel level sensor (B8).

Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.)
Is resistance within specification?
Result:

NO:Replace fuel level sensor (B8).
Action:
Switched power OFF.

Fuel level sensor (B8) disconnected.
Disconnect SDM connector (X4).
Switched power ON.
Check for voltage at pin 2 (wire Y108 YEL) on SDM connector (X4).
Is voltage present?
Result:
YES:Repair or replace harness. See appropriate schematic or wiring diagram.

NO:Go to Open Check.
( 6 ) Open Check
Action:
Switched power OFF.

SDM connector (X4) disconnected.
Pin 1 (wire R108 BLK) on fuel level sensor connector (B8) and pin F of SDM connector (X4).
Pin 2 (wire Y108 YEL) on fuel level sensor connector (B8) and pin N of SDM connector (X4).
Result:

NO:Repair or replace harness. See appropriate schematic or wiring diagram.
( 7 ) Harness Check
Action:
Disconnect negative battery cable or turn battery disconnect switch OFF.

Check for continuity between pin N (wire Y108 YEL) of SDM connector (X4) and all other pins of SDM connector (X4).
Result:
YES:Wire Y108 YEL is short to wire that indicated continuity. Repair wire or replace harness.
NO:Program standard display monitor (SDM).
000096.04- Fuel Level Sensor

276
Fuel level sensor (B8) circuit is short to ground.
Alarm Level:
Fuel Level Sensor Short to Ground Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Switched power ON.
Check for active SDM codes.
Result:

NO:Checks complete.
Action:
Switched power OFF.

Measure resistance across pins 1 and 2 of fuel level sensor.

Result:
YES:Go to Short Circuit Check.

( 5 ) Short Circuit Check
Action:
Switched power OFF.

Check pin N (wire Y108 YEL) on SDM (X4) for continuity to machine ground.
Is continuity to machine ground indicated?
Result:

NO:Go to Harness Check
( 6 ) Harness Check
Action:

Result:
000168.03- Battery Voltage
276
Battery voltage input is above 15.5 V with engine running.
Alarm Level:

Battery Voltage Diagnostic Procedure

Action:
Result:
NO:Go to System Voltage Check.
( 2 ) System Voltage Check
Action:
Start engine.
Measure voltage across positive and negative battery terminals.
Is voltage more than 15.5 V?
Result:
YES:Go to Alternator Check.

NO:Program controller.
( 3 ) Alternator Check
Action:
See Alternator Test . (Group 9015-20.)

Does alternator pass test procedure?
Result:
YES:Checks complete.
NO:Repair or replace alternator.

276
Battery voltage input is below 11.7 V with engine running.
Alarm Level:

( 1 ) Battery Voltage Check
Action:
Switched power OFF.

Is voltage approximately 12 V?
Result:
YES:Go to Intermittent Check.

NO:Clean and tighten battery terminals. See Check Battery Electrolyte Level and Terminals . (Operator′s Manual.) Charge
batteries. See Using Battery Charger . (Operator′s Manual.)
Action:
Result:
Action:
Switched power OFF.

continuity.
Standard display monitor (SDM) connector. See Cab Harness (W14) Component Location or see Canopy Harness (W15)
Fuse and relay block (X3). See Cab Harness (W14) Component Location or see Canopy Harness (W15) Component
Operator station floor ground (W2). See Cab Harness (W14) Component Location or see Canopy Harness (W15)
Ignition relay (K10). See Cab Harness (W14) Component Location . (Group 9015-15.)
Are connectors in good condition and free of corrosion or debris?
Result:

( 4 ) Fuse Check
Action:
Switched power OFF.

Check for following fuses for continuity and proper amperage rating. See Fuse and Relay Location and Specifications . (Group
9015-10.)
Main 250 A Fuse (F1)

Monitor Switched Power 5 A Fuse (F30)
Monitor Unswitched Power 5 A Fuse (F15)
Result:
YES:Go to Relay Check.

NO:Replace fuse(s).
( 5 ) Relay Check
Action:
Switched power OFF.

Disconnect ignition relay (K10).
Apply 12 V to pin 1 of ignition relay (K10).
Apply ground to pin 1 of ignition relay (K10).
sss:
Did ignition relay (K10) “click?”
Check for continuity between pin 3 of ignition relay (K10) and pin 5 of ignition relay (K10).
Result:

NO:Replace ignition relay (K10).
( 6 ) Voltage Check
Action:
Start engine.
Is voltage 12 V or less?
Result:

Action:

Result:

Action:
Switched power OFF.

Disconnect standard display monitor (SDM) connector (X4).
Disconnect fuse and relay block (X3).
Pin A (wire P015 RED) of SDM connector (X4) and pin D5 of fuse and relay block (X3).
Pin L (wire P030 RED) of SDM connector (X4) and pin AA7 of fuse and relay block (X3).
Pin P (wire G001 BLK) of SDM connector (X4) and operator station floor ground (W2).
Result:
000234.02- Software Incorrect
276
The vehicle control unit (VCU) does not have appropriate software version to be compatible with standard display monitor
(SDM).
Alarm Level:
Check Service Code Indicator
Software Revision Mismatch Diagnostic Procedure

Action:
Switched power ON. Using Service ADVISOR ™ or standard display monitor (SDM), clear diagnostic trouble codes (DTC). Cycle
switched power. Does DTC return?
Result:

NO:Checks complete.
Action:
Result:
000237.02- VIN Mismatch
276
The model number and VIN number is missing in the standard display monitor (SDM).
Alarm Level:

For additional information, See Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.)
VIN Mismatch Diagnostic Procedure

Action:
Result:
NO:Go to Software PIN Check.
( 2 ) Software PIN Check
Action:
Using Service ADVISOR ™ , verify proper PIN is stored in software.

Is correct PIN number stored?
Result:
NO:Update controller with correct PIN number.
276
Alarm Level:
For additional information, See Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.)
VIN Missing Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.)
Result:

Action:
Result:
000237.31- VIN Missing
276
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

Result:

Action:
Result:
17
The engine control unit (ECU) has detected an internal error.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

Wait 20 seconds.
Switched power ON.
Check for active ECU codes.
Result:
NO:Checks complete.
000629.12- Controller Fault
276
The standard display monitor (SDM) has detected an internal error.
Alarm Level:
Red Stop Indicator
Cycle switched power. If code still exists, program SDM.
000920.12- Alarm Output

276
The monitor alarm (H1) circuit is open or short to ground.
Alarm Level:
Monitor Alarm Output Voltage Low Diagnostic Procedure

Action:
Switched power OFF.

Using Service ADVISOR ™ or standard display monitor (SDM), clear diagnostic trouble codes (DTC). Cycle switched power.
Does DTC return?
Result:
YES:Go to Connector Check.

NO:DTC is intermittent. Check P015 RED and C101 GRY wires for intermittent opens or shorts. Check SDM connector (X4) pin E
for loose connection.
Action:
Switched power OFF.

continuity.
Monitor alarm connector (H1). See Cab Harness (W14) Component Location or see Canopy Harness (W15) Component
Standard display monitor connector (X4). See Cab Harness (W14) Component Location or see Canopy Harness (W15)
Result:

Action:
Measure resistance of monitor alarm.

Is resistance approximately 1.5 kilo-ohms?
Result:
YES:Go to Open Check.

NO:Replace monitor alarm (H1).
( 4 ) Open Check
Action:
Switched power OFF.

Monitor alarm (H1) disconnected.

Pin A (wire P015 RED) on monitor alarm connector (H1) and pin A of SDM connector (X4).
Pin B (wire C101 GRY) on monitor alarm connector (H1) and pin E of SDM connector (X4).
Result:

Action:
Switched power OFF.

Disconnect monitor alarm (H1).
Switched power ON.
Check for voltage at pin A (wire R015 RED) on SDM connector (X4).
Is voltage present?
Result:

( 6 ) Harness Check
Action:
Disconnect negative battery cable or turn battery disconnect switch to OFF.

Monitor alarm (H1) disconnected.
Check for continuity between pin A (wire P015 RED) on SDM connector (X4) and all other pins of SDM connector (X4).
Result:
YES:Circuit P015 RED is short to circuit that indicated continuity. Repair or replace harness.
001196.11- Antitheft
276
Door lock status message from ECU is not received by SDM.
Alarm Level:
NO CAN From ECU Diagnostic Procedure

Action:
Result:
NO:Go to CAN Resistor Check.
Action:

Did CAN resistance check within specification?
Result:
YES:Go to CAN Circuit Check.

Action:

Did CAN circuit check within specification?
Result:
002000.09- No CAN from ECU

189
The standard display monitor (SDM) has lost CAN communication with engine control unit (ECU).
→NOTE:
Diagnostic procedures for Stage II and Tier 3 engines provided.
No CAN From ECU Diagnostic Procedure—Stage II Engine

Action:
Does diagnostic trouble code (DTC) periodically go away?
Result:
YES:DTC is intermittent. See Intermittent DTC Diagnostics . (Group 9015-20.)

NO:Go to ECU Software Version Check.
( 2 ) ECU Software Version Check
Action:
Access machine service menu. See Standard Display Monitor (SDM)—Service Menu . (Group 9015-16.)
Select DIAGNOSTICS.
Select SOFTWARE VERSION.
Select ECU SW VERSION.
→NOTE:
If ECU software version does not display, CAN communication issue exists.
Does ECU software version display?
Result:
YES: Go to Connector Check .

Action:

Result:
YES:Program malfunctioning controller.

Action:
Switched power OFF.

Disconnect ECU connector (X10).
IMPORTANT:
Prevent possible damage to connector terminals. Use correct size male terminal pin for checking female
terminals.
Inspect pins and terminals on ECU connector (X10) and ECU (A2) for wear or damage.
Do pins or terminals show signs of wear or damage?
Result:
YES:Repair or replace damaged pins or terminals.

NO:Go to Battery Check.
( 5 ) Battery Check
Action:
→NOTE:
Wires on positive battery terminal are molded together and could cause power issues with ECU.
Ensure all wire leads to positive battery terminal have a good connection.
Inspect battery terminals and cables for corrosion, wear, or damage.
Are terminals or cables corroded, worn, or damaged?
Result:
YES:Clean, repair, or replace terminals or cables.

NO:Go to Fuse Check.
( 6 ) Fuse Check
Action:
Switched power OFF.

Check ECU unswitched power 10 A fuse (F4) and sealed switch module (SSM) 7.5 A fuse (F17) for continuity. See Fuse and
Relay Location and Specifications . (Group 9015-10.)
Result:

NO:Replace fuse.
( 7 ) Voltage Check
Action:
Switched power OFF.

Check for voltage at ECU unswitched power 10 A fuse (F4) and sealed switch module (SSM) 7.5 A fuse (F17). See Fuse and
Is voltage (approximately 12 V) indicated?
Result:
YES:Go to Voltage Drop Check.

NO:Battery power is directly supplied to fuses (F4 and F17). Diagnose and repair connection issue.
( 8 ) Voltage Drop Check
Action:
→NOTE:
If voltage is indicated and DTC is stored, but not active, it is necessary to check for voltage while engine
is cranking. Engine will not crank if code is active.
Switched power ON, engine cranking.

Check for voltage at ECU unswitched power 10 A fuse (F4) and sealed switch module (SSM) 7.5 A fuse (F17).
→NOTE:
Significant voltage drop while cranking will cause ECU to lose power and DTC to become active. When key
switch is returned to ON position, code will be stored.
Is significant voltage drop indicated at either fuse while cranking engine?
Result:
YES:Battery power is directly supplied to fuses (F4 and F10). Diagnose and repair connection issue.
NO:Go to Wiring Check.
( 9 ) Wiring Check
Action:
Switched power OFF.

Check for continuity on P017 red wire from SSM 7.5 A fuse (F17) to SSM (A74). See Fuse and Relay Location and Specifications
and see Cab Harness (W14) Component Location . (Group 9015-10.)
Result:
YES:Go to Ground Check.

NO:Repair or replace harness. See Cab Harness (W14) Component Location . (Group 9015-10.)
( 10 ) Ground Check
Action:
Switched power OFF.

Inspect frame ground near motor (W1). See Engine Harness (W10) Component Location . (Group 9015-10.)
Is connection corroded, worn, or damaged?
Result:
YES:Repair or replace frame ground near motor (W1). See Engine Harness (W10) Component Location . (Group 9015-10.)
NO:Continue check.
Action:
Check continuity to ground at pin J2 (wire G002 black) on ECU connector (X10). See Engine Harness (W10) Wiring Diagram .
(Group 9015-10.)
Is continuity to ground at all pins indicated?
Result:
YES:Go to ECU Power Check.

NO:Repair or replace harness. See Engine Harness (W10) Component Location . (Group 9015-10.)
( 11 ) ECU Power Check
Action:
Switched power ON.

Check for voltage at pins K1 (wire P004 red) and A2 (wire U110 red) on ECU connector (X10). See Engine Harness (W10) Wiring
Diagram . (Group 9015-10.)
Is voltage (approximately 12 V) indicated at all pins?
Result:
YES:Go to ECU Voltage Drop Check.

( 12 ) ECU Voltage Drop Check
Action:
→NOTE:

Check for voltage at the pins K1 (wire P004 red) and A2 (wire U110 red) on ECU connector (X10).
→NOTE:
Is significant voltage drop indicated and any pins while cranking engine?
Result:
YES:Repair or replace harness. See Engine Harness (W10) Component Location . (Group 9015-10.)
NO:Go to ECU Check.
( 13 ) ECU Check
Action:
Program ECU.
Does DTC stop appearing?
Result:
NO:Continue check.
Action:
Replace ECU.
Result:
NO:Repair or replace engine harness (W10). See Engine Harness (W10) Component Location . (Group 9015-10.)
No CAN From ECU Diagnostic Procedure—Tier 3 Engine

Action:
Result:

Action:
Select DIAGNOSTICS.
→NOTE:
Result:
YES: Go to Battery Check .

Action:

Result:

( 4 ) Battery Check
Action:
→NOTE:
Result:

( 5 ) Fuse Check
Action:
Switched power OFF.

Result:

NO:Replace fuse.
( 6 ) Voltage Check
Action:
Switched power OFF.

Check for voltage at ECU unswitched power 20 A fuse (F4) and SSM 7.5 A fuse (F17). See Fuse and Relay Location and
Specifications . (Group 9015-10.)
Result:

Action:
→NOTE:
is cranking. Engine will not crank if DTC is active.

Check for voltage at ECU unswitched power 20 A fuse (F4) and SSM 7.5 A fuse (F17).
→NOTE:
switch is returned to ON position, DTC will be stored.
Result:
( 8 ) Wiring Check
Action:
Switched power OFF.

Result:

( 9 ) Ground Check
Action:
Switched power OFF.

Inspect frame ground near starter motor (W1). See Transmission Harness (W13) Component Location . (Group 9015-10.)
Result:
YES:Repair or replace frame ground near starter motor (W1). See Transmission Harness (W13) Component Location . (Group
9015-10.)
NO:Continue check.
Action:
Check continuity to ground at the following pins on ECU 48-pin connector (X42): L2, L3, and M2 (wires G002 black). See Engine
Harness (W10) Wiring Diagram . (Group 9015-10.)
Result:

Action:
Switched power ON.

Check for voltage at the following pins on ECU 48-pin connector (X42): L1, L4, M1, M4 (wires P004 red), and B2 (wire U110 red).
See Engine Harness (W10) Wiring Diagram . (Group 9015-10.)
Result:

Action:
→NOTE:

Check for voltage at the following pins: L1, L4, M1, M4 (wires P004 red), and B2 (wire U110 red).
→NOTE:
Result:
NO:Program ECU.
002003.09- No CAN from TCU
276
The standard display monitor (SDM) has lost CAN communication with transmission control unit (TCU).
For more information:
See Transmission Control Circuit Theory of Operation . (Group 9015-15.)

NO CAN From TCU Diagnostic Procedure

Action:
Result:
Action:

Result:

Action:

Result:
002071.09- No CAN from VCU
276
The standard display monitor (SDM) has lost CAN communication with vehicle control unit (VCU).
See Vehicle Control Unit (VCU) Circuit Theory of Operation . (Group 9015-15.)
NO CAN From VCU Diagnostic Procedure

Action:
Result:
Action:

Result:

Action:

Result:
002141.09- No CAN from SSM
276
The standard display monitor (SDM) has lost CAN communication with sealed switch module (SSM).
NO CAN From SSM Diagnostic Procedure

Action:
Result:
Action:
Result:

Action:

Result:
002228.09- No CAN from HVC
276
The standard display monitor (SDM) has lost CAN communication with hydraulic valve controller (HVC).
NO CAN From HVC Diagnostic Procedure

Action:
Result:
Action:

Result:

Action:

Result:

002251.09- No CAN from MTG
276
The standard display monitor (SDM) has lost CAN communication with modular telematics gateway (MTG) module.
NO CAN From MTG Diagnostic Procedure

Action:
Result:
Action:

Result:

Action:

Result:
003509.03- Sensor Supply 1

276
Sensor supply voltage 1 is out of range high. (Above 5.25 V)
Alarm Level:
Fuel Level Sensor Open or Short Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Switched power ON.
Check for active standard display monitor (SDM) codes.
Result:

NO:Checks complete.
Action:
Switched power OFF.

Measure resistance across pins 1 and 2 of fuel level sensor (B8).

Result:

Action:
Switched power OFF.

Switched power ON.
Check for voltage at pin 2 (wire Y108 YEL) on SDM connector (X4).
Is voltage present?
Result:

NO:Go to Open Check.
( 6 ) Open Check
Action:
Switched power OFF.

Pin 1 (wire R108 BLK) on fuel level sensor connector (B8) and pin F of SDM connector (X4).
Pin 2 (wire Y108 YEL) on fuel level sensor connector (B8) and pin N of SDM connector (X4).
Result:

( 7 ) Harness Check
Action:

Result:

276
Sensor supply voltage 1 is out of range low. (Below 4.75 V)
Alarm Level:
Fuel Level Sensor Short to Ground Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Switched power ON.
Result:

NO:Checks complete.
Action:
Switched power OFF.

Measure resistance across pins 1 and 2 of fuel level sensor.

Result:

Action:
Switched power OFF.

Check pin N (wire Y108 YEL) on SDM (X4) for continuity to machine ground.
Is continuity to machine ground indicated?
Result:

NO:Go to Harness Check
( 6 ) Harness Check
Action:

Result:
524082.07- Display Buttons
276
Button on standard display monitor (SDM) is stuck.
Alarm Level:
Monitor Button Stuck Diagnostic Procedure

Action:
Result:
NO:Go to Button Check.
( 2 ) Button Check
Section 9001 - DIAGNOSTICS Group 30: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Action:
Switched power ON.

Press all buttons on standard display monitor (SDM).
Is code 524082.07 present?
Result:
YES:Go to Power ON/OFF Check.

NO:Checks complete.
( 3 ) Power ON/OFF Check
Action:
Switched power OFF.

Switched power ON.
Is code 524082.07 present?
Result:
NO:Checks complete.
Group 30 - Transmission Control Unit (TCU) Diagnostic Trouble Codes

Transmission Control Unit (TCU) Diagnostic Trouble Codes
Note: For in-depth diagnostics on all VCU diagnostic trouble codes, see specific code diagnostic procedure in this group.
000070.14- Park Brake

44
Transmission control unit (TCU) lost CAN communication with sealed switch module (SSM) or invalid ground speed. TCU
automatically applied the park brake after a 15 second delay.
Alarm Level:
Red Stop Lamp Indicator

See Park Brake Operation . (Group 9020-05.)
Park Brake Diagnostic Procedure

( 1 ) Active Code Check
Action:
Check for active TCU diagnostic trouble codes.

Are any TCU DTCs active?
Result:
YES:Diagnose and clear all active TCU DTCs.

NO:Go to Intermittent Check.
Action:
Result:
NO:Go to Pressure Check.
( 3 ) Pressure Check
Action:
Perform Park Brake Release Pressure Test . (Group 9020-25.)

Is pressure to specification?
Result:

NO:Diagnose and repair pressure malfunction.
Action:
Switched power OFF.

continuity.
Park Brake Pressure Switch (B13). See Transmission Harness (W13) Component Location . (Group 9015-10.)
Transmission harness-to-cab/canopy harness connector (X21). See Transmission Harness (W13) Component Location .
(Group 9015-10.)
Vehicle control unit (VCU) connector 1 (X11). See Cab Harness (W14) Component Location . (Group 9015-10.)
Result:
000177.00- Trans Oil Temp

44
Transmission temperature high.
Alarm Level:
See Transmission Overheats . (Group 9020-15.)

See Power Train Overview . (Group 9020-15.)
See Transmission Filter Operation . (Group 9020-05.)
Trans Oil Temp Diagnostics Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Torque converter oil temperature sensor (B6). See Transmission Harness (W13) Component Location . (Group 9015-10.)
Transmission harness-to-cab/canopy harness connector (X21). See Cab Harness (W14) Component Location or see
Canopy Harness (W15) Component Location . (Group 9015-10.)
Vehicle control unit (VCU) connector 1 (X11). See Cab Harness (W14) Component Location or see Canopy Harness (W15)
Result:
YES:Go to Cooler Check.

( 3 ) Cooler Check
Action:
Perform Cooler In and Cooler Out Pressure Test . (Group 9020-25.)

Was test successful?
Result:
NO:Diagnose and repair transmission cooler.
000177.04- Trans Oil Temp

44
Torque converter oil temperature sensor (B6) short to ground. (Below 0.25 V.)
Alarm Level:
See Transmission Overheats . (Group 9020-15.)

See Transmission Filter Operation . (Group 9020-05.)
Trans Oil Temp Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Torque converter oil temperature sensor (B6). See Transmission Harness (W13) Component Location . (Group 9015-10.)
Result:

Action:
Switched power OFF.

Disconnect torque converter oil temperature sensor (B6).
Check torque converter oil temperature sensor (B6). See Electrical Component Specifications . (Group 9015-20.)
Does torque converter oil temperature sensor (B6) meet specifications?
Result:
NO:Replace torque converter oil temperature sensor (B6).

( 4 ) Voltage Check
Action:
Torque converter oil temperature sensor (B6) disconnected.

Switched power ON.
Check voltage at pin A (wire X006 YEL) of torque converter oil temperature sensor (B6).
Is voltage above 0.5 V?
Result:
YES:Go to Circuit Check.

( 5 ) Circuit Check
Action:
Switched power OFF.

Disconnect vehicle control unit (VCU) connector 1 (X11).
Pin A (wire X006 YEL) of torque converter oil temperature sensor (B6) and pin 43 of VCU connector (X13).
Pin B (wire R038 BLK) of torque converter oil temperature sensor (B6) and pin L2 of VCU connector (X11).
Result:

Action:
Switched power OFF.

Pin A (wire X006 YEL) of torque converter oil temperature sensor (B6) and machine ground.
Pin B (wire R038 BLK) of torque converter oil temperature sensor (B6) and machine ground.
Result:

NO:Checks complete.
000191.00- Transmission Speed
44
Transmission output speed sensor (B14) is reading above 4000 rpm.
When transmission output speed sensor (B14) is invalid the transmission will default to manual mode.
Alarm Level:


Transmission Speed Diagnostic Procedure

Action:
Check for any active TCU or VCU codes.

Are any TCU or VCU codes active?
Result:
YES:Diagnose and clear all active TCU and VCU codes.

( 2 ) Machine Operation Check
Action:
Clear active diagnostic trouble codes.

Operate machine on smooth level surface through all gear ranges.
Check for active TCU code 000191.00—Transmission Speed.
Is code active?
Result:
YES:Go to Equipment Check.

NO:Checks complete. Instruct owner/operator of proper machine operations.
( 3 ) Equipment Check
Action:
Check machine tires for proper inflation and size. See Tire Pressures . (Operator’s Manual.)
Are tires properly inflated and correct size?
Result:
NO:Inflate tire to specification or replace with appropriate size.

44
Transmission output speed sensor (B14) out of range high.
Alarm Level:


Action:
Result:
Action:
Switched power OFF.

continuity.
Transmission output speed sensor (B14). See Transmission Harness (W13) Component Location . (Group 9015-10.)
Result:

( 3 ) Voltage Check
Action:
Switched power OFF.

Disconnect transmission output speed sensor (B14).
Switched power ON.
Check voltage at:
Pin A (wire M014 PUR) of transmission output speed sensor (B14).

Pin B (wire R014 BLK) of transmission output speed sensor (B14).
Result:
YES:Circuit is short to power. Repair or replace harness. See appropriate wiring diagram or schematic.
( 4 ) Harness Check
Action:
Switched power OFF.

Transmission output speed sensor (B14) disconnected.
Vehicle control unit (VCU) connector 1 (X11) disconnected.
Pin L2 (wire R059 BLK) of VCU connector 1 (X11) and all other connectors to VCU.
Pin 17 (wire M014 PUR) of VCU connector 2 (X12) and all other connectors to VCU.
Result:
YES:Circuit is short. Repair or replace harness. See appropriate wiring diagram or schematic.
NO:Checks complete.

44
Transmission output speed sensor (B14) out of range low.
Alarm Level:


Action:
Result:
Action:
Switched power OFF.

continuity.
Transmission output speed sensor (B14). See Transmission Harness (W13) Component Location . (Group 9015-10.)
Result:

( 3 ) Voltage Check
Action:
Switched power OFF.

Disconnect transmission output speed sensor (B14).
Switched power ON.
Check voltage at pin A of transmission output speed sensor (B14).
Result:


Action:
Switched power OFF.

Pin L2 (wire R059 BLK) of VCU connector 1 (X11) and pin B of transmission output speed sensor (B14).
Pin 17 (wire M014 PUR) of VCU connector 2 (X12) and pin A of transmission output speed sensor (B14).
Result:

Action:
Switched power OFF.

Pin A (wire M014 PUR) of transmission output speed sensor (B14) and machine ground.
Pin B (wire R014 BLK) of transmission output speed sensor (B14) and machine ground.
Result:

NO:Checks complete.
44
Transmission output speed sensor (B14) is reading above 3600 rpm.
Alarm Level:


Action:
Check for any active TCU or VCU codes.

Are any TCU or VCU codes active?
Result:
YES:Diagnose and clear all active TCU and VCU codes.

( 2 ) Machine Operation Check
Action:
Clear active diagnostic trouble codes.

Operate machine on smooth level surface through all gear ranges.
Check for active TCU code 000191.16—Transmission Speed.
Is code active?
Result:
YES:Go to Equipment Check.

NO:Checks complete. Instruct owner/operator of proper machine operations.
( 3 ) Equipment Check
Action:
Check machine tires for proper inflation and size. See Tire Pressures . (Operator’s Manual.)
Are tires properly inflated and correct size?
Result:
NO:Inflate tire to specification or replace with appropriate size.
000525.02- Requested Gear

44
Gear select switch (S6) inputs have invalid combination.
Alarm Level:

Requested Gear Diagnostic Procedure

( 1 ) Transmission Control Lever Check
Action:
Check transmission control lever (TCL). See Transmission Control Lever (TCL) Test . (Group 9015-20.)
Did TCL check OK?
Result:

NO:Repair or replace TCL.
Action:
Result:
Action:
Switched power OFF.

continuity.
Transmission control lever (TCL) connector (X48). See Cab Harness (W14) Component Location or see Canopy Harness
(W15) Wiring Diagram . (Group 9015-10.)
Operator station floor ground (W2). See Cab Harness (W14) Component Location or see Canopy Harness (W15) Wiring
Wiring Diagram . (Group 9015-10.)
Result:

Action:
Switched power OFF.

Disconnect transmission control lever (TCL) connector (X48).
Switched power ON.
Pin 2 (T105 BLU) of TCL connector (X48).

Pin 12 (G001 BLK) of TCL connector (X48).
Is system voltage (approximately 12 V) indicated?
Result:

( 5 ) Harness Check
Action:
Switched power OFF.

Transmission control lever (TCL) connector (X48) disconnected.
Check for continuity between pins listed below and all other pins of VCU connectors (X11, X12, and X13).
Pin A3 (T505 BLU) of VCU connector (X11).

Pin C1 (T705 BLU) of VCU connector (X11).
Pin 7 (T105 BLU) of VCU connector (X12).
Is continuity indicated between pins?
Result:


44
Gear select switch (S6) inputs shorted to power.
Alarm Level:


Action:
Check transmission control lever. See Transmission Control Lever (TCL) Test . (Group 9015-20.)
Did TCL check OK?
Result:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Switched power ON.

Result:

( 5 ) Harness Check
Action:
Switched power OFF.

Check for continuity between pins listed bellow and all other pins of VCU connectors (X11, X12, and X13).

Result:


44
Gear select switch (S6) is shorted to ground.
Alarm Level:


Action:
Did TCL check OK?
Result:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Check for continuity between pins listed below and machine ground.

Result:


44
Gear select switch (S6) circuit is open.
Alarm Level:


Action:
Did TCL check OK?
Result:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

( 4 ) Fuse Check
Action:
Switched power OFF.

Check transmission control 5 A fuse (F35) for continuity. See Fuse and Relay Location and Specifications . (Group 9015-10.)
Result:

NO:Replace transmission control 5 A fuse (F35).
( 5 ) Voltage Check
Action:
Switched power OFF.

Install transmission control 5 A fuse (F35).
Switched power ON.
Pin 1 (wire P035 RED) of TCL connector (X48).

Result:

Action:
Switched power OFF.

Pin 2 (T105 BLU) of TCL connector (X48) and pin 7 of VCU connector (X12).
Pin 4 (T605 BLU) of TCL connector (X48) and pin C2 of VCU connector (X11).
Pin 5 (T505 BLU) of TCL connector (X48) and pin A3 of VCU connector (X11).
Pin 12 (G001 BLK) of TCL connector (X48) and machine ground.
Result:
000604.04- TCL Neutral SW

44
Forward, neutral, reverse (FNR) switch (S5) input short to ground.

TCL Neutral SW Diagnostic Procedure

Action:
Did TCL check OK?
Result:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Check for continuity between pins listed below and machine ground.

Result:

000617.07- Park Brake Circuit

44
Park brake release solenoid (Y7) inputs conflict with park brake pressure switch (B13).
Park brake release solenoid (Y7) is stuck, indicating low pressure.
Alarm Level:
Park Brake Indicator Displayed

Park Brake Circuit Diagnostic Procedure

Action:
Result:
Action:

Result:

Action:
Switched power OFF.

continuity.
Park brake release solenoid (Y7). See Transmission Harness (W13) Component Location . (Group 9015-10.)
(Group 9015-10.)
Frame ground near starter motor (W1). See Transmission Harness (W13) Component Location . (Group 9015-10.)
Result:

( 4 ) Voltage Check
Action:
Switched power OFF.

Disconnect park brake release solenoid (Y7).
Switched power ON.
Check for voltage at pin A (wire J007 TAN) of park brake release solenoid (Y7).
Result:

Action:
Switched power OFF.

Park brake release solenoid (Y7) disconnected.
Check for continuity between pin A and pin B of park brake release solenoid (Y7).
Result:
YES:Replace park brake release solenoid (Y7).

Action:
Switched power OFF.

Check switch for continuity between:
Pin A (wire J007 TAN) of park brake release solenoid (Y7) and pin G4 of VCU connector (X11).
Pin B (wire R007 BLK) of park brake release solenoid (Y7) and pin B4 of VCU connector (X11).
Result:

NO:Circuit is open. Repair or replace harness. See appropriate wiring diagram or schematic.
( 7 ) Harness Check
Action:
Disconnect battery power.

Disconnect VCU connectors (X12 and X13).
Pin G4 (wire J007 TAN) of VCU connector (X11) and all other pins on VCU connectors (X11, X12, and X13).
Pin B4 (wire R007 BLK) of VCU connector (X11) and all other pins on VCU connectors (X11, X12, and X13).
Result:

000618.07- Park Brake Circuit

44
Park brake release solenoid (Y7) inputs conflict with park brake pressure switch (B13).
Park brake release solenoid (Y7) is stuck, indicating low pressure.
Alarm Level:
Park Brake Indicator Displayed

Park Brake Circuit Diagnostic Procedure

Action:
Result:
Action:

Result:

Action:
Switched power OFF.

continuity.
(Group 9015-10.)
Result:

( 4 ) Voltage Check
Action:
Switched power OFF.

Switched power ON.
Result:

Action:
Switched power OFF.

Check for continuity between pin A and pin B of park brake release solenoid (Y7).
Result:
YES:Replace park brake release solenoid (Y7).

Action:
Switched power OFF.

Pin A (wire J007 TAN) of park brake release solenoid (Y7) and pin G4 of VCU connector (X11).
Pin B (wire R007 BLK) of park brake release solenoid (Y7) and pin B4 of VCU connector (X11).
Result:

( 7 ) Harness Check
Action:

Pin G4 (wire J007 TAN) of VCU connector (X11) and all other pins on VCU connectors (X11, X12 and X13).
Pin B4 (wire R007 BLK) of VCU connector (X11) and all other pins on VCU connectors (X11, X12 and X13).
Result:

44
The vehicle control unit (VCU) has detected an internal error.
Cycle switched power. If code still exists, program VCU.
000734.03- Y1 Solenoid
44
Transmission forward direction solenoid (Y1) high side driver short to power.
Alarm Level:

See Wire Harness Test . (Group 9015-20.)
See Transmission Control Circuit Test . (Group 9015-20.)
See Transmission Solenoid Check . (Group 9015-20.)
Y1 Solenoid Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Transmission forward direction solenoid (Y1). See Transmission Harness (W13) Component Location . (Group 9015-10.)
(Group 9015-10.)
Result:

( 3 ) Voltage Check
Action:
Switched power OFF.

Disconnect transmission forward direction solenoid (Y1).
Disconnect VCU connector (X11).
Switched power ON.
Check for voltage at pin A (wire T001 BLU) of transmission forward direction solenoid (Y1).
Result:
NO:Go to Component Check.

Action:
Switched power OFF.

Transmission forward direction solenoid (Y1) disconnected.
Check for resistance between pin A and pin B of transmission forward direction solenoid (Y1).
See Electrical Component Specifications . (Group 9015-20.)
Is correct resistance indicated?
Result:

NO:Replace transmission forward direction solenoid (Y1).
( 5 ) Harness Check
Action:
Switched power OFF.

VCU connector (X11) disconnected.
Check for continuity between pin M4 (wire T001 BLU) of VCU connector (X11) and all other pins on VCU connectors (X11, X12,
and X13).
Result:
YES:High side circuit (wire T001 BLU) is short to power. Repair or replace harness. See appropriate wiring diagram or
schematic.
NO:Checks complete.
44
Transmission control solenoid (Y1) high side driver shorted to ground.
Alarm Level:


Action:
Result:
Action:
Switched power OFF.

continuity.
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Result:

Action:
Switched power OFF.

Check for continuity between pin A (wire T001 BLU) of transmission forward direction solenoid (Y1) and machine ground.
Result:
YES:High side circuit (wire T001 BLU) is short to ground. Repair or replace harness. See appropriate wiring diagram or
schematic.
OK:
( 5 ) Harness Check
Action:
Switched power OFF.

Check for continuity between pin M4 (wire T001 BLU) of VCU connector (X11) and all other pins on VCU connectors (X11, X12,
and X13).
Result:
YES:High side driver circuit (wire T001 BLU) is short to ground. Repair or replace harness. See appropriate wiring diagram or
schematic.
NO:Checks complete.
44
Transmission forward direction solenoid (Y1) circuit is open.


Action:
Result:
Action:
Switched power OFF.

continuity.
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Result:

Action:
Switched power OFF.

Pin A (wire T001 BLU) of transmission forward direction solenoid (Y1) and pin M4 of VCU connector (X11).
Pin B (wire R001 BLK) of transmission forward direction solenoid (Y1) and pin F4 of VCU connector (X11).
Result:
44
Transmission forward direction solenoid (Y1) low side driver short to power.
Alarm Level:


Action:
Result:
Action:
Switched power OFF.

continuity.
(Group 9015-10.)
Result:

( 3 ) Voltage Check
Action:
Switched power OFF.

Switched power ON.
Check for voltage at pin B (wire R001 BLK) of transmission forward direction solenoid (Y1).
Result:

Action:
Switched power OFF.

Result:

( 5 ) Harness Check
Action:
Switched power OFF.

Check for continuity between pin F4 (wire R001 BLK) of VCU connector (X11) and all other pins on VCU connectors (X11, X12,
and X13).
Result:
YES:Low side driver circuit (wire R001 BLK) is short to power. Repair or replace harness. See appropriate wiring diagram or
schematic.
NO:Checks complete.
44
Transmission reverse direction Solenoid (Y2) high side driver short to power.
Alarm Level:


Action:
Result:
Action:
Switched power OFF.

continuity.
Transmission reverse direction solenoid (Y2). See Transmission Harness (W13) Component Location . (Group 9015-10.)
(Group 9015-10.)
Result:

( 3 ) Voltage Check
Action:
Switched power OFF.

Disconnect transmission reverse direction solenoid (Y2).
Switched power ON.
Check for voltage at pin A (wire T002 BLU) of transmission reverse direction solenoid (Y2).
Result:

Action:
Switched power OFF.

Transmission reverse direction solenoid (Y2) disconnected.
Check for resistance between pin A and pin B of transmission reverse direction solenoid (Y2).
Result:

NO:Replace transmission reverse direction solenoid (Y2).
( 5 ) Harness Check
Action:
Switched power OFF.

Check for continuity between pin J4 (wire T002 BLU) of VCU connector (X11) and all other pins on VCU connectors (X11, X12,
and X13).
Result:
YES:High side driver circuit (wire T002 BLU) is short to power. Repair or replace harness. See appropriate wiring diagram or
schematic.
NO:Checks complete.
44
Transmission reverse direction Solenoid (Y2) high side driver shorted to ground.


Action:
Result:
Action:
Switched power OFF.

continuity.
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Result:

Action:
Switched power OFF.

Check for continuity between pin A (wire T002 BLU) of transmission reverse direction solenoid (Y2) and machine ground.
Result:
YES:High side circuit (wire T002 BLU) is short to ground. Repair or replace harness. See appropriate wiring diagram or
schematic.
OK:
( 5 ) Harness Check
Action:
Switched power OFF.

Check for continuity between pin J4 (wire T002 BLU) of VCU connector (X11) and all other pins on VCU connectors (X11, X12,
and X13).
Result:
YES:High side driver circuit (wire T002 BLU) is short to ground. Repair or replace harness. See appropriate wiring diagram or
schematic.
NO:Checks complete.
44
Transmission reverse direction solenoid (Y2) circuit is open.
Alarm Level:


Action:
Result:
Action:
Switched power OFF.

continuity.
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Result:

Action:
Switched power OFF.

Pin A (wire T002 BLU) of transmission reverse direction solenoid (Y2) and pin J4 of VCU connector (X11).
Pin B (wire R202 BLK) of transmission reverse direction solenoid (Y2) and pin A4 of VCU connector (X11).
Result:
44
Transmission reverse direction solenoid (Y2) low side driver short to power.
Alarm Level:


Action:
Result:
Action:
Switched power OFF.

continuity.
(Group 9015-10.)
Result:

( 3 ) Voltage Check
Action:
Switched power OFF.

Switched power ON.
Check for voltage at pin B (wire R202 BLK) of transmission reverse direction solenoid (Y2).
Result:

Action:
Switched power OFF.

Result:

( 5 ) Harness Check
Action:
Switched power OFF.

Check for continuity between pin F4 (wire R202 BLK) of VCU connector (X11) and all other pins on VCU connectors (X11, X12,
and X13).
Result:
schematic.
NO:Checks complete.
44
Transmission speed solenoid 1 (Y3) short to power.
Alarm Level:


Action:
Result:
Action:
Switched power OFF.

continuity.
Transmission speed solenoid 1 (Y3). See Transmission Harness (W13) Component Location . (Group 9015-10.)
Transmission harness-to-cab/canopy harness connector (X21). See Transmission Harness (W13) Component Location or
see Canopy Harness (W15) Component Location . (Group 9015-10.)
Result:

( 3 ) Voltage Check
Action:
Switched power OFF.

Disconnect transmission speed solenoid 1 (Y3).
Switched power ON.
Check for voltage at pin A (wire T003 BLU) of transmission speed solenoid (Y3).
Result:


Action:
Switched power OFF.

Transmission speed solenoid 1 (Y3) disconnected.
Check for resistance between pin A and pin B of transmission speed solenoid (Y3).
Result:

NO:Replace transmission speed solenoid (Y3).
( 5 ) Harness Check
Action:
Switched power OFF.

Disconnect VCU connector (X11) and (X13).
Check for continuity between pin 14 (wire T003 BLU) of VCU connector (X13) and all other pins on VCU connectors (X11, X12,
and X13).
Result:
schematic.
NO:Checks complete.
44
Transmission speed solenoid 1 (Y3) circuit is open.
Alarm Level:


Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Check for resistance between pin A and pin B of transmission speed solenoid 1 (Y3).
Result:

Action:
Switched power OFF.

Pin A (wire T003 BLU) of transmission speed solenoid (Y3) and pin 14 of VCU connector (X13).
Pin B (wire G011 BLK) of transmission speed solenoid (Y3) and machine ground.
Result:
44
Transmission speed solenoid 1 (Y3) short to ground.
Alarm Level:


Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Result:

Action:
Switched power OFF.

Check for continuity between pin A (wire T003 BLU) of transmission speed solenoid 1 (Y3) and machine ground.
Result:

NO:Checks complete.
44
Alarm Level:


Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

( 3 ) Voltage Check
Action:
Switched power OFF.

Switched power ON.
Check for voltage at pin A (wire T004 BLU) of transmission speed solenoid 2 (Y4).
Result:


Action:
Switched power OFF.

Result:

( 5 ) Harness Check
Action:
Switched power OFF.

and X13).
Result:
schematic.
NO:Checks complete.
44
Alarm Level:


Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Check for resistance between pin A and pin B of transmission speed solenoid (Y4).
Result:

Action:
Switched power OFF.

Pin A (wire T004 BLU) of transmission speed solenoid 2 (Y4) and pin 16 of VCU connector (X13).
Pin B (wire G011 BLK) of transmission speed solenoid 2 (Y4) and machine ground.
Result:
44
Alarm Level:


Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Result:

Action:
Switched power OFF.

Result:

NO:Checks complete.
44
Alarm Level:


Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

( 3 ) Voltage Check
Action:
Switched power OFF.

Switched power ON.
Result:


Action:
Switched power OFF.

Result:

( 5 ) Harness Check
Action:
Switched power OFF.

and X13).
Result:
schematic.
NO:Checks complete.
44
Alarm Level:


Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Result:

NO:Replace transmission speed solenoid 3 (Y5).
Action:
Switched power OFF.

Result:
44
Alarm Level:


Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Result:

Action:
Switched power OFF.

Result:

NO:Checks complete.
44
Alarm Level:


Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

( 3 ) Voltage Check
Action:
Switched power OFF.

Switched power ON.
Result:


Action:
Switched power OFF.

Result:

( 5 ) Harness Check
Action:
Switched power OFF.

and X13).
Result:
schematic.
NO:Checks complete.
44
Alarm Level:


Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Result:

Action:
Switched power OFF.

Result:
44
Alarm Level:


Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Result:

Action:
Switched power OFF.

Result:

NO:Checks complete.
000746.03- Differential Lock

44
Differential lock solenoid (Y10) short to power.
Alarm Level:
Amber Amber Check Service Code Indicator

See Differential Operation . (Group 9020-05.)
See Differential Lock Operation . (Group 9020-05.)
See Differential Lock Pressure Test . (Group 9020-25.)
Differential Lock Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Differential lock solenoid (Y10). See Transmission Harness (W13) Component Location . (Group 9015-10.)
(Group 9015-10.)
Result:

( 3 ) Voltage Check
Action:
Switched power OFF.

Disconnect differential lock solenoid (Y10).
Switched power ON.
Check for voltage at pin A (wire W110 BLU) of differential lock solenoid (Y10).
Result:

Action:
Switched power OFF.

Differential lock solenoid (Y10) disconnected.
Check for resistance between pin A and pin B of differential lock solenoid (Y10).
Result:

NO:Replace differential lock solenoid (Y10).
( 5 ) Harness Check
Action:
Switched power OFF.

Check for continuity between pin 11 (wire W110 BLU) of VCU connector (X13) and all other pins on VCU connectors (X11, X12,
and X13).
Result:
YES:High side circuit (wire W110 BLU) is short to power. Repair or replace harness. See appropriate wiring diagram or
schematic.
NO:Checks complete.

44
Differential lock solenoid (Y10) circuit is open.
Alarm Level:


Action:
Result:
Action:
Switched power OFF.

continuity.
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Result:

Action:
Switched power OFF.

Pin A (wire W110 BLU) of differential lock solenoid (Y10) and pin 11 of VCU connector (X13).
Pin B (wire G011 BLK) of differential lock solenoid (Y10) and machine ground.
Result:

44
Differential lock solenoid (Y10) short to ground.
Alarm Level:


Action:
Result:
Action:
Switched power OFF.

continuity.
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Result:

Action:
Switched power OFF.

Check for continuity between pin A (wire W110 BLU) of differential lock solenoid (Y10) and machine ground.
Result:

NO:Checks complete.
44
Differential lock switch was engaged while engine or transmission speed was too high to allow engagement.
Alarm Level:


Action:
Check for active TCU DTC 523689.07—Diff Lock Switch.

Is TCU DTC 523689.07—Diff Lock Switch active?
Result:
YES:Diagnose and clear code.

NO:Go to Machine Operation.
( 2 ) Machine Operation
Action:
Clear active TCU DTCs.

Operate machine on smooth level surface through all transmission speeds.
Do NOT engage differential lock switch.
Is 000746.31—Differential Lock TCU DTC active?
Result:
NO:Checks complete. Instruct owner/ operator on proper differential lock usage. See Differential Lock Operation . (Operator’s
Manual.)
000767.05- TCL Reverse SW

44
Forward, neutral, reverse (FNR) switch (S5) circuit is open.
Alarm Level:


Action:
Did TCL check OK?
Result:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

( 4 ) Fuse Check
Action:
Switched power OFF.

Result:

( 5 ) Voltage Check
Action:
Switched power OFF.

Switched power ON.

Result:

Action:
Switched power OFF.

Check for between:
Result:
000880.03- Brake Lights

44
The vehicle control unit (VCU) (A1) measured voltage ≥ 7.4 V for 1 second when driver was commanded OFF.
Alarm Level:

Brake Lights Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Left brake/tail light (E9). See Roof Harness (W17) Component Location . (Group 9015-10.)
Right brake/tail light (E10). See Roof Harness (W17) Component Location . (Group 9015-10.)
Roof ground (W3). See Roof Harness (W17) Component Location . (Group 9015-10.)
Cab/canopy harness-to-roof harness connector (X26). See Cab Harness (W14) Component Location or see Canopy
Result:
YES:Go to next check.

( 3 ) Voltage Check
Action:
Switched power OFF.

Disconnect left brake/tail light (E9).
Disconnect right brake/tail light (E10).
Switched power ON.
Pin A (wire L046 BRN) of left brake/tail light (E9) and right tail brake/tail light (E10).
Is 0 V indicated?
Result:
YES:Program vehicle control unit (VCU).

NO:Go to next check.
( 4 ) Harness Check
Action:
Switched power OFF.

Disconnect VCU connectors (X11, X12 and X14).
Left brake/tail light (E9) disconnected.
Right brake/tail light (E10) disconnected.
Check for continuity between pin 41 (wire L046 BRN) of VCU connector (X13) and all other pins on VCU connectors (X11, X12
and X14).
Result:
YES:Circuit is short to power. Repair circuit or replace harness. See appropriate wiring diagram or schematic.
NO:Program vehicle control unit (VCU).

44
Brake lights circuit open.
Alarm Level:


Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Check light for continuity between:
Pin A and pin C of left brake/tail light (E9).

Pin A and pin C of right brake/tail light (E10).
Result:

NO:Replace left brake/tail light (E9) or right brake/tail light (E10).
( 4 ) Voltage Check
Action:
Switched power OFF.

Switched power ON.
Apply one of the brake pedal.
Check voltage at:
Pin A (wire L046 BRN) of left brake/tail light (E9) and right tail brake/tail light (E10) for system voltage (approximately 12
V).
Result:
YES:Go to Open Circuit Check.

( 5 ) Open Circuit Check
Action:
Switched power OFF.

Pin A (wire L046 BRN) of left brake/tail light (E9) and pin 41 of VCU connector (X13).
Pin C (wire G020 BLK) of left brake/tail light (E9) and machine ground.
Pin A (wire L046 BRN) of right brake/tail light (E10) and pin 41 of VCU connector (X13).
Pin C (wire G020 BLK) of right brake/tail light (E10) and machine ground.
Result:

44
Brake lights circuit short to ground.
Alarm Level:


Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Check for continuity between pin A of both left brake/tail light (E9) and right brake/tail light (E10) and machine ground.
Result:
YES:Circuit is short to ground. Repair circuit or replace harness. See appropriate wiring diagram or schematic.
Action:
Switched power OFF.

Check for resistance between pins A (L046 BRN) and G (G020 BLK) of left brake/tail light (E9) and right brake/tail light (E10).
Is resistance indicated?
Result:

NO:Light is internally short to ground. Replace light.
000903.05- TCL Forward SW

44
Alarm Level:


Action:
Did TCL check OK?
Result:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

( 4 ) Fuse Check
Action:
Switched power OFF.

Result:

( 5 ) Voltage Check
Action:
Switched power OFF.

Disconnect transmission control lever (TCL) connector(X48).
Switched power ON.

Result:

Action:
Switched power OFF.

Check for between:
Result:
001045.04- Brake Light SW

44
Brake light switch 1 (S26) or brake light switch 2 (S27) detected as closed for 10 minutes.
Alarm Level:

Brake Light Switch Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Brake light switch 1 (S26). See Cab Harness (W14) Component Location or see Canopy Harness (W15) Component
Brake light switch 2 (S27). See Cab Harness (W14) Component Location or see Canopy Harness (W15) Component
Result:

Action:
Switched power OFF.

Disconnect VCU connectors (X12, X13, and X14).
Brake light switch 1 (S26) disconnected.
Brake light switch 2 (S27) disconnected.
Check for continuity between pin F3 (wire N005 YEL) of VCU connector (X11) and machine ground.
Result:
002000.09- No CAN from ECU

44
The engine control unit (ECU) has lost CAN communication with vehicle control unit (VCU).
→NOTE:
Diagnostic procedures for Stage II and Tier 3 engines provided.
No CAN From ECU Diagnostic Procedure—Stage II Engine

Action:
Result:

Action:
Select DIAGNOSTICS.
→NOTE:
Result:
YES: Go to Connector Check .

Action:

Result:

Action:
Switched power OFF.

Disconnect ECU connector (X10).
IMPORTANT:
Prevent possible damage to connector terminals. Use correct size male terminal pin for checking female
terminals.
Inspect pins and terminals on ECU connector (X10) and ECU (A2) for wear or damage.
Do pins or terminals show signs of wear or damage?
Result:
YES:Repair or replace damaged pins or terminals.

( 5 ) Battery Check
Action:
→NOTE:
Result:

( 6 ) Fuse Check
Action:
Switched power OFF.

Result:

NO:Replace fuse.
( 7 ) Voltage Check
Action:
Switched power OFF.

Check for voltage at ECU unswitched power 10 A fuse (F4) and sealed switch module (SSM) 7.5 A fuse (F17). See Fuse and
Result:

Action:
→NOTE:

Check for voltage at ECU unswitched power 10 A fuse (F4) and sealed switch module (SSM) 7.5 A fuse (F17).
→NOTE:
Result:
( 9 ) Wiring Check
Action:
Switched power OFF.

Result:

( 10 ) Ground Check
Action:
Switched power OFF.

Inspect frame ground near motor (W1). See Engine Harness (W10) Component Location . (Group 9015-10.)
Result:
YES:Repair or replace frame ground near motor (W1). See Engine Harness (W10) Component Location . (Group 9015-10.)
NO:Continue check.
Action:
Check continuity to ground at pin J2 (wire G002 black) on ECU connector (X10). See Engine Harness (W10) Wiring Diagram .
(Group 9015-10.)
Result:

Action:
Switched power ON.

Check for voltage at pins K1 (wire P004 red) and A2 (wire U110 red) on ECU connector (X10). See Engine Harness (W10) Wiring
Result:

Action:
→NOTE:

Check for voltage at the pins K1 (wire P004 red) and A2 (wire U110 red) on ECU connector (X10).
→NOTE:
Result:
NO:Go to ECU Check.
( 13 ) ECU Check
Action:
Program ECU.
Result:
NO:Continue check.
Action:
Replace ECU.
Result:
NO:Repair or replace engine harness (W10). See Engine Harness (W10) Component Location . (Group 9015-10.)
No CAN From ECU Diagnostic Procedure—Tier 3 Engine

Action:
Result:

Action:
Select DIAGNOSTICS.
→NOTE:
Result:
YES: Go to Battery Check .

Action:

Result:

( 4 ) Battery Check
Action:
→NOTE:
Result:

( 5 ) Fuse Check
Action:
Switched power OFF.

Result:

NO:Replace fuse.
( 6 ) Voltage Check
Action:
Switched power OFF.

Check for voltage at ECU unswitched power 20 A fuse (F4) and SSM 7.5 A fuse (F17). See Fuse and Relay Location and
Result:

Action:
→NOTE:

Check for voltage at ECU unswitched power 20 A fuse (F4) and SSM 7.5 A fuse (F17).
→NOTE:
Result:
( 8 ) Wiring Check
Action:
Switched power OFF.

Result:

( 9 ) Ground Check
Action:
Switched power OFF.

Inspect frame ground near starter motor (W1). See Transmission Harness (W13) Component Location . (Group 9015-10.)
Result:
YES:Repair or replace frame ground near starter motor (W1). See Transmission Harness (W13) Component Location . (Group
9015-10.)
NO:Continue check.
Action:
Check continuity to ground at the following pins on ECU 48-pin connector (X42): L2, L3, and M2 (wires G002 black). See Engine
Harness (W10) Wiring Diagram . (Group 9015-10.)
Result:

Action:
Switched power ON.

Check for voltage at the following pins on ECU 48-pin connector (X42): L1, L4, M1, M4 (wires P004 red), and B2 (wire U110 red).
See Engine Harness (W10) Wiring Diagram . (Group 9015-10.)
Result:

Action:
→NOTE:

Check for voltage at the following pins: L1, L4, M1, M4 (wires P004 red), and B2 (wire U110 red).
→NOTE:
Result:
NO:Program ECU.
002023.09- No CAN From SDM
44
The standard display monitor (SDM) has lost CAN communication with vehicle control unit (VCU).
NO CAN From SDM Diagnostic Procedure

Action:
Result:
Action:

Result:

Action:

Result:
002034.09- No CAN From AVC
44
The auxiliary valve controller (AVC) has lost CAN communication with vehicle control unit (VCU).
No CAN From AVC Diagnostic Procedure

Action:
Result:
Action:

Result:

Action:

Result:
002071.09- No CAN From VCU
44
The vehicle control unit (VCU) has lost CAN communication with vehicle control unit (VCU).
No CAN From ECU Diagnostic Procedure

Action:
Result:
Action:

Result:

Action:

Result:
002213.09- No CAN From JSR
44
The right joystick controller (JSR) has lost CAN communication with vehicle control unit (VCU).
NO CAN From JSR Diagnostic Procedure

Action:
Result:
Action:

Result:

Action:

Result:

44
Backup light circuit is short to power.
IMPORTANT:
315SK, 325SK and 710K ONLY
Alarm Level:


Action:
Result:
Action:
Switched power OFF.

continuity.
Note: 710K
Backup light (E22). See Roof Harness (W17) Wiring Diagram. (Group 9015-10.)
Cab/canopy harness-to-roof harness connector (X26). See Roof Harness (W17) Wiring Diagram. (Group 9015-10.)
Wiring Diagram. (Group 9015-10.)
Note: 315SK & 325SK
Left backup light (E23). See Rear Frame Harness (W38) Component Location. (Group 9015-10.)
Right backup light (E24). See Rear Frame Harness (W38) Component Location. (Group 9015-10.)
Rear Frame Harness connector(X33). See Rear Frame Harness (W38) Component Location. (Group 9015-10.)
Result:

( 3 ) Voltage Check
Action:
Switched power OFF.
Disconnect Backup light (E22). Note: 710K

Disconnect left backup light (E23). Note: 315SK & 325SK .
Disconnect right backup light (E24). Note: 315SK & 325SK .
Disconnect VCU connector 3 (X13).
Switched power ON.
Check for voltage at pin 29 (wire L017 BRN) of VCU connector (X13).
Result:

( 4 ) Harness Check
Action:
Switched power OFF.

Brake light(s) disconnected.
VCU connector 3 (X13) disconnected.
Check for continuity between pin 29 (wire L017 BRN) of VCU connector 3 (X13) and all other pins on VCU connectors (X11, X12,
and X13).
Result:
YES:Circuit (wire L017 BRN) is short to power. Repair or replace harness. See appropriate wiring diagram or schematic.
NO:Checks complete.
002392.05- Backup Lights

44
Backup light circuit is open.
IMPORTANT:
Alarm Level:

Backup Lights Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Note: 710K
Note: 315SK & 325SK
Rear frame harness connector (X33). See Rear Frame Harness (W38) Component Location. (Group 9015-10.)
Result:

Action:
Switched power OFF.
Remove backup light(s) and check for continuity.

Result:

NO:Replace backup light(s).
Action:
Switched power OFF.

Disconnect backup light (E22). Note: 710K
Note: 710K
Check for continuity between pin 29 (wire L017 BRN) of VCU connector 1 (X11) and pin 1 of backup light (E22).
Note: 315SK & 325SK
Check for continuity between pin 29 (wire L017 BRN) of VCU connector 1 (X11) and pin 1 of left backup light (E23).
Check for continuity between pin 29 (wire L017 BRN) of VCU connector 1 (X11) and pin 1 of right backup light (E24).
Result:
002392.06- Backup Lights

44
Backup light circuit is short to ground.
IMPORTANT:
Alarm Level:

Backup Lights Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Note: 710K
Note: 315SK & 325SK
Rear frame harness connector (X33). See Rear Frame Harness (W38) Component Location. (Group 9015-10.)
Result:

Action:
Switched power OFF.
Remove backup light(s) and check for continuity.

Result:

NO:Replace backup light(s).
Action:
Switched power OFF.

Disconnect backup light (E22). Note: 710K
Note: 710K
Check for continuity between pin 29 (wire L017 BRN) of VCU connector (X13) and machine ground.
Note: 315SK & 325SK
Check for continuity between pin 29 (wire L017 BRN) of VCU connector (X13) and machine ground.
Result:
002612.03- MFWD Solenoid

44
Mechanical front wheel drive (MFWD) solenoid (Y11) is short to power.
Alarm Level:

MFWD Solenoid Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Mechanical front wheel drive (MFWD) solenoid (Y11). See Transmission Harness (W13) Component Location . (Group
9015-10.)
(Group 9015-10.)
Result:

( 3 ) Voltage Check
Action:
Switched power OFF.

Disconnect mechanical front wheel drive (MFWD) solenoid (Y11).
Switched power ON.
Check for voltage at pin A (wire W111 BLU) of mechanical front wheel drive (MFWD) solenoid (Y11).
Result:

Action:
Switched power OFF.

Mechanical front wheel drive (MFWD) solenoid (Y11) disconnected.
Check for resistance between pin A and pin B of mechanical front wheel drive (MFWD) solenoid (Y11).
Result:

NO:Replace mechanical front wheel drive (MFWD) solenoid (Y11).
( 5 ) Harness Check
Action:
Switched power OFF.

Check for continuity between pin 13 (wire W111 BLU) of VCU connector (X13) and all other pins on VCU connectors (X11, X12,
and X13).
Result:
YES:Circuit (wire W111 BLU) is short to power. Repair or replace harness. See appropriate wiring diagram or schematic.
NO:Checks complete.

44
Mechanical front wheel drive (MFWD) solenoid (Y11) circuit is open.
Alarm Level:

MWFD Solenoid Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
9015-10.)
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Disconnect mechanical front wheel drive (MFWD) solenoid (Y11) disconnected.
Result:

Action:
Switched power OFF.

MFWD solenoid (Y11) disconnected.
Pin A (wire W111 BLU) of MFWD solenoid (Y11) and pin 13 of VCU connector (X13).
Pin B (wire G011 BLK) of MFWD solenoid (Y11) and machine ground.
Result:

44
Mechanical front wheel drive (MFWD) solenoid circuit is short to ground.
Alarm Level:

MFWD Solenoid Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
9015-10.)
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Disconnect mechanical front wheel drive (MFWD) solenoid (Y11) disconnected.
Result:

Action:
Switched power OFF.

Check for continuity between pin A (wire W111 BLU) of MFWD solenoid (Y11) and machine ground.
Result:

NO:Checks complete.
004312.02- TCL Selector

44
Forward, neutral, reverse (FNR) switch (S5) inputs have invalid combination.
Alarm Level:

TCL Selector Diagnostic Procedure

Action:
Did TCL check OK?
Result:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Switched power ON.

Result:

( 5 ) Harness Check
Action:
Switched power OFF.


Result:


44
Forward, neutral, reverse (FNR) switch (S5) inputs shorted to power.
Alarm Level:


Action:
Did TCL check OK?
Result:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Switched power ON.

Result:

( 5 ) Harness Check
Action:
Switched power OFF.


Result:


44
Alarm Level:


Action:
Did TCL check OK?
Result:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

( 4 ) Fuse Check
Action:
Switched power OFF.

Result:

( 5 ) Voltage Check
Action:
Switched power OFF.

Switched power ON.

Result:

Action:
Switched power OFF.

Check for between:
Result:
004312.06- TCL Direction Driver

44
Forward, neutral, reverse (FNR) switch (S5) inputs shorted to ground.
Alarm Level:


Action:
Did TCL check OK?
Result:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Check for continuity between pin A3 (wire T505 BLU) of VCU connector (X11) and machine ground.
Result:

( 5 ) Harness Check
Action:
Switched power OFF.


Result:


44
Park brake release solenoid (Y7) high side driver circuit is short to power.
Alarm Level:

See Park Brake Release Pressure Test . (Group 9020-25.)

Action:
Result:
Action:
Switched power OFF.

continuity.
(Group 9015-10.)
Result:

( 3 ) Voltage Check
Action:
Switched power OFF.

Switched power ON.
Result:

Action:
Switched power OFF.

Check for resistance between pin A and pin B of park brake release solenoid (Y7).
Result:

NO:Replace park brake release solenoid (Y7).
( 5 ) Harness Check
Action:
Switched power OFF.

Check for continuity between pin G4 (wire J007 TAN) of VCU connector (X11) and all other pins on VCU connectors (X11, X12,
and X13).
Result:
YES:High side circuit (wire J007 TAN) is short to power. Repair or replace harness. See appropriate wiring diagram or
schematic.
NO:Checks complete.

44
Park brake release solenoid (Y7) high side driver circuit is shorted to ground.
Alarm Level:


Action:
Result:
Action:
Switched power OFF.

continuity.
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Result:

Action:
Switched power OFF.

Check for continuity between pin A (wire J007 TAN) of park brake release solenoid (Y7) and machine ground.
Result:
YES:High side driver circuit (wire J007 TAN) is short to ground. Repair or replace harness. See appropriate wiring diagram or
schematic.
OK:
( 5 ) Harness Check
Action:
Switched power OFF.

Check for continuity between pin G4 (wire J007 TAN) of VCU connector (X11) and all other pins on VCU connectors (X11, X12,
and X13).
Result:
schematic.
NO:Checks complete.

44
Park brake release solenoid (Y7) circuit is open.
Alarm Level:


Action:
Result:
Action:
Switched power OFF.

continuity.
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Result:

Action:
Switched power OFF.

Pin A (wire J007 TAN) of park brake release solenoid (Y7) and pin G4 of VCU connector 1 (X11).
Pin B (wire R007 BLK) of park brake release solenoid (Y7) and pin B4 of VCU connector 1 (X11).
Result:

44
Park brake release solenoid (Y7) low side driver short to power and high side driver circuit is short to ground.
Alarm Level:


Action:
Result:
Action:
Switched power OFF.

continuity.
(Group 9015-10.)
Result:

( 3 ) Voltage Check
Action:
Switched power OFF.

Switched power ON.
Check for voltage at pin B (wire R007 BLK) of park brake release solenoid (Y7).
Result:

NO:Short to Ground Check
Action:
Switched power OFF.

Check for continuity between pin A (wire J007 TAN) of park brake release solenoid (Y7) and machine ground.
Result:
schematic.
Action:
Switched power OFF.

Result:
YES:Go to Component Interchange Check.

( 6 ) Component Interchange Check
Action:
Exchange park brake solenoid (Y7) with differential lock solenoid (Y10).
Does problem follow solenoid?
Result:
YES:Solenoid is internally shorting under load. Replace differential lock solenoid (Y10).
( 7 ) Harness Check
Action:
Switched power OFF.

Check for continuity between pin B4 (wire R007 BLK) of VCU connector (X11) and all other pins on VCU connectors (X11, X12,
and X13).
Result:
schematic.
NO:Checks complete.
522382.03- Reverse Alarm

44
The vehicle control unit (VCU) (A1) measured voltage ≥ 7.4 V for 1 second when driver was commanded OFF.
Alarm Level:

Reverse Alarm Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Backup alarm (H3). See Transmission Harness (W13) Component Location . (Group 9015-10.)
Result:

( 3 ) Voltage Check
Action:
Switched power OFF.

Disconnect backup alarm (H3).
Switched power ON.
Check for voltage at pin G3 (wire M705 PUR) of VCU connector 1 (X11).
Is voltage ≥ 7.4?
Result:

( 4 ) Harness Check
Action:
Switched power OFF.

Backup alarm (H3) disconnected.
Check for continuity between pin G3 (wire M705 PUR) of VCU connector 1 (X11) and all other pins on VCU connectors (X11,
X12, X13, and X14).
Result:
522382.06- Reverse Alarm

44
Backup alarm (H3) circuit is short to ground.
Alarm Level:

Reverse Alarm Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Backup alarm (H3). See Transmission Harness (W13) Component Location . (Group 9015-10.)
Result:

Action:
Switched power OFF.

Disconnect backup alarm (H3).
Apply approximately 12 V to the positive (+) terminal and machine ground to negative (-) terminal of backup alarm (H3).
Did backup alarm (H3) become active?
Result:

NO:Replace backup alarm (H3).
Action:
Switched power OFF.

Check for continuity between pin H3 (wire M705 PUR) of VCU connector 1 (X11) and machine ground.
Result:

( 5 ) Harness Check
Action:
Switched power OFF.

Check for continuity between pin G3 (wire M705 PUR) of VCU connector 1 (X11) and all other pins on VCU connectors (X11,
X12, X13, and X14).
Result:
YES:Repair circuit or replace harness. See appropriate wiring diagram or schematic.

522405.03- PB Pressure Switch

44
Park brake pressure switch (B13) circuit is shorted to power.
Alarm Level:

Park Brake Pressure Switch Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Park brake pressure switch (B13). See Transmission Harness (W13) Component Location . (Group 9015-10.)
(Group 9015-10.)
Vehicle Control Unit (VCU) Connector 2 (X12). See Cab Harness (W14) Component Location or see Canopy Harness (W15)
Result:

( 3 ) Voltage Check
Action:
Switched power OFF.

Disconnect park brake pressure switch (B13).
Switched power ON.
Check pin A (wire M513 PUR) of park brake pressure switch (B13) for 0.0 V.
Is 0.0 V indicated?
Result:

NO:Go to VCU Connector Check.

( 4 ) VCU Connector Check
Action:
Switched power OFF.

Park brake pressure switch (B13) disconnected.
Check for continuity between pin D1 of VCU connector (X12) and all other pins of VCU connector (X12).
Result:

( 5 ) Harness Check
Action:
Switched power OFF.

Park brake pressure switch (B13) disconnected.
Disconnect VCU connector (X11 and X13)
Check for continuity between pin D1 (wire M513 PUR) of VCU connector (X12) and all other pins on VCU connectors (X11, X12,
and X13).
Result:

523689.04- Diff Lock Switch

44
Differential lock switch (S10) circuit is short to ground.
Alarm Level:

Diff Lock Switch Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Differential lock switch (S10). See Cab Harness (W14) Component Location or see Canopy Harness (W15) Component
Result:

Action:
Switched power OFF.

Disconnect differential lock switch (S10).
Check for continuity between pin A and pin B of differential lock switch (S10) in OFF position.
Is continuity indicated in OFF position?
Result:
YES:Replace differential lock switch (S10).

( 4 ) Harness Check
Action:
Switched power OFF.

Differential lock switch (S10) disconnected.
Disconnect VCU connector (X11, X12, and X13).
Check for continuity between pin 31 (wire W010 BLU) of VCU connector (X12) and machine ground.
Result:

NO:Checks complete.
523689.07- Diff Lock Switch

44
Differential lock switch (S10) has been closed for more than 10 minutes or for 20 seconds after power up.
Alarm Level:

Diff Lock Switch Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Differential lock switch (S10). See Cab Harness (W14) Component Location or see Canopy Harness (W15) Component
Result:

Action:
Switched power OFF.

Disconnect differential lock switch (S10).
Check for continuity between pin A and pin B of differential lock switch (S10) in OFF position.
Is continuity indicated in OFF position?
Result:
YES:Replace differential lock switch (S10).

( 4 ) Harness Check
Action:
Switched power OFF.

Differential lock switch (S10) disconnected.
Disconnect VCU connector (X11, X12, and X13).
Check for continuity between pin 31 (wire W010 BLU) of VCU connector (X12) and machine ground.
Result:

NO:Checks complete.
523702.07- Flexpower
44
The engine control unit (ECU) is not receiving the flex power message from the vehicle control unit (VCU).
Alarm Level:
No Warning Lamp
Flexpower Diagnostic Procedure

Action:
Result:
Action:

Result:

Action:

Result:
YES:Program controllers.
44
The vehicle control unit (VCU) has received a message from the engine control unit (ECU) indicating the ECU has not received
the torque limit message from the VCU.
Alarm Level:
No Warning Lamp

Action:
Result:
Action:

Result:

Action:

Result:
44
The vehicle control unit (VCU) is not receiving the flex power message from the engine control unit (ECU).
Alarm Level:
No Warning Lamp

Action:
Result:
Action:

Result:

Action:

Result:
44
The vehicle control unit (VCU) has received a message from the engine control unit (ECU) at an abnormal rate of change.
Alarm Level:
No Warning Lamp

Action:
Result:
Action:

Result:

Action:

Result:
523769.07- MFWD Switch
44
MFWD switch conflicting CAN data. Momentary and Maintained switch status.
MFWD Switch Diagnostic Procedure

Action:
Result:
Action:

Result:

Action:

Result:
524172.03- Clutch Disconnect

44
Clutch disconnect switch stuck or circuit is short to power.
Alarm Level:

→NOTE:
Clutch disconnect switch (S8) is used without single lever loader control with auxiliary.
Clutch disconnect switch (S38) is used with single lever loader control with auxiliary.
Clutch Disconnect Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
→NOTE:
Clutch disconnect switch (S8). See Cab Harness (W14) Component Location or see Canopy Harness (W15) Wiring Diagram
. (Group 9015-10.)
Loader control lever connector (X58). See Cab Harness (W14) Component Location or see Canopy Harness (W15) Wiring
→NOTE:
Clutch disconnect switch (S38). See Cab Harness (W14) Component Location or see Canopy Harness (W15) Wiring
Result:

( 3 ) Voltage Check
Action:
Switched power OFF.

Disconnect loader control lever connector (X58).
Switched power ON.
Check for voltage at pin 6 (wire T008 BLU) of loader control lever connector (X58).
Result:

Action:
sss:
Is clutch disconnect switch stuck ON?
Switched power OFF.

Clutch disconnect switch disconnected.
Check for continuity between pin A and pin B of clutch disconnect switch in OFF position.
Result:
YES:Replace clutch disconnect switch.

( 5 ) Harness Check
Action:
Switched power OFF.

and X13).
Result:

NO:Checks complete.

44
Clutch disconnect switch circuit is shorted to ground.
Alarm Level:

→NOTE:

Action:
Result:
Action:
Switched power OFF.

continuity.
→NOTE:
. (Group 9015-10.)
→NOTE:
Result:

Action:
Switched power OFF.

Pin 6 (wire T008 BLU) of loader control lever connector (X58) and machine ground.
Pin 7 (wire P035 RED) of loader control lever connector (X58) and machine ground.
Result:
YES:Circuit is short to ground. Repair or replace harness. See appropriate wiring diagram or schematic.
( 4 ) Harness Check
Action:
Switched power OFF.

and X13).
Result:

NO:Checks complete.

44
Clutch disconnect switch circuit open.
Alarm Level:

→NOTE:

Action:
Result:
Action:
Switched power OFF.

continuity.
→NOTE:
. (Group 9015-10.)
→NOTE:

Result:

( 3 ) Voltage Check
Action:
Switched power OFF.

Switched power ON.
Check for voltage at pin 7 (wire P035 RED) of loader control lever connector (X58).
Result:

( 4 ) Fuse Check
Action:
Switched power OFF.

Remove transmission control 5 A fuse (F35).
Check fuse for continuity.
Result:

Action:
sss:
Does clutch disconnect switch move freely?
Switched power OFF.

Disconnect clutch disconnect switch.
Check for continuity between pin A and pin B of clutch disconnect switch in ON position.
Result:

NO:Replace clutch disconnect switch.
Action:
Switched power OFF.

Loader control lever connector (X58) disconnected.
Section 9001 - DIAGNOSTICS Group 40: Vehicle Control Unit (VCU) Diagnostic Trouble Codes
Pin 6 (wire T008 BLU) of loader control lever connector (X58) and pin 23 of VCU connector (X13).
Pin 7 (wire P035 RED) of loader control lever connector (X58) and pin C7 of fuse and relay block (X3).
Result:
44
CAN communication lost between the JSR & TCU.

Action:
Result:
Action:

Result:

Action:

Result:
Group 40 - Vehicle Control Unit (VCU) Diagnostic Trouble Codes

Vehicle Control Unit (VCU) Diagnostic Trouble Codes
Note: For in-depth diagnostics on all VCU diagnostic trouble codes, see specific code diagnostic procedure in this group.
328
Battery voltage input is above 15 V.
Alarm Level:

See Vehicle Control Unit (VCU) Circuit Theory of Operation

Action:
Switched power OFF.

Is voltage less than 15 V?
Result:
YES:Go to System Voltage Check.

NO:Replace battery.
Action:
Engine RUNNING.
Is voltage more than 15 V?
Result:

NO:Reprogram controller.
Action:

Result:

328
Battery voltage input is below 11.7 V.
Alarm Level:

Action:
Switched power OFF.

Result:

Action:
Result:
Action:
Switched power OFF.

continuity.
Accessory relay (K20). See Cab Harness (W14) Component Location or see Canopy Harness (W15) Component Location .
(Group 9015-15.)
Result:

( 4 ) Fuse Check
Action:
Switched power OFF.

9015-10.)

VCU Switched Power 5 A Fuse (F33)
Result:

NO:Replace fuse(s).
( 5 ) Relay Check
Action:
Switched power OFF.

Disconnect accessory relay (K20).
Apply 12 V to pin 1 of accessory relay (K20).
Apply ground to pin 1 of accessory relay (K20).
sss:
Did accessory relay (K20) “Click”
Check for continuity between pin 3 of accessory relay (K20) and pin 5 of accessory relay (K20).
Result:

NO:Replace accessory relay (K20).
( 6 ) Voltage Check
Action:
Switched power ON.

Engine RUNNING.
Result:

NO:Go to Alternator Check.
Action:

Result:

Action:
Switched power OFF.

Disconnect vehicle control unit (VCU) connector 2 (X12)
Pin L1 (wire P017 RED) of VCU connector (X11) and pin D8 of fuse and relay block (X3).
Pin M1 (wire P033 RED) of VCU connector (X11) and pin AA8 of fuse and relay block (X3).
Pin 3 (wire G001 BLK) of VCU connector (X12) and operator station floor ground (W2).
Result:
328
The software on the controllers are not compatible. Install the latest payloads.
Alarm Level:
Additional References: See Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.)
Software Incorrect Diagnostic Procedure

Action:
Switched power ON. Using Service ADVISOR ™ or standard display monitor (SDM), clear diagnostic trouble codes (DTC). Cycle
switched power. Does DTC return?
Result:

NO:Checks complete.
Action:
Check software version numbers for VCU and SDM. Do controllers have the same major revision number?
Result:
328
Software data erratic, intermittent or incorrect.
Alarm Level:

Action:
Result:
Action:

Result:
328
Messages are missing or other controllers in CAN network are not completed in the required time.
Alarm Level:

Action:
Result:
NO:Go to
Action:
Switched power OFF.

Result:

NO:Repair or replace circuit. See appropriate schematic or wiring diagram.
Action:
Result:
NO:Update controller with correct software.
328
The model number and VIN number is missing in the vehicle control unit (VCU).
Alarm Level:
Additional References: See Vehicle Control Unit (VCU) Circuit Theory of Operation . (Group 9015-15.)

Action:
Result:
NO:
( 2 ) Program Controller
Action:
Program the vehicle control unit (VCU).

Is DTC 000237.31 still active?
Result:
YES:Replace vehicle control unit (VCU).

NO:Checks complete.
17
The engagement and monitor unit (EMU) has detected an internal error.
Alarm Level:
Additional References: See Engagement and Monitor Unit (EMU) Circuit Theory of Operation . (Group 9015-15.)

Action:
Result:

Action:
Switched power OFF.

Wait 20 seconds.
Switched power ON.
Check for active EMU codes.
Is EMU code 000628.12 present?
Result:
NO:Checks complete.
328
The vehicle control unit (VCU) is faulty.
Alarm Level:
Additional References: See Vehicle Control Unit (VCU) Circuit Theory of Operation . (Group 9015-15.)
Controller Fault Diagnostic Procedure

Action:
Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes (DTCs) . (Group 9015-20.)
Are other CAN communication diagnostic trouble codes present?
Result:
YES:Correct other diagnostic trouble codes and recheck.

NO:Replace vehicle control unit (VCU).
000677.03- Start Relay

328
Starter relay (K5) circuit is short to power. (IT4 only.)
Alarm Level:
See Vehicle Control Unit (VCU) Output Test . (Group 9015-20.)
Starter Relay Diagnostic Procedure

Action:
Result:
NO:Go to Connector Check
Action:
Switched power OFF.

continuity.
ECU connector 3 (X5503). See Engine Harness (W10) Component Location . (Group 9015-10.)
Result:

( 3 ) Start Relay Check
Action:
Switched power OFF.

Disconnect negative battery terminal.
Apply 12 V to terminal 1 and ground to terminal 2 of starter relay (K5).
sss:
Does starter relay (K5) “Click”?
IMPORTANT:
Starter relay (K5) contains a diode between terminal C1 and C2.
Check for continuity between terminal C1 (positive) and terminal C2 (negative) of starter relay (K5).
Result:

Action:
Disconnect ECU connector 3 (X5503).

Connect negative battery terminal.
Switched power ON.
Check for 0.0 V at:
Pin 26 (R005 BLK) of ECU connector 3 (X5503).

Pin 30 (E005 WHT) of ECU connector 3 (X5503).
Result:

NO:Circuit with voltage is short to power. Repair or replace harness. See appropriate wiring diagram or schematic.
( 5 ) Harness Check
Action:
Switched power OFF.

ECU connector 3 (X5503) disconnected.
Disconnect ECU Connector 1 (X5501).
Pin 26 (R005 BLK) of ECU connector 3 (X5503) and all other pins of ECU connectors.
Pin 30 (E005 WHT) of ECU connector 3 (X5503) and all other pins of ECU connectors.
Result:
YES:Circuit with continuity is short to power. Repair or replace harness. See appropriate wiring diagram or schematic.
NO:Program Controller.

328
Start relay (K5) control circuit is open. (IT4 Only.)
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

( 3 ) Start Relay Check
Action:
Switched power OFF.

Apply 12 V to terminal 1 and ground to terminal 2 of starter relay (K5).
sss:
Does starter relay (K5) “Click”?
IMPORTANT:
Result:

Action:
Switched power OFF.

Pin 26 (R005 BLK) of ECU connector 3 (X5503) and terminal C2 of starter relay (K5).
Pin 30 (E005 WHT) of ECU connector 3 (X5503) and terminal C1 of starter relay (K5).
Result:
YES:Program Controller.
NO:Circuit with out continuity is open. Repair or replace harness. See appropriate wiring diagram or schematic.

328
Starter relay (K5) circuit is short to ground. (IT4 Only.)
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

IMPORTANT:
Result:
YES:Replace starter relay (K5).

NO:Go to Short Circuit Check.
Action:

Pin 26 (R005 BLK) of ECU connector 3 (X5503) and machine ground.

Pin 30 (E005 WHT) of ECU connector 3 (X5503) and machine ground.
Result:
YES:Circuit with continuity is short to ground. Repair or replace harness. See appropriate wiring diagram or schematic.
( 5 ) Harness Check
Action:
Switched power OFF.

ECU connector 3 (X5503) disconnected.
Pin 26 (R005 BLK) of ECU connector 3 (X5503) and all other pins of ECU connectors.
Pin 30 (E005 WHT) of ECU connector 3 (X5503) and all other pins of ECU connectors.
Result:
001237.31- Engine Shutdown
328
Delayed engine shutdown was not properly completed. During turbocharger cool down period (120 seconds maximum) engine
was shut down before the proper amount of cool down time was allowed to pass.
Alarm Level:
Engine Shutdown Diagnostic Procedure

( 1 ) Code Check
Action:
Run machine at slow idle for 5—10 minutes.

Turn machine Off.
IMPORTANT:
If “ENGINE SHUTDOWN” is displayed on monitor, do not abort.
Switched power ON.

Check for active VCU DTC 001237.31—Engine Shutdown.
Is code active?
Result:
NO:Checks complete.

328
Starter motor (M1) was engaged for 30 or more seconds. Starter motor needs to be disengaged for 60 seconds to reset engine
control unit (ECU) internal timer. (IT4 Only.)
Alarm Level:

Action:
Result:
NO:Go to Active Code Check.
Action:
Switched power ON.

Check for active VCU diagnostic trouble code 000677.03—Start Relay.
Is code active?
Result:
YES:Diagnose and clear active code 000677.03.

Action:
Switched power OFF.

continuity.
Starter motor (M1). See Engine Harness (W10) Component Location . (Group 9015-10.)
Result:
YES:Go to Start Relay Check.

Action:
Switched power OFF.

Disconnect starter motor (M1).
Switched power ON.
Check wire (E009 WHT) for system voltage (approximately 12 V).
Result:
NO:Repair or replace starter.
001638.00- Hyd Temp Sensor

328
Hydraulic oil temperature sensor (B10) measured temperature exceeding 230ºF (110ºC). (IT4 Only.)
Alarm Level:
See Hydraulic Oil Overheats . (Group 9025-15.)
Hydraulic Temperature Sensor Diagnostic Procedure

Action:
Result:
NO:Go to Hydraulic Oil Cooler Restriction Check.
( 2 ) Hydraulic Oil Cooler Restriction Check
Action:
Perform Hydraulic Oil Cooler Restriction Test . (Group 9025-25.)
Result:
YES:Go to Hydraulic Circuit Pressure Check

NO:Diagnose and repair hydraulic oil cooler.
( 3 ) Hydraulic Circuit Pressure Check
Action:
Perform Hydraulic Circuit Pressure Release test. (Group 9025-25.)

Does hydraulic circuit pressure release test OK?
Result:
YES:Go to Hydraulic Oil Filter Check.

NO:Diagnose and repair hydraulic circuit.
( 4 ) Hydraulic Oil Filter Check
Action:
See Replace Hydraulic Oil Filter . (Operator’s manual.)

Warm up hydraulic oil. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)
Check for active code 001638.00—Hyd Temp Sensor.
Is code active?
Result:
NO:Checks complete.

328
Hydraulic oil temperature sensor (B10) circuit voltage is out of range low. (IT4 Only.)
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Hydraulic oil temperature sensor (B10). See Transmission Harness (W13) Component Location . (Group 9015-10.)
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Disconnect hydraulic oil temperature sensor (B10).
Measure hydraulic oil temperature sensor (B10). See Electrical Component Specifications . (Group 9015-20.)
Does hydraulic oil temperature sensor (B10) meet specifications?
Result:

NO:Replace hydraulic oil temperature sensor (B10).

( 4 ) Circuit Check
Action:
Switched power OFF.

Hydraulic oil temperature sensor (B10) disconnected.
Check for continuity between
Pin 31 (wire X010 YEL) of VCU connector (X13) and pin A of hydraulic oil temperature sensor (B10).
Pin L2 (wire R059 BLK ) of VCU connector (X11) and pin A of hydraulic oil temperature sensor (B10).
Result:

328
Hydraulic oil temperature sensor (B10) is measuring temperature is rising and exceeds 210ºF (99ºC). (IT4 Only.)
Alarm Level:

Action:
Result:
NO:Go to Hydraulic Oil Cooler Restriction Check.
Action:
Result:
YES:Go to Hydraulic Oil Filter Check.

Action:

Check for active code 001638.16—Hyd Temp Sensor.
Is code active?
Result:
NO:Checks complete.
001713.00- Hyd Oil Restriction

328
Hydraulic oil filter restriction switch (B12) is closed. (Restricted.)
Alarm Level:
Hydraulic Oil Restriction Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Hydraulic oil filter restriction switch (B12). See Transmission Harness (W13) Component Location . (Group 9015-10.)
(Group 9015-10.)
Result:
YES:Go to Switch Check.

( 3 ) Switch Check
Action:
Switched power OFF.

Disconnect hydraulic oil filter restriction switch (B12) connector.
Check for continuity between pins 1 and 2 on hydraulic oil filter restriction switch (B12) connector.
Result:
YES:Short in hydraulic oil filter restriction switch (B12). Replace switch.

Action:
Switched power OFF.

Disconnect hydraulic oil filter restriction switch (B12).
Check for continuity between pin 1 of hydraulic oil filter restriction switch (B12) and machine ground.
Result:
YES:Replace hydraulic oil filter restriction switch (B12).

NO:Go to Circuit Check.
( 5 ) Circuit Check
Action:
Switched power OFF.

Hydraulic oil filter restriction switch (B12) disconnected.
Check for continuity between pin 31 (wire N112 YEL) of VCU connector (X13) and machine ground.
Result:
YES:Go to Hydraulic Oil Cooler Restriction Check.

Action:
Result:
YES:Go to Hydraulic Circuit Pressure Check

Action:

Check for active code 001713.00—Hyd Oil Restriction.
Is code active?
Result:
NO:Checks complete.
001762.03- Hydraulic Pressure

328
Hydraulic system pressure sensor (B26) circuit is short to power. (Above 4.5 V.)
Alarm Level:
Hydraulic Pressure Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Hydraulic system pressure sensor (B26). See Transmission Harness (W13) Component Location . (Group 9015-10.)
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Disconnect:
Hydraulic system pressure sensor (B26).

Vehicle control unit (VCU) connector 1 (X11).
Switched power ON.

Check the following pins for 0.0 V.
Pin 1 (wire R055 BLK) of hydraulic system pressure sensor (B26).

Pin 2 (wire P055 RED) of hydraulic system pressure sensor (B26).
Pin 4 (wire N030 YEL) of hydraulic system pressure sensor (B26).
Result:

NO:Circuit with voltage is short to power. Repair circuit or replace harness. See appropriate wiring diagram or schematic.
( 4 ) Harness Check
Action:
Hydraulic system pressure sensor (B26) disconnected.

Disconnect:
Negative terminal of the battery.

Vehicle control unit (VCU) connectors (X13 and X14)
Seat position sensor (B9).
Pin H2 (wire R055 BLK) of VCU connector X11 and all other pins on VCU connectors (X11, X12, X13, and X14).
Pin J2 (wire P055 RED) of VCU connector X11 and all other pins on VCU connectors (X11, X12, X13, and X14).
Pin 13 (wire N030 YEL) of VCU connector X12 and all other pins on VCU connectors (X11, X12, X13, and X14).
Result:
YES:Circuit with continuity indicated is short to power. Repair circuit or replace harness. See appropriate wiring diagram or
schematic.

328
Hydraulic system pressure sensor (B26) circuit is open or short to ground. (Below 0.4 V)
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
(Group 9015-10.)
Result:

( 3 ) Voltage Check
Action:
Switched power OFF.

Disconnect hydraulic system pressure sensor (B26) connector.
Switched power ON.
Check pin 2 (wire P055 RED) for voltage above 0.4 V.
Result:

Action:
Switched power OFF.

Measure resistance between pins 2 (wire P055 RED) and 4 (wire N030 YEL) of hydraulic system pressure sensor (B26).
Result:

NO:Replace hydraulic system pressure sensor (B26).
Action:
Switched power OFF.

Disconnect:

Pin 1 (wire R055 BLK) of hydraulic system pressure sensor (B26) and pin H2 of VCU connector X11.
Pin 2 (wire P055 RED) of hydraulic system pressure sensor (B26) and pin J2 of VCU connector X11.
Pin 4 (wire N030 YEL) of hydraulic system pressure sensor (B26) and pin 13 of VCU connector X12 .
Result:

NO:Circuit with out continuity is open. Repair circuit or replace harness. See appropriate wiring diagram or schematic.
Action:
Switched power OFF.

VCU connectors X11 and X12 disconnected.
Pin 1 (wire R055 BLK) of hydraulic system pressure sensor (B26) and machine ground.
Pin 2 (wire P055 RED) of hydraulic system pressure sensor (B26) and machine ground.
Pin 4 (wire N030 YEL) of hydraulic system pressure sensor (B26) and machine ground.
Result:
YES:Circuit with continuity indicated is short to ground. Repair circuit or replace harness. See appropriate wiring diagram or
schematic.
( 7 ) Harness Check
Action:

Disconnect:

Vehicle control unit (VCU) connectors (X13 and X14)
Pin 13 (wire N030 YEL) of VCU connector X12 and all other pins on VCU connectors (X11, X12, X13, and X14).
Result:
schematic.

328
Hydraulic system pressure sensor (B26) data above maximum values during calibration.
Alarm Level:
See Hydraulic System Operation . (Group 9025-05.)

Action:
Result:
Action:
Switched power OFF.

continuity.
(Group 9015-10.)
Result:
YES:Go to Calibrate Machine Check.

( 3 ) Calibrate Machine Check
Action:
Calibrate machine hydraulics.

See Standard Display Monitor (SDM)—Service Menu . (Group 9015-16.)
Does machine pass hydraulic calibration?
Result:
NO: See Hydraulic System Operation . (Group 9025-05.)

328
Hydraulic system pressure sensor (B26) data below minimum values during calibration.
Alarm Level:
See Hydraulic System Operation . (Group 9025-05.)

Action:
Result:
Action:
Switched power OFF.

continuity.
(Group 9015-10.)
Result:
YES:Go to Calibrate Machine Check.

( 3 ) Calibrate Machine Check
Action:
Calibrate machine hydraulics.

See Standard Display Monitor (SDM)—Service Menu . (Group 9015-16.)
Does machine pass hydraulic calibration?
Result:
NO: See Hydraulic System Operation . (Group 9025-05.)

328
Loss of controller area network (CAN) communication with sealed switch module (SSM).
Alarm Level:
See Engine Control Unit (ECU) Circuit Theory of Operation
No CAN from SSM Diagnostic Procedure

Action:
Result:
( 2 ) Fuse Check
Action:
Ignition OFF.
Disconnect fuse (F17). See Fuse and Relay Location and Specifications . (Group 9015-10.)
Check fuse (F17) for continuity.
Result:

NO:Replace fuse(s) without continuity indicated.
( 3 ) Voltage Check
Action:
Ignition OFF.
Disconnect SSM connector (X40). See Cab Harness (W14) Component Location or see Canopy Harness (W15) Component
Ignition ON.
Check circuit P017 RED for voltage at pin 1 on SSM connector (X40).
Is system voltage (approximately 12 Volts) present at all pins?
Result:
YES:Go to Ground Circuit Check.

NO:Wire(s) without voltage are open. Repair wire or replace harness. See appropriate wiring diagram or schematic.
( 4 ) Ground Circuit Check
Action:
Ignition OFF.
Check circuit G001 BLK for ground at pin 2 on SSM connector (X40).
Is ground present?
Result:
YES:Circuit G001 BLK is open. Repair circuit or replace harness. See appropriate wiring diagram or schematic.
Action:

Result:
YES:Program sealed switch module (SSM).


328
Loss of controller area network (CAN) communication with sealed switch module (SSM).
Alarm Level:
No CAN from SSM Diagnostic Procedure

Action:
Result:
( 2 ) Fuse Check
Action:
Ignition OFF.
Disconnect fuse (F17). See Fuse and Relay Location and Specifications . (Group 9015-10.)
Result:

( 3 ) Voltage Check
Action:
Ignition OFF.
Ignition ON.
Check circuit P017 RED for voltage at pin 1 on SSM connector (X40).
Result:

Action:
Ignition OFF.
Check circuit G001 BLK for ground at pin 2 on SSM connector (X40).
Is ground present?
Result:
Action:

Result:
YES:Program sealed switch module (SSM).

002228.09- No CAN from HVC

328
Loss of controller area network (CAN) communication with hydraulic valve controller (HVC).
Alarm Level:
No CAN from HVC Diagnostic Procedure

( 1 ) HVC Sensor Check
Action:
Turn battery disconnect to OFF. Wait 5 seconds and turn battery disconnect to ON.
View hydraulic valve controller (HVC) monitored sensor outputs, by accessing the Diagnostics submenu on the standard display
monitor (SDM). See Standard Display Monitor (SDM)—Diagnostics . (Group 9015-16.)
Are all hydraulic valve controller sensor values displayed on the SDM?
Result:
YES:Program hydraulic valve controller (HVC).

( 2 ) Fuse Check
Action:
Ignition OFF.
Disconnect fuses (F14 and F32). See Fuse and Relay Location and Specifications . (Group 9015-10.)
Check fuses (F14 and F32) for continuity.
Result:

( 3 ) Voltage Check
Action:
Ignition OFF.
Disconnect HVC connector (X16).
Ignition ON.
Check circuit P014 RED for voltage at pins L1 on HVC connector (X16).
Check circuit P032 RED for voltage at pin M1 on HVC connector (X16).
Result:

Action:
Ignition OFF.
Disconnect HVC connectors (X16).
Check circuit G007 BLK for ground at pins G1, K4, L2, and M2 on HVC connector (X16).
Check circuit G007 BLK for ground at pin H4 on HVC connector (X15).
Is ground present?
Result:
Action:

Result:
YES:Replace the hydraulic valve controller (HVC).

002228.12- EH Watchdog
328
The VCU is not receiving the HVC messages.
Alarm Level:
EH Watchdog Diagnostic Procedure

Action:
Result:
Action:

Result:

Action:

Result:
002350.03- Drive Lights

328
Left front turn signal (E12), left rear turn signal (E11), right front turn signal (E14) or right rear turn signal (E13) circuit is short
to power.
Alarm Level:
See Horn, Lights, and Beacon Circuit Theory of Operation . (Group 9015-15.)
Drive Lights Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Left front turn signal (E12). See Roof Harness (W17) Component Location . (Group 9015-10.)
Left rear turn signal (E11). See Roof Harness (W17) Component Location . (Group 9015-10.)
Right front turn signal (E14). See Roof Harness (W17) Component Location . (Group 9015-10.)
Right rear turn signal (E13). See Roof Harness (W17) Component Location . (Group 9015-10.)
Result:
YES:Go to Left Component Check.

( 3 ) Left Component Check
Action:
Switched power OFF.

Disconnect left front turn signal (E12).
Disconnect left rear turn signal (E11).
Check light for continuity.
Result:
YES:Go to Right Component Check.

NO:Replace left front turn signal (E12) or left rear turn signal (E11).
( 4 ) Right Component Check
Action:
Switched power OFF.

Disconnect right front turn signal (E14).
Disconnect right rear turn signal (E13).
Result:

NO:Replace right front turn signal (E14) or right rear turn signal (E13).
Action:
Ignition OFF.
Left front turn signal (E12) disconnected.
Left rear turn signal (E11) disconnected.
Right front turn signal (E14) disconnected.
Right rear turn signal (E13) disconnected.
Check circuit L047 BRN for power at pin A of turn signals (E11, E12, E13, and E14) harness connectors.
Is voltage present?
Result:
YES:Circuit L047 BRN or L048 BRN is short to power. Repair circuit or replace harness. See appropriate wiring diagram or
schematic.
( 6 ) Harness Check
Action:
Turn battery disconnect switch OFF.

Disconnect VCU connector (X11, X12, X13, and X14).
Check for continuity between pin 18 (wire L047 BRN) on VCU connector (X12) and all other pins on VCU connector (X11, X12,
X13, and X14).
X13, and X14).
Result:
YES:Circuit L047 BRN or L048 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See
appropriate wiring diagram or schematic.

328
Left front turn signal (E12), left rear turn signal (E11), right front turn signal (E14) or right rear turn signal (E13) circuit is open.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Result:

Action:
Switched power OFF.

Result:

Action:
Switched power OFF.

Check for continuity from pin 18 (wire L047 BRN) of VCU connector (X12) to machine ground.
Result:

NO:Checks complete.

328
Left front turn signal (E12), left rear turn signal (E11), right front turn signal (E14) or right rear turn signal (E13) circuit is short
to ground.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:
YES:Go to Component Check — Left.

( 3 ) Component Check — Left
Action:
Switched power OFF.

Check for continuity.
Result:
YES:Go to Component Check — Right.

( 4 ) Component Check — Right
Action:
Switched power OFF.

Result:

( 5 ) Circuit Check
Action:
Switched power OFF.

Check for continuity at:
Pin 30 (wire L048 BRN) of VCU connector (X12) to machine ground.Pin 18 (wire L047 BRN) of VCU connector (X12) to
machine ground.
Result:

NO:Checks complete.
002354.03- Front Work Lights

328
Left front drive light (E7), right front drive light (E8), left brake/tail light (E9), or right brake/tail light (E10) circuit is short power.
Alarm Level:
Front Work Lights Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Left front drive light (E7). See Roof Harness (W17) Component Location . (Group 9015-10.)
Right front drive light (E8). See Roof Harness (W17) Component Location . (Group 9015-10.)
Result:

Action:
Switched power OFF.

Disconnect left front drive light (E7).
Result:

NO:Replace left front drive light (E7) or left brake/tail light (E9).
Action:
Switched power OFF.

Disconnect right front drive light (E8).
Result:

NO:Replace right front drive light (E8) or right brake/tail light (E10).
Action:
Ignition OFF.
Left front drive light (E7) disconnected.
Right front drive light (E8) disconnected.
Check circuit L043 BRN for power at pin A of turn signals (E7, E8, E9, and E10) harness connectors.
Is voltage present?
Result:
YES:Circuit L043 BRN is short to power. Repair circuit or replace harness. See appropriate wiring diagram or schematic.
( 6 ) Harness Check
Action:

X13, and X14).
Result:
YES:Circuit L043 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See appropriate wiring
diagram or schematic.

328
Left front drive light (E7), right front drive light (E8), left brake/tail light (E9), or right brake/tail light (E10) circuit is open.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Result:

NO:Replace left front drive light (E7) or left brake/tail light (E9).
Action:
Switched power OFF.

Result:

NO:Replace right front drive light (E8) or right brake/tail light (E10).
( 5 ) Voltage Check
Action:

Switched power ON.
Check voltage at:
Pin 1 (wire L043 BRN) of left front drive light (E7) for system voltage (approximately 12 V).
Pin 2 (wire G020 BLK) of left front drive light (E7) for 0.0 V.
Pin 1 (wire L043 BRN) of right front drive light (E8) for system voltage (approximately 12 V).
Pin 2 (wire G020 BLK) of right front drive light (E8) for 0.0 V.
Pin 1 (wire L043 BRN) of left brake/tail light (E9) for system voltage (approximately 12 V).
Pin 2 (wire G020 BLK) of left brake/tail light (E9) for 0.0 V.
Pin 1 (wire L043 BRN) of right brake/tail light (E10) for system voltage (approximately 12 V).
Pin 2 (wire G020 BLK) of right brake/tail light (E10) for 0.0 V.
Result:

Action:
Switched power OFF.

Pin 1 (wire L043 BRN) of left front drive light (E7) and pin 5 of VCU connector (X13).
Pin 2 (wire G020 BLK) of left front drive light (E7) and machine ground.
Pin 1 (wire L043 BRN) of right front drive light (E8) and pin 5 of VCU connector (X13).
Pin 2 (wire G020 BLK) of right front drive light (E8) and machine ground.
Pin 1 (wire L043 BRN) of left brake/tail light (E9) and pin 5 of VCU connector (X13).
Pin 2 (wire G020 BLK) of left brake/tail light (E9) and machine ground.
Pin 1 (wire L043 BRN) of right brake/tail light (E10) and pin 5 of VCU connector (X13).
Pin 2 (wire G020 BLK) of right brake/tail light (E10) and machine ground.
Result:

( 7 ) Harness Check
Action:
Switched power OFF.

Check for continuity between pin 5 of VCU connector (X13) and all other pins in VCU connector (X13).
Result:
YES:Short to power. Repair or replace harness. See appropriate wiring diagram or schematic.
NO:Checks complete.

328
Left front drive light (E7) or right front drive light (E8) circuit is short to ground.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Result:

NO:Replace left front drive light (E7).

Action:
Switched power OFF.

Result:

NO:Replace right front drive light (E8).
Action:
Switched power OFF.

Result:

NO:Checks complete.

328
Left front work light (E5) or right front work light (E6) circuit is short to power.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Left front work light (E5). See Roof Harness (W17) Component Location . (Group 9015-10.)
Right front work light (E5). See Roof Harness (W17) Component Location . (Group 9015-10.)
Result:

Action:
Switched power OFF.

Disconnect left front work light (E5).
Result:

NO:Replace left front work light (E5).

Action:
Switched power OFF.

Disconnect right front work light (E6).
Result:

NO:Replace right front work light (E6).
Action:
Ignition OFF.
Left front work light (E5) disconnected.
Right front work light (E6) disconnected.
Check circuit L042 BRN for power at pin A of turn signals (E5 and E6) harness connectors.
Is voltage present?
Result:
( 6 ) Harness Check
Action:

X13, and X14).
Result:

328
Left front work light (E5) or right front work light (E6) circuit is open.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Result:


Action:
Switched power OFF.

Result:

NO:Replace right front work light (E6).
( 5 ) Voltage Check
Action:

Switched power ON.
Check voltage at:
Pin 1 (wire L042BRN) of left front work light (E5) for system voltage (approximately 12 V).
Pin 2 (wire G020 BLK) of left front work light (E5) for 0.0 V.
Pin 1 (wire L042 BRN) of right front work light (E6) for system voltage (approximately 12 V).
Pin 2 (wire G020 BLK) of right front work light (E6) for 0.0 V.
Result:

Action:
Switched power OFF.

Pin 1 (wire L042 BRN) of left front work light (E5) and pin 4 of VCU connector (X13).
Pin 1 (wire L042 BRN) of right front work light (E6) and pin 4 of VCU connector (X13).
Pin 2 (wire G020 BLK) of left front work light (E5) and machine ground.
Pin 2 (wire G020 BLK) of right front work light (E6) and machine ground.
Result:

( 7 ) Harness Check
Action:
Switched power OFF.

Result:
NO:Checks complete.

328
Left front work light (E5) or right front work light (E6) circuit is short to ground.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Result:


Action:
Switched power OFF.

Result:

NO:Replace front work light (E6).
( 5 ) Circuit Check
Action:
Switched power OFF.

Pin G2 (wire L042 BRN) of VCU connector (X13) to machine ground.
Result:

NO:Checks complete.
002360.03- Rear Work Lights

328
Left rear work light (E1) or right rear work light (E4) circuit short to power.
Alarm Level:
Rear Work Lights Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Left rear work light (E1). See Roof Harness (W17) Component Location . (Group 9015-10.)
Right rear work light (E4). See Roof Harness (W17) Component Location . (Group 9015-10.)
Result:

Action:
Switched power OFF.

Disconnect left rear work light (E1).
Result:

NO:Replace left rear work light (E1).

Action:
Switched power OFF.

Disconnect right rear work light (E4).
Result:

NO:Replace right rear work light (E4).
Action:
Ignition OFF.
Left rear work light (E1) disconnected.
Right rear work light (E4) disconnected.
Is voltage present?
Result:
( 6 ) Harness Check
Action:

X13, and X14).
Result:

328
Left rear work light (E1) or right rear work light (E4) circuit open.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Result:


Action:
Switched power OFF.

Result:

( 5 ) Voltage Check
Action:

Switched power ON.
Check voltage at:
Pin 1 (wire L040 BRN) of left rear work light (E1) for system voltage (approximately 12 V).
Pin 2 (wire G020 BLK) of left rear work light (E1) for 0.0 V.
Pin 1 (wire L040 BRN) of right rear work light (E4) for system voltage (approximately 12 V).
Pin 2 (wire G020 BLK) of right rear work light (E4) for 0.0 V.
Result:

Action:
Switched power OFF.

Pin 1 (wire L040 BRN) of left rear work light (E1) and pin 2 of VCU connector (X13).
Pin 1 (wire L040 BRN) of right rear work light (E4) and pin 2 of VCU connector (X13).
Pin 2 (wire G020 BLK) of left rear work light (E1) and machine ground.
Pin 2 (wire G020 BLK) of right rear work light (E4) and machine ground.
Result:

( 7 ) Harness Check
Action:
Switched power OFF.

Result:
NO:Checks complete.

328
Left rear work light (E1) or right rear work light (E4) circuit short to ground.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Result:


Action:
Switched power OFF.

Result:

( 5 ) Circuit Check
Action:
Switched power OFF.

Pin 2 (wire L040 BRN) of VCU connector (X13) to machine ground.
Result:

NO:Checks complete.

328
Left rear work light (if equipped) (E2) or right rear work light (if equipped) (E3) circuit is short to power.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Result:


Action:
Switched power OFF.

Result:

Action:
Ignition OFF.
Is voltage present?
Result:
( 6 ) Harness Check
Action:

X13, and X14).
Result:

328
Left rear work light (if equipped) (E2) or right rear work light (if equipped) (E3) circuit is open.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Result:


Action:
Switched power OFF.

Result:

( 5 ) Voltage Check
Action:

Switched power ON.
Check voltage at:
Pin 1 (wire L041 BRN) of left rear work light (E2) for system voltage (approximately 12 V).
Pin 2 (wire G020 BLK) of left rear work light (E2) for 0.0 V.
Pin 1 (wire L041 BRN) of right rear work light (E3) for system voltage (approximately 12 V).
Pin 2 (wire G020 BLK) of right rear work light (E3) for 0.0 V.
Result:

Action:
Switched power OFF.

Pin 1 (wire L041 BRN) of left rear work light (E2) and pin 3 of VCU connector (X13).
Pin 1 (wire L041 BRN) of right rear work light (E3) and pin 3 of VCU connector (X13).
Result:

( 7 ) Harness Check
Action:
Switched power OFF.

Result:
NO:Checks complete.

328
Left rear work light (if equipped) (E2) or right rear work light (if equipped) (E3) circuit is short to ground.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Disconnect left docking light (E15).
Result:

NO:Replace left docking light (E15).

Action:
Switched power OFF.

Disconnect right docking light (E16).
Result:

NO:Replace right docking light (E16).
( 5 ) Circuit Check
Action:
Switched power OFF.

Left docking light (E15) disconnected.
Right docking light (E16) disconnected.
Pin 17 and 53 (wires L044 BRN) of VCU connector (X13) to machine ground.
Result:

NO:Checks complete.

328
Left docking light (E15) or right docking light (E16) circuit is short to power.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Left docking light (E15). See Roof Harness (W17) Component Location . (Group 9015-10.)
Right docking light (E16). See Roof Harness (W17) Component Location . (Group 9015-10.)
Result:

Action:
Switched power OFF.

Result:


Action:
Switched power OFF.

Result:

Action:
Ignition OFF.
Is voltage present?
Result:
( 6 ) Harness Check
Action:

Check for continuity between pin 17 and 53 (wire L044 BRN) on VCU connector (X13) and all other pins on VCU connector (X11,
X12, X13, and X14).
Result:
002366.05- Side Work Lights

328
Left docking light (E15) or right docking light (E16) circuit open.
Alarm Level:
Side Work Lights Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Left docking light (E15). See Roof Harness (W17) Component Location . (Group 9015-10.)
Right docking light (E16). See Roof Harness (W17) Component Location . (Group 9015-10.)
Result:

Action:
Switched power OFF.

Result:


Action:
Switched power OFF.

Result:

( 5 ) Voltage Check
Action:

Switched power ON.
Check voltage at:
Pin 1 (wire L044 BRN) of left docking light (E15) for system voltage (approximately 12 V).
Pin 2 (wire G020 BLK) of left docking light (E15) for 0.0 V.
Pin 1 (wire L044 BRN) of right docking light (E16) for system voltage (approximately 12 V).
Pin 2 (wire G020 BLK) of right docking light (E16) for 0.0 V.
Result:

Action:
Switched power OFF.

Left front docking light (E15) disconnected.
Pin 1 (wire L044 BRN) of left rear work light (E2) and pin 17 and 53 of VCU connector (X13).
Pin 1 (wire L044 BRN) of right rear work light (E3) and pin 17 and 53 of VCU connector (X13).
Result:

( 7 ) Harness Check
Action:
Switched power OFF.

Check for continuity between pin 17 and 53 of VCU connector (X13) and all other pins in VCU connector (X13).
Result:
NO:Checks complete.
002366.06- Side Work Lights

328
Left docking light (E15) or right docking light (E16) circuit is short to ground.
Alarm Level:
Side Work Lights Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Result:


Action:
Switched power OFF.

Result:

( 5 ) Circuit Check
Action:
Switched power OFF.

Pin 17 and 53 (wires L044 BRN) of VCU connector (X13) to machine ground.
Result:

NO:Checks complete.
002368.03- Left Flasher

328
Left front turn signal (E35) or left rear turn signal (E39) circuit is short to power.
Alarm Level:
Left Flasher Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

Check the following connectors for damage, corrosion, and debris. Use JDG10466 Flex Probe Kit to check for pin fit and
continuity.
Left front drive light/turn signal connector (X32). See Roof Harness (W17) Component Location . (Group 9015-10.)
Cab/canopy harness-to-roof harness connector (X26). See Cab Harness (W14) Component Location . (Group 9015-10.)
(S.N. —232969): Left rear turn signal (E39) connector. See Roof Harness (W17) Component Location . (Group 9015-10.)
(S.N. 235590— ): Left rear light assembly (E45) connector. See Rear Frame Harness (W38) Component Location . (Group
9015-10.)
Turn signal switch (S30) connector. See Cab Harness (W14) Component Location . (Group 9015-10.)
Rear frame harness connector (X33). See Rear Frame Harness (W38) Component Location . (Group 9015-10.)
Result:

Action:
Switched power OFF.

Disconnect left front drive light/turn signal connector (X32).
(S.N. —232969): Disconnect left rear turn signal (E39) connector.
(S.N. 235590— ): Disconnect left rear light assembly (E45) connector.
Switched power ON.
All driving lights, work lights, and beacon light (if equipped) switched ON.
Check circuit L048 BRN for power at pin 30 of VCU connector (X12).
Is voltage present?
Result:
YES:Circuit L048 BRN is short to power with circuit not on VCU connector 2 (X12). Repair circuit or replace harness. See
( 4 ) Harness Check
Action:

Left front drive light/turn signal connector (X32) disconnected.
Left rear turn signal (E39) (S.N. —232969) or left rear light assembly (E45) (S.N. 235590— ) disconnected.
Check for continuity between pin 30 (wire L048 BRN) and all other pins of VCU connector 2 (X12).
Result:

328
Left front turn signal (E35) or left rear turn signal (E39) circuit is open.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Operator station floor ground (W2). See Cab Harness (W14) Component Location . (Group 9015-10.)
9015-10.)
Result:
YES:Go to Visual Check.

( 3 ) Visual Check
Action:
Switched power ON.

Activate left turn signal.
sss:
Is one turn signal (front or rear) flashing?
Result:
YES:Malfunction in circuit with light not flashing. Go to Component Check.

NO:Open in shared supply voltage circuit (between pin 30 of VCU connector 2 [X12] and splice L048 BRN [X591] of cab harness
[W14]). Repair or replace harness. See appropriate wiring diagram or schematic.
Action:
Switched power OFF.
→NOTE:
Only disconnect light that is not functioning.

or


Result:

NO:Replace light.
( 5 ) Voltage Check
Action:
Non-functioning light disconnected:
Left front drive light/turn signal connector (X32)

(S.N. —232969): Left rear turn signal (E39) connector
(S.N. 235590— ): Left rear light assembly (E45) connector
Switched power ON.
Check for system voltage (approximately 12 V) at:
Pin 5 (wire L048 BRN) of left front drive light/turn signal connector (X32).
or
(S.N. —232969): Pin 1 (wire L048 BRN) of left rear turn signal (E39) connector.
(S.N. 235590— ): Pin 6 (wire L048 BRN) of left rear light assembly (E45) connector.
Result:
YES:Go to Open Ground Circuit Check.

NO:Repair or replace supply circuit. See appropriate wiring diagram or schematic.
( 6 ) Open Ground Circuit Check
Action:
Switched power OFF.

Left front drive light/turn signal connector (X32)

(S.N. —232969): Left rear turn signal (E39) connector
(S.N. 235590— ): Left rear light assembly (E45) connector

Pin 1 (wire G020 BRN) of left rear drive light/turn signal (X32) and machine ground.
or
(S.N. —232969): Pin 5 (wire G033 BLK) of left rear turn signal (E39) connector and machine ground.
(S.N. 235590— ): Pin 4 (wire G031 BLK) of left rear light assembly (E45) connector and machine ground.
Result:
YES:Program VCU.

328
Left front turn signal (E35) or left rear turn signal (E39) circuit is short to ground.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
9015-10.)
Result:

Action:
Switched power OFF.

or
Check for continuity from pin 30 (wire L048 BRN) of VCU connector 2 (X12) to machine ground.
Result:
YES:Repair or replace circuit with continuity. See appropriate wiring diagram or schematic.
NO:Program VCU.
002370.03- Right Flasher

328
Right rear turn signal (E38) or right front turn signal (E36) is short to power.
Alarm Level:
Right Flasher Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Right front drive light/turn signal connector (X31). See Roof Harness (W17) Component Location . (Group 9015-10.)
(S.N. —232969): Right rear turn signal (E38) connector. See Roof Harness (W17) Component Location . (Group 9015-10.)
(S.N. 235590— ): Right rear light assembly (E46) connector. See Rear Frame Harness (W38) Component Location . (Group
9015-10.)
Result:

Action:
Switched power OFF.

Disconnect right front drive light/turn signal connector (X31).
(S.N. —232969): Disconnect right rear turn signal (E38) connector.
(S.N. 235590— ): Disconnect right rear light assembly (E46) connector.
Switched power ON.
All driving lights, work lights, and beacon light (if equipped) switched ON.
Check circuit L047 BRN for power at pin 18 of VCU connector (X12).
Is voltage present?
Result:
YES:Circuit L047 BRN is short to power with circuit not on VCU connector 2 (X12). Repair circuit or replace harness. See
( 4 ) Harness Check
Action:

Right front drive light/turn signal connector (X31) disconnected.
Right rear turn signal (E38) (S.N. —232969) or right rear light assembly (E46) (S.N. 235590— ) disconnected.
Check for continuity between pin 18 (wire L047 BRN) and all other pins of VCU connector 2 (X12).
Result:

328
Right front turn signal (E36) or right rear turn signal (E38) circuit is open.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

Check the following connectors for damage, corrosion, and debris. Use JDG10466 Flex Probe Kit to check for pint fit and
continuity.
9015-10.)
Result:
YES:Go to Visual Check.

( 3 ) Visual Check
Action:
Switched power ON.

Activate right turn signal.
sss:
Is one turn signal (front or rear) flashing?
Result:
YES:Malfunction in circuit with light not flashing. Go to Component Check.

NO:Open in shared supply voltage circuit (between pin 18 of VCU connector 2 [X12] and splice L047 BRN [X592] of cab harness
[W14]). Repair or replace harness. See appropriate wiring diagram or schematic.
Action:
Switched power OFF.
→NOTE:
Only disconnect light that is not functioning.

or


Result:

NO:Replace light.
( 5 ) Voltage Check
Action:
Right front drive light/turn signal connector (X31)

(S.N. —232969): Right rear turn signal (E38) connector
(S.N. 235590— ): Right rear light assembly (E46) connector
Switched power ON.
Check for system voltage (approximately 12 V) at:
Pin 5 (wire L047 BRN) of right front drive light/turn signal connector (X31).
or
(S.N. —232969): Pin 2 (wire L047 BRN) of right rear turn signal (E38) connector.
(S.N. 235590— ): Pin 6 (wire L047 BRN) of right rear light assembly (E46) connector.
Result:
YES:Go to Open Ground Circuit Check.

NO:Repair or replace supply circuit. See appropriate wiring diagram or schematic.
( 6 ) Open Ground Circuit Check
Action:
Switched power OFF.

Right front drive light/turn signal connector (X31)

(S.N. —232969): Right rear turn signal (E38) connector
(S.N. 235590— ): Right rear light assembly (E46) connector

Pin 1 (wire G020 BRN) of right rear drive light/turn signal (X31) and machine ground.
or
(S.N. —232969): Pin 5 (wire G033 BLK) of right rear turn signal (E38) connector and machine ground.
(S.N. 235590— ): Pin 4 (wire G033 BLK) of right rear light assembly (E46) connector and machine ground.
Result:
YES:Program VCU.

328
Right rear turn signal (E38) or right front turn signal (E36) is short to ground.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
9015-10.)
Result:

Action:
Switched power OFF.

or
Check for continuity from pin 18 (wire L047 BRN) of VCU connector 2 (X12) to machine ground.
Result:
YES:Repair or replace circuit with continuity. See appropriate wiring diagram or schematic.
NO:Program VCU.
002378.03- Marker Light

328
Left front marker light (E33) or right front marker light (E34) circuit is short to power. (315SK, 325SK, and 710K ONLY)
Alarm Level:
Marker Light Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Radio Connector (A5). See Radio Harness (W18) Component Location . (Group 9015-10.)
License Plate Light (E21). See Roof Harness (W17) Component Location . (Group 9015-10.)
Left front marker light (E33). See Roof Harness (W17) Component Location . (Group 9015-10.)
Right front marker light (E34). See Roof Harness (W17) Component Location . (Group 9015-10.)
Cab Harness-to-Radio Harness Connector (X9). See Cab Harness (W14) Component Location or see Canopy Harness
Result:
YES:Go to Front Component Check.

( 3 ) Front Component Check
Action:
Switched power OFF.
Disconnect left front marker light (E33).

Disconnect right front marker light (E34).
Result:
YES:Go to Rear Component Check.

NO:Replace left front marker light (E33) or right front maker light (E34).
( 4 ) Rear Component Check
Action:
Switched power OFF.

Disconnect license plate light (E21).
Result:

NO:Replace left brake/tail light (E9), right brake/tail light (E10), or license plate light (E21).
Action:
Ignition OFF.
License plate light (E21) disconnected.
Left front marker light (E33) disconnected.
Right front marker light (E34) disconnected.
Check circuit L055 BRN for power at pin A of turn signals (E9, E10, E21, E33, and E34) harness connectors.
Is voltage present?
Result:
( 6 ) Harness Check
Action:


X13, and X14).
Result:

328
Left front marker light (E33) or right front marker light (E34) circuit is open. (315SK, 325SK, and 710K ONLY)
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Result:

Action:
Switched power OFF.

Result:

( 5 ) Voltage Check
Action:

Switched power ON.
Check voltage at:
Pin 1 (wire L055 BRN) of light connectors (E9, E10, E21, E32, and E33) for system voltage (approximately 12 V).
Pin 2 (wire G020 BLK) of light connectors (E9, E10, E21, E32, and E33) for 0.0 V.
Result:

Action:
Switched power OFF.


Pin 1 (wire L055 BRN) of light connectors (E9, E10, E21, E32, and E33) and pin 8 of VCU connector (X13).
Result:

( 7 ) Harness Check
Action:
Switched power OFF.

Result:
NO:Checks complete.

328
Left front marker light (E33) or right front marker light (E34) circuit is short to ground. (315SK, 325SK, and 710K ONLY)
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Result:

Action:
Switched power OFF.

Result:

( 5 ) Voltage Check
Action:
Radio (A9) connector disconnected

Switched power ON.
Check voltage at:
Pin 1 (wire L055 BRN) of light connectors (E9, E10, E21, E33, and E34) for system voltage (approximately 12 V).
Pin 2 (wire G020 BLK) of light connectors (E9, E10, E21, E33, and E34) for 0.0 V.
Result:

Action:
Switched power OFF.

Radio (A9) connector disconnected

Pin 1 (wire L055 BRN) of light connectors (E9, E10, E21, E33, and E34) and pin 8 of VCU connector (X13).
Pin 2 (wire G020 BLK) of light connectors (E9, E10, E21, E33, and E34) and machine ground.
Result:

( 7 ) Harness Check
Action:
Switched power OFF.

Result:
NO:Checks complete.
0002641.03- EH Horn
328
Horn relay (K40) circuit is short to power. (TMC machines ONLY.)
Alarm Level:
EH Horn Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Horn relay (K40). See Cab Harness (W14) Component Location or see Canopy Harness (W15) Component Location .
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Disconnect horn relay (K40).
Check continuity between terminals 30 and 87 of horn relay (K40).
Result:
YES:Replace horn relay (K40).

Action:
Switched power OFF.

Horn relay (K40) disconnected.
Disconnect vehicle control unit (VCU) connector (X13).
Switched power ON.
Check pin 7 (wire A140 GRY) of VCU connector X13 for system voltage. (Approximately 12 V.)
Result:
( 5 ) Harness Check
Action:

Disconnect:

Vehicle control unit (VCU) connectors (X11, X12, and X14)
Check for continuity between pin 7 (wire A140 GRY) of VCU connector X13 and all other pins on VCU connectors (X11, X12,
X13, and X14).
Result:
schematic.
0002641.05- EH Horn
328
Horn relay (K40) circuit is open. (TMC machines ONLY)
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
(Group 9015-10.)
Result:

Action:
Switched power OFF.

→NOTE:
Horn relay (K40) contains a diode between terminals 85 and 86.
Apply system voltage (approximately 12 V) to terminal 86 and ground to terminal 85.

sss:
Does Horn relay (K40) “click”?

Result:

NO:Replace horn relay (K40).
Action:
Switched power OFF.

Pin B10 (wire A140 GRY) of horn relay (K40) and pin 7 of VCU connector X13.
Pin D9 (wire G001 BLK) of horn relay (K40) and machine ground.
Result:
0002641.06- EH Horn
328
Horn relay (K40) circuit is short to ground. (TMC machines ONLY)
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Result:
YES:Replace horn relay (K40).

Action:
Switched power OFF.

Check for continuity between pin 7 (wire A140 GRY) of VCU connector X13 and machine ground.
Result:

NO:Circuit is short to ground. Repair or replace harness. See appropriate wiring diagram or schematic.
( 5 ) Harness Check
Action:

Disconnect:

Vehicle control unit (VCU) connectors (X11, X12, and X14)
Check for continuity between pin 7 (wire A140 GRY) of VCU connector X13 and all other pins on VCU connectors (X11, X12,
X13, and X14).
Result:
schematic.
002875.03- Hazard Wakeup

328
Sealed switch module (SSM) to vehicle control unit (VCU) circuit is short to power.
Alarm Level:
Hazard Wakeup Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Sealed switch module (SSM) connector (X40). See Cab Harness (W14) Component Location or see Canopy Harness (W15)
Vehicle control unit (VCU) connector (X11). See Cab Harness (W14) Component Location or see Canopy Harness (W15)
Result:

Action:
Switched power OFF.

Disconnect:
Sealed switch module (SSM) connector (X40).

Vehicle control unit (VCU) connector (X11).
Switched power ON.

Pin 4 (wire L011 BRN) of SSM connector (X40).

Pin F2 (wire L011 BRN) of VCU connector (X11).

Result:

( 4 ) Harness Check
Action:
Vehicle control unit (VCU) connector (X11) disconnected.

Disconnect:

Vehicle control unit (VCU) connectors (X12, X13 and X14).
Check for continuity between pin F2 (wire L011 BRN) of VCU connector (X11) and all other pins on VCU connectors (X11, X12,
X13, and X14).
Result:
schematic.
002876.07- Turn Signal Switch

328
Turn signal switch (S30) data is conflicting.
Alarm Level:
Turn Signal Switch Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Turn signal switch (S30). See Cab Harness (W14) Component Location or see Canopy Harness (W15) Component Location
. (Group 9015-10.)
Result:

Action:
Switched power OFF.

Disconnect turn signal switch (S30).
Turn signal switch (S30) in the OFF position.
→NOTE:
Turn signal switch (S30) contains two diodes. One diode is located between pins 7 and 8, the other diode
is located between pins 7 and 10.
Pin 2 of turn signal switch (S30) and all other pins of turn signal switch (S30).
Pin 7 of turn signal switch (S30) and all other pins of turn signal switch (S30).
Result:
YES:Switch malfunction. Replace turn signal switch (S30).

Action:
Switched power OFF.

Turn signal switch (S30) disconnected.
Disconnect:

Pin 1 (wire L147 BRN) of turn signal switch (S30) and machine ground.
Result:
YES:Circuit with voltage is short to ground. Repair circuit or replace harness. See appropriate wiring diagram or schematic.
( 5 ) Harness Check
Action:
Turn signal switch (S30) disconnected.

VCU connectors (X11 and X12) disconnected.
Disconnect:

Vehicle control unit (VCU) connectors (X13 and X14).
Pin D3 (wire L147 BRN) of VCU connector (X11) and all other pins on VCU connectors (X11, X12, X13, and X14).
Pin E2 (wire L148 BRN) of VCU connector (X11) and all other pins on VCU connectors (X11, X12, X13, and X14).
Pin 30 (wire L048 BRN) of VCU connector (X12) and all other pins on VCU connectors (X11, X12, X13, and X14).
Pin 18 (wire L047 BRN) of VCU connector (X12) and all other pins on VCU connectors (X11, X12, X13, and X14).
Result:
schematic.
003416.03- Right Door Sw

328
Right door switch (S99) circuit is short to power. (TMC ONLY)
Alarm Level:
Right Door Switch Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Right exit bar (B100). See Cab Harness (W14) Component Location or see Canopy Harness (W15) Component Location .
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Disconnect right exit bar switch (S100).
Move exit lever into the UP position.
Check for continuity between pins 2 and 3 on switch (S100).
Move exit lever into the DOWN position.
Result:
YES:Right exit bar switch (S100) malfunction. Replace switch.

Action:
Switched power OFF.

Switched power ON.
Check circuit M199 PUR for voltage at pin 1 on switch (S100) connector.
Check circuit M099 PUR for voltage at pin 2 on switch (S100) connector.
Is system voltage present on either circuit?
Result:
YES:Circuit with system voltage present is short to power. Repair circuit or replace harness.
NO:Go to Short Circuit Check—Input Circuits.
( 5 ) Short Circuit Check—Input Circuits
Action:
Switched power OFF.

Disconnect vehicle control unit (VCU) connector (X13) and right exit bar switch (S100).
Check for continuity between pin 2 (circuit M099 PUR) on switch (S100) connector and pin 1 (circuit M199 PUR) on switch
(S100) connector.
Result:
YES:Circuits M099 PUR and M199 PUR are short to each other. Repair circuits or replace harness.
003416.04- Right Door Sw

328
Right door switch (S99) circuit is short to ground. (TMC ONLY)
Alarm Level:
Right Door Switch Diagnostic Procedure

Action:
Switched power OFF.

Move exit lever into the UP position.
Move exit lever into the DOWN position.
Result:
YES:Right exit bar switch (S100) malfunction. Replace switch.

Action:
Switched power OFF.

Disconnect vehicle control unit (VCU) connector (X13) and right exit switch (S100).
Check circuit M199 PUR for ground at pin 1 on switch (S100) connector.
Check circuit M099 PUR for ground at pin 2 on switch (S100) connector.
Is ground present?
Result:
YES:Circuit with ground present is short. Repair circuit or replace harness.

( 3 ) Harness Check
Action:

Disconnect vehicle control unit (VCU) connectors (X11, X12, and X13) and right exit bar switch (S100).
Check for continuity between pin 22 (circuit M199 PUR) on VCU connector (X13) and all other pins on VCU connectors (X11,
X12, and X13).

Check for continuity between pin 46 (circuit M099 PUR) on VCU connector (X13) and all other pins on VCU connectors (X11,
X12, and X13).
Is continuity indicated between any pins?
Result:
YES:Circuit with continuity indicated to another circuit is short. Repair circuit or replace harness.

328
Alarm Level:
Sensor Supply 1 Diagnostic Procedure

Action:
Result:
NO:Go to Code Check
( 2 ) Code Check
Action:
Switched power ON.

Check for active VCU code:
520713.03 - Seat Position.
Are VCU codes active?
Result:
YES:Clear codes.
Action:
Switched power OFF.

continuity.
Seat Position Sensor (B9). See Cab Harness (W14) Component Location or see Canopy Harness (W15) Component
Result:

Action:
Switched power OFF.
→NOTE:
Check voltage on VCU side of connector.
Disconnect seat position sensor (B9).

Switched power ON.
Check pins 3 and 6 (wire P055 RED) of seat position sensor (B9) connector for voltage.
Result:

( 5 ) Harness Check
Action:
Switched power OFF.

Disconnect VCU connectors (X11, X12, X13, and X14).
Seat position sensor (B9) connector disconnected.
Check for continuity between pin J2 (wire P055 RED) of VCU connector (X11) and all other pins on VCU connectors (X11, X12,
X13, and X14).
Is continuity indicated between any circuits?
Result:

NO:Checks complete.

328
Alarm Level:

Action:
Result:
NO:Go to Code Check
( 2 ) Code Check
Action:
Switched power ON.

Result:
YES:Clear codes.
Action:
Switched power OFF.

continuity.
Result:

( 4 ) Voltage Check
Action:
Ignition OFF.
Ignition ON.
Check for ground at pins 3 and 6 (wire P055 RED) on seat position sensor (B9) connector.
Is ground present?
Result:
YES:Circuit P055 RED is short to ground. Repair circuit or replace harness. See appropriate wiring diagram or schematic
( 5 ) Harness Check
Action:
Switched power OFF.

X13, and X14).
Result:

NO:Checks complete.

328
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Loader control lever (X58). See Cab Harness (W14) Component Location or see Canopy Harness (W15) Component
Result:

Action:
Switched power OFF.

Disconnect loader control lever (X58).
Switched power ON.
Check pin 9 (wire P053 RED) of loader control lever (X58) connector for voltage.
Result:
YES:Circuit is short to power. Go to Harness Check to determine which circuits are shorted. See appropriate wiring diagram or
schematic.
( 4 ) Harness Check
Action:
Switched power OFF.

Loader control lever (X58) connector disconnected.
X13, and X14).
Result:

NO:Checks complete.

328
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

( 3 ) Voltage Check
Action:
Ignition OFF.
Ignition ON.
Check for ground at pin 9 (wire P055 RED) on loader control lever (X58) connector.
Is ground present?
Result:
( 4 ) Harness Check
Action:
Switched power OFF.

Loader control lever (X58) connector disconnected.
X13, and X14).
Result:

NO:Checks complete.

328
Sensor supply voltage 3 is out of range high. (Above 5.25 V.)
Alarm Level:

Action:
Result:
NO:Go to Code Check.
( 2 ) Code Check
Action:
Switched power ON.

520654.03 - Brake Charge Press.
Result:
YES:Clear codes.
Action:
Switched power OFF.

continuity.
Brake pressure sensor harness connector (X35). See Cab Harness (W14) Component Location or see Canopy Harness
Result:

Action:
Switched power OFF.

Remove cap of brake pressure sensor harness connector (X35).
Switched power ON.
Check pin 1 (wire P059 RED) of brake pressure sensor harness connector (X35) for voltage.
Result:
YES:Circuit is short to power. Go to Harness Check to determine which circuits are shorted. See appropriate wiring diagram or
schematic.
( 5 ) Harness Check
Action:
Switched power OFF.

Check for continuity between pin K1 (wire P059 RED) of VCU connector (X11) and all other pins on VCU connectors (X11, X12,
X13, and X14).
Result:

NO:Checks complete.

328
Sensor supply voltage 3 is out of range low. (Below 4.75 V.)
Alarm Level:

Action:
Result:
NO:Go to Code Check
( 2 ) Code Check
Action:
Switched power ON.

520654.04 - Brake Charge Press.
Result:
YES:Clear codes.
Action:
Switched power OFF.

continuity.
Brake Pressure Sensor Harness Connector (X35). See Cab Harness (W14) Component Location or see Canopy Harness
Result:

( 4 ) Voltage Check
Action:
Ignition OFF.
Check for ground at pin K1 (wire P059 RED) on vehicle control unit (VCU) connector (X11).
Is ground present?
Result:
( 5 ) Harness Check
Action:
Switched power OFF.

Check for continuity between pin K1 (wire P059 RED) of VCU connector (X11) and all other pins on VCU connectors (X11, X12,
X13, and X14).
Result:

NO:Checks complete.
003997.03- Accessory Relay

328
Accessory relay (K20) circuit is short to power.
Alarm Level:
Accessory Relay Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Apply 12 V to terminal 1 and ground to terminal 2 of accessory relay (K20).
sss:
Does accessory relay (K20) “Click”?
Check for continuity between terminal 2 and terminal 5 of accessory relay (K20).
Result:

NO:Accessory relay (K20) malfunction. Replace relay.
Action:
Switched power OFF.

Accessory relay (K20) disconnected.
Switched power ON.
Check for 0.0 V at pin G2 (wire U120 RED) of VCU connector (X11).
Result:

( 5 ) Harness Check
Action:
Switched power OFF.

Disconnect VCU connectors ( X12, X13, and X14).
Check for continuity between pin G2 (wire U120 RED) of VCU connector (X11) and all other pins on VCU connectors (X11, X12,
X13, and X14)
Result:

328
Accessory relay (K20) circuit is open.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Apply 12 V to terminal 1 and ground to terminal 2 of accessory relay (K20).
sss:
Result:

NO:Accessory relay (K20) malfunction. Replace relay.
Action:
Switched power OFF.

Check for continuity between pin G2 (wire U120 RED) of VCU connector (X11) and pin 1 of accessory relay (K20).
Result:
YES:Program Controller.

328
Accessory relay (K20) is short to ground.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
(Group 9015-10.)
Result:

Action:
Switched power OFF.

sss:
Result:
YES:Accessory relay (K20) malfunction. Replace relay.

Action:
Switched power OFF.

Check for continuity between pin G2 (wire U120 RED) of VCU connector (X11) and machine ground.
Result:
YES:Circuit is short to ground. Repair or replace harness. See appropriate wiring diagram or schematic.
( 5 ) Harness Check
Action:
Switched power OFF.

Disconnect VCU connectors ( X12, X13, and X14).
Check for continuity between pin G2 (wire U120 RED) of VCU connector (X11) and all other pins on VCU connectors (X11, X12,
X13, and X14)
Result:
520416.03- Valve Power

328
Vehicle control unit (VCU) supply voltage from VCU connector 4 (X14) is above 15.5 V.
Alarm Level:
Valve Power Diagnostic Procedure

Action:
Check for active VCU DTC 000168.03—Battery Voltage.

Is VCU DTC 000168.03—Battery Voltage active?
Result:
YES:Diagnose and clear active VCU DTC code 000168.03—Battery Voltage. See 000168.03—Battery Voltage . (Group
9001-40.)
NO:Go to Battery Voltage Check.
Action:
Switched power OFF.

Result:

NO:Replace battery.
Action:
Engine RUNNING.
Result:

Action:

Result:

328
Vehicle control unit (VCU) supply voltage from VCU connector 4 (x14) is below 11.7 V.
Alarm Level:

Action:

Result:
YES:Diagnose and clear active VCU DTC code 000168.04—Battery Voltage. See 000168.04—Battery Voltage . (Group
9001-40.)
NO:Go to Battery Voltage Check.
Action:
Switched power OFF.

Result:

NO:Replace battery.
Action:
Engine RUNNING.
Result:

Action:

Result:

328
Vehicle control unit (VCU) supply circuit on VCU connector 4 (X14) is open.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Main 250 A fuse (F1). See Engine Harness (W10) Component Location . (Group 9015-10.)
Result:

( 3 ) Fuse Check
Action:
Disconnect negative terminal from battery.

Remove main 250 A fuse (F1). See Fuse and Relay Location and Specifications . (Group 9015-10.)
Check for continuity through fuse.
Result:

Action:
Negative terminal disconnected.

Main 250 A fuse (F1) removed.
Check for continuity between pin 1 (wire P001 RED) of VCU connector (X14) and main fuse terminal.
Result:
520546.03- Pilot Enable Switch

328
Pilot enable switch (S52) is stuck or circuit is short to power.
Alarm Level:
Pilot Enable Switch Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Pilot enable switch (S52). See Pilot Enable Pattern Select Valve Harness (W30) Component Location or see Pilot Enable
Switch Harness (W31) Component Location . (Group 9015-10.)
Pilot enable switch harness connector (X53). See Pilot Enable Pattern Select Valve Harness (W30) Component Location or
see Pilot Enable Switch Harness (W31) Component Location . (Group 9015-10.)
Pilot control console harness connector (X52). See Cab Harness (W14) Component Location or see Canopy Harness (W15)
Transmission control 5 A fuse (F35). See Cab Harness (W14) Component Location or see Canopy Harness (W15)
Result:

Action:
Switched power OFF.

Disconnect pilot enable switch (S52).
→NOTE:
Does pilot enable switch (S52) move freely between Enable and Disable?
Pilot enable switch (S52) in “Disable” position.

Pin 2 and 3.
Pin 2 and 6.
Pin 5 and 3.
Pin 5 and 6.
Result:
YES:Switch malfunction. Replace pilot enable switch (S52).

NO:Got to Voltage Check.
( 4 ) Voltage Check
Action:
Switched power OFF.

Pilot enable switch (S52) disconnected.
Switched power ON.
Check the following for 0.0 V:
Pin 2 (wire H014 GRN) of switch (S52).

Result:
YES:Go to Harness Check

( 5 ) Harness Check
Action:
Switched power OFF.

Pin 34 (wire H252_H019 GRN) of VCU connector (X13) and all other pins of VCU connectors (X11, X12, X13, and X14).
Result:
520546.07- Pilot Enable Switch

328
Pilot enable switch (S52) inputs are conflicted.
Alarm Level:
Pilot Enable Switch Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Pilot enable switch (S52). See Pilot Enable Pattern Select Valve Harness (W30) Component Location or see Pilot Enable
Switch Harness (W31) Component Location . (Group 9015-10.)
Pilot enable switch harness connector (X53). See Pilot Enable Pattern Select Valve Harness (W30) Component Location or
see Pilot Enable Switch Harness (W31) Component Location . (Group 9015-10.)
Transmission control 5 A fuse (F35). See Cab Harness (W14) Component Location or see Canopy Harness (W15)
Result:

Action:
Switched power OFF.

Disconnect pilot enable switch (S52).
→NOTE:
Does pilot enable switch (S52) move freely between Enable and Disable?
Pilot enable switch (S52) in “Disable” position.

Pin 2 and 3.
Pin 2 and 6.
Pin 5 and 3.
Pin 5 and 6.
Result:
YES:Switch malfunction. Replace pilot enable switch (S52).

NO:Got to Voltage Check.
( 4 ) Voltage Check
Action:
Switched power OFF.

Switched power ON.
Check the following for system voltage: (Approximately 12 V.)

Result:
YES:Go to Short Circuit Check—Power.

( 5 ) Short Circuit Check—Power
Action:
Switched power OFF.

Switched power ON.

Result:
YES:Go to Short Circuit Check—Ground.

( 6 ) Short Circuit Check—Ground
Action:
Switched power OFF.


Pin 3 (wire H019 GRN) of switch (S52) and machine ground.

Pin 6 (wire H013 GRN) of switch (S52) and machine ground.
Result:
YES:Go to Continuity Check

NO:Circuit with continuity is short to ground. Repair or replace harness. See appropriate wiring diagram or schematic.
( 7 ) Fuse Check
Action:
Switched power OFF.

Remove transmission control 5 A fuse (F35).
Result:

Action:
Switched power OFF.

Check continuity between:
Pin 2 (wire H014 GRN) and pin 5 of switch (S52).

Pin 2 (wire H014 GRN) of switch (S52) and pin D7 of fuse and relay block (X3).
Pin 3 (wire H019 GRN) of switch (S52) and pin 34 of VCU connector (X13).
Pin 6 (wire H013 GRN) of switch (S52) and pin 47 of VCU connector (X13).
Result:

NO:Circuit without continuity is open. Repair or replace harness. See appropriate wiring diagram or schematic.
( 9 ) Harness Check
Action:
Switched power OFF.

Result:
YES:Circuit with continuity is short. Repair or replace harness. See appropriate wiring diagram or schematic.
520688.03- Pilot Enable Driver

328
Pilot enable solenoid (Y52) circuit is short to power. (Above 7.4 V.)
Alarm Level:
Pilot Enable Driver Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Pilot enable solenoid (Y52). See Pilot Enable Pattern Select Valve Harness (W30) Component Location . (Group 9015-10.)
Result:

Action:
Switched power OFF.

Disconnect pilot enable solenoid (Y52).
Measure resistance of solenoid (Y52).
Item Measurement Specification
Pilot enable solenoid (Y52) Resistance 7.25 ohms at 68° F (20° C)
Is resistance with in specification?
Result:

NO:Solenoid malfunction. Replace pilot enable solenoid (Y52).
Action:
Switched power OFF.

Pilot enable solenoid (Y52) disconnected.
Switched power ON.
Check for 0.0 V at:
Pin 1 (wire H019 GRN) of pilot enable solenoid (Y52).

Pin 2 (wire G031 BLK) of pilot enable solenoid (Y52).
Result:

NO:Circuit with voltage above 0.0 V is short to power. Repair circuit or replace harness. See appropriate wiring diagram or
schematic.
( 5 ) Harness Check
Action:
Switched power OFF.

Check for continuity between pin 28 (wire H019 GRN) on VCU connector (X13) and all other pins on VCU connector (X11, X12,
X13, and X14).
Result:

328
Pilot enable solenoid (Y52) circuit is open.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Result:

Action:
Switched power OFF.

Pin 1 (wire H019 GRN) of pilot enable solenoid (Y52) and pin 28 of VCU connector X13.
Pin 2 (wire G031 BLK) of pilot enable solenoid (Y52) and machine ground.
Result:
NO:Circuit is open. Repair circuit or replace harness. See appropriate wiring diagram or schematic.

328
Pilot enable solenoid (Y52) circuit is short to ground.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Result:

Action:
Switched power OFF.

Check for continuity between pin 1 (wire H019 GRN) of pilot enable solenoid (Y52) and machine ground.
Result:
( 5 ) Harness Check
Action:
Switched power OFF.

X13, and X14).
Result:
520696.03- Pattern Select Driver

328
Pattern select solenoid 1 (Y58) or pattern select solenoid 2 (Y59) circuit is short to power. (Above 7.4 V.)
Alarm Level:
Pattern Select Driver Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Pattern select solenoid 1 (Y58). See Pilot Enable Pattern Select Valve Harness (W30) Component Location . (Group
9015-10.)
9015-10.)
Result:

Action:
Switched power OFF.

Disconnect pattern select solenoid 1 (Y58).
Measure resistance of solenoids between pins A and B.
→NOTE:
Pattern select solenoids contain a diode.
Pattern select solenoid 1 (Y58) Resistance 8.536-9.064 ohms at 68° F (20° C)
Result:

NO:Solenoid malfunction. Replace pattern select solenoid.
Action:
Switched power OFF.

Pattern select solenoid 1 (Y58) disconnected.
Switched power ON.
Check for 0.0 V at:
Pin A (wire H058 GRN) of solenoid (Y58).

Pin B (wire G031 BLK) of solenoid (Y58).
Pin A (wire H058 GRN) of solenoid (Y59).
Pin B (wire G031 BLK) of solenoid (Y59).
Result:

schematic.
( 5 ) Harness Check
Action:
Switched power OFF.

X13, and X14).
Result:

328
Pattern select solenoid 1 (Y58) or pattern select solenoid 2 (Y59) circuit is open.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
9015-10.)
9015-10.)
Result:

Action:
Switched power OFF.

→NOTE:
Result:

Action:
Switched power OFF.

Pin A (wire H058 GRN) of solenoid (Y58) and pin 6 of VCU connector (X12).
Pin B (wire G031 BLK) of solenoid (Y58) and machine ground.
Pin A (wire H058 GRN) of solenoid (Y59) and pin 6 of VCU connector (X12).
Pin B (wire G031 BLK) of solenoid (Y59) and machine ground.
Result:

328
Pattern select solenoid 1 (Y58) or pattern select solenoid 2 (Y59) circuit is short to ground.
Alarm Level:
Check Service Code Indicator

Action:
Result:
Action:
Switched power OFF.

continuity.
9015-10.)
9015-10.)
Result:

Action:
Switched power OFF.

→NOTE:
Result:

Action:
Switched power OFF.

Check for continuity between pin 6 (wire H058 GRN) on VCU connector (X12) machine ground.
Result:
( 5 ) Harness Check
Action:
Switched power OFF.

X13, and X14).
Result:
520697.03- Loader Coupler Press

328
Loader coupler pressure solenoid (Y30) circuit is short to power. (Above 7.4 V.)
Alarm Level:
Loader Coupler Press Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Loader coupler pressure solenoid (Y30). See Loader Coupler Solenoid Harness (W26) Component Location . (Group
9015-10.)
Loader coupler solenoid harness connector (X81). See Loader Coupler Solenoid Harness (W26) Component Location .
(Group 9015-10.)
Component Location . (Group 9015-10.) Operator Station Floor Ground (W2). See Cab Harness (W14) Component Location
or see Canopy Harness (W15) Component Location . (Group 9015-10.)
Result:

Action:
Switched power OFF.

Disconnect loader coupler pressure solenoid (Y30).
Measure resistance between terminals A and B on loader coupler pressure solenoid (Y30).
Result:

NO:Loader coupler pressure solenoid (Y30) malfunction. Replace solenoid.
Action:
Switched power OFF.

Loader coupler pressure solenoid (Y30) disconnected.
Switched power ON.
Check pin A (wire H008 GRN) of pressure solenoid (Y30) connector for 0.0 V.
Result:

NO:Circuit is short to power. Repair circuit or replace harness. See appropriate wiring diagram or schematic.
( 5 ) Harness Check
Action:

Disconnect vehicle control unit (VCU) connectors (X11, X12, and X14).
Check for continuity between pin 50 (wire H008 GRN) on VCU connector (X13) and all other pins on VCU connectors (X11, X12,
X13, and X14).
Result:

328
Loader coupler pressure solenoid (Y30) circuit is open.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
9015-10.)
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Result:

Action:
Switched power OFF.

60
Pin 50 (wire H008 GRN) of VCU connector (X13) and pin A of loader coupler pressure solenoid (Y30).
Pin B (wire G031 BLK) of loader coupler pressure solenoid (Y30) and machine ground.
Result:
YES:Circuit is open. Repair circuit or replace harness. See appropriate wiring diagram or schematic.

328
Loader coupler pressure solenoid (Y30) circuit is short to ground.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
9015-10.)
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Result:

Action:
Switched power OFF.

Check for continuity between pin 50 (wire H008 GRN) and machine ground.
Result:
( 5 ) Harness Check
Action:

Check for continuity between pin 50 (wire H008 GRN) on VCU connector (X13) and all other pins on VCU connectors (X11, X12,
X13, and X14).
Result:
520708.03- HVC Valve Power

328
Hydraulic valve controller (HVC) input is short to power. (Above 7.4 V.)(TMC ONLY)
HVC Valve Power Diagnostic procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Chassis harness-to-cab/canopy harness connector (X74). See Cab Harness (W14) Component Location or see Canopy
Hydraulic valve controller (HVC) connector (X15). See Transmission Harness (W13) Component Location . (Group
9015-10.)
9015-10.)
9015-10.)
Result:

Action:
Switched power OFF.

Disconnect:

Hydraulic valve controller (HVC) connector (X15).
Switched power ON.
Pin 18 (wire K037 GRN) of VCU connector (X13).

Pin H3 (wire K037 GRN) of HVC connector (X15).
Pin D4 (wire K037 GRN) of HVC connector (X16).
Pin M4 (wire K037 GRN) of HVC connector (X16).
Result:

( 4 ) Harness Check
Action:

Hydraulic valve controller (HVC) connector (X15) disconnected.
Disconnect:

Vehicle control unit (VCU) connectors (X11, X12, and X14).
Pin 18 (wire K037 GRN) of VCU connector (X13) and all other pins on VCU connectors (X11, X12, X13, and X14) and HVC
connectors (X15, X16, and X17).
Pin H3 (wire K037 GRN) of HVC connector (X15) and all other pins on VCU connectors (X11, X12, X13, and X14) and HVC
Pin D4 (wire K037 GRN) of HVC connector (X16) and all other pins on VCU connectors (X11, X12, X13, and X14) and HVC
Pin M4 (wire K037 GRN) of HVC connector (X16) and all other pins on VCU connectors (X11, X12, X13, and X14) and HVC
Result:
schematic.
520708.06- HVC Valve Power

328
Hydraulic valve controller (HVC) input is short to ground. (TMC ONLY)
Alarm Level:
HVC Valve Power Diagnostic procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Chassis harness-to-cab/canopy harness connector (X74). See Cab Harness (W14) Component Location or see Canopy
9015-10.)
9015-10.)
9015-10.)
Result:

Action:
Switched power OFF.

Disconnect:

Check for continuity to machine ground on the following:.

Pin D4 (wire K037 GRN) of HVC connector (X16).
Pin M4 (wire K037 GRN) of HVC connector (X16).
Result:
YES:Circuit with continuity is short to ground. Repair circuit or replace harness. See appropriate wiring diagram or schematic.
( 4 ) Harness Check
Action:

Disconnect:

Vehicle control unit (VCU) connectors (X11, X12, and X14).
Pin D4 (wire K037 GRN) of HVC connector (X16) and all other pins on VCU connectors (X11, X12, X13, and X14) and HVC
Pin M4 (wire K037 GRN) of HVC connector (X16) and all other pins on VCU connectors (X11, X12, X13, and X14) and HVC
Result:
schematic.
520713.03- Seat Position

328
Seat position sensor (B9) circuit is short to power. (Above 4.50 V.)
Alarm Level:
Seat Position Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Seat position sensor (B9). See Cab Harness (W14) Component Location or see Canopy Harness (W15) Component
Result:

Action:
Switched power OFF.

Disconnect:

Switched power ON.

Pin J2 (wire P055 RED) of VCU connector (X11).
Pin H2 (wire R055 BLK) of VCU connector (X11).

Pin 37 (wire M016 PUR) of VCU connector (X12).
Result:

( 4 ) Harness Check
Action:
Seat position sensor (B9) disconnected.

Disconnect:

Load sense pressure sensor (B16) or hydraulic system pressure sensor (B26).
Pin 37 (wire M016 PUR) of VCU connector X12 and all other pins on VCU connectors (X11, X12, X13, and X14).
Result:
schematic.
Action:
Switched power OFF.

Connect:

Vehicle control unit (VCU) connectors (X11, X12, X13, and X14).

Use JDG10466 Flex Probe Kit and jumper wires to complete circuits listed below.
Switched power ON.
Measure and record voltage at signal circuit—channel 1.
CHANNEL 1
Ground circuit—Pin 1 (wire R055 BLK) of seat position sensor connector to pin 1 of seat position sensor (B9).
Signal circuit—Pin 2 (wire M016 PUR) of seat position sensor connector to pin 2 of seat position sensor (B9).
Power circuit—Pin 3 (wire P055 RED) of seat position sensor connector to pin 3 of seat position sensor (B9).
Compare to specifications:
Channel 1—Loader position. (front) Voltage 4.5
Channel 1—Backhoe position. (rear) Voltage 0.5

CHANNEL 2
Ground circuit—Pin 4 (wire R055 BLK) of seat position sensor connector to pin 4 of seat position sensor (B9).
Does sensor circuits meet specifications?
Result:
NO:Sensor malfunction. Replace seat position sensor (B9).

328
Seat position sensor (B9) circuit is short to ground. (Below 0.4 V.)
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

( 3 ) Voltage Check
Action:
Switched power OFF.

Switched power ON.
Check the following for voltage above 0.4 V:
Pin 3 (wire P055 RED) of seat position sensor (B9).

Pin 6 (wire P055 RED) of seat position sensor (B9).
Result:

Action:
Switched power OFF.

Disconnect:

Pin J2 (wire P055 RED) of VCU connector (X11) and pin 3 of seat position sensor (B9).
Pin J2 (wire P055 RED) of VCU connector (X11) and pin 6 of seat position sensor (B9).
Pin H2 (wire R055 BLK) of VCU connector (X11) and pin 1 of seat position sensor (B9).
Pin H2 (wire R055 BLK) of VCU connector (X11) and pin 4 of seat position sensor (B9).
Pin 37 (wire M016 PUR) of VCU connector (X12) and pin 2 of seat position sensor (B9).
Pin 48 (wire M017 PUR) of VCU connector (X12) and pin 5 of seat position sensor (B9).
Result:

NO:Circuit without continuity is open. Repair circuit or replace harness. See appropriate wiring diagram or schematic.
Action:
Switched power OFF.

Pin J2 (wire P055 RED) of VCU connector (X11) and machine ground.
Pin H2 (wire R055 BLK) of VCU connector (X11) and machine ground.
Pin 37 (wire M016 PUR) of VCU connector (X12) and machine ground.
Result:
( 6 ) Harness Check
Action:

Disconnect:

Result:
schematic.
Action:
Switched power OFF.

Connect:


Switched power ON.
CHANNEL 1
Ground circuit—Pin 1 (wire G055 BLK) of seat position sensor connector to pin 1 of seat position sensor (B9).

CHANNEL 2
Result:

328
Seat position sensor (B9) is reading an angle that is out of range for the seat position. (Sensor measured 0º-25º or 220º-240º)
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Connect all connectors.
Switched power ON.
CHANNEL 1

CHANNEL 2
Result:

328
Seat position sensor (B9) inputs are out of range.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:
YES:Go to Short Circuit Check—Power.

( 3 ) Short Circuit Check—Power
Action:
Switched power OFF.

Disconnect:

Switched power ON.


Result:
YES:Go to Short Circuit Check—Ground.

( 4 ) Short Circuit Check—Ground
Action:
Switched power OFF.

Result:
( 5 ) Harness Check
Action:

Disconnect:

Result:
schematic.
Action:
Switched power OFF.

Connect:


Switched power ON.
CHANNEL 1

CHANNEL 2
Result:
328
Seat position sensor (B9) calibration is invalid.
Alarm Level:

Action:
Check active VCU codes listed below. See Standard Display Monitor (SDM)—Service Menu . (Group 9025-16.)
520713.03—Seat Position
Are VCU seat position codes active?
Result:
YES:Clear active VCU seat position codes.

NO:Go to Calibration Check.
( 2 ) Calibration Check
Action:
Calibrate seat position. See Standard Display Monitor (SDM)—Service Menu . (Group 9025-16.)
Was seat position successful?
Result:
520714.06- Bucket Level LEDs

328
Bucket position indicator (E75) circuit is short to ground.
Alarm Level:
Bucket Level Indicator Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Bucket position indicator (E75). See Cab Harness (W14) Component Location or see Canopy Harness (W15) Component
Result:

Action:
Switched power OFF.

Disconnect bucket level indicator (E75).
Result:

NO:Replace bucket level indicator (E75).
Action:
Switched power OFF.

Bucket level indicator (E75) disconnected.
Check for continuity from pin L3 (wire M150 PUR) of VCU connector (X11) to machine ground.
Result:

NO:Checks complete.
522426.03- Rear Wiper Park

328
Rear wiper motor (M14) circuit is short to power or open. (Rear wiper park switch is showing park position for more than 10
seconds while wiper is on.)
Alarm Level:
See Wiper and Washer Circuit Theory of Operation . (Group 9015-15.
Rear Wiper Park Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Rear wiper motor (M14). See Cab Harness (W14) Component Location . (Group 9015-10.)
Result:

Action:
Ignition OFF.
Disconnect rear wiper motor (M14).
Apply 12 V to pin 3 and ground to pin 2 on rear wiper motor (M14).
Does motor activate?
Result:
NO:Replace rear wiper motor (M14).

Action:
Ignition OFF.
Disconnect rear wiper motor (M14) connector.
Check circuit A014 GRY for ground at pin 3 on rear wiper motor (M14) connector.
Is voltage present?
Result:
YES:Circuit A014 GRY is short to ground. Repair circuit or replace harness.

( 5 ) Harness Check
Action:
Turn battery disconnect OFF.

Check for continuity between pin 20 (circuit A014 GRY) on VCU connector (X13) and all other pins on VCU connectors (X11,
X12, X13, and X14).
Result:
YES:Circuit A014 GRY is short to circuit with continuity indicated. Repair circuit or replace harness.
522426.04- Rear Wiper Park

328
Rear wiper motor (M14) circuit is short to ground. (Rear wiper park switch is not showing park position for more than 10
seconds while wiper is on.)
Alarm Level:
Rear Wiper Park Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Ignition OFF.
Apply 12 V to pin 3 and ground to pin 2 on rear wiper motor (M14).
Result:

Action:
Ignition OFF.
Check circuit A014 GRY for ground at pin 3 on rear wiper motor (M14) connector.
Is ground present?
Result:

( 5 ) Harness Check
Action:

X12, X13, and X14).
Result:
YES:Wire A014 GRY is short to circuit with continuity indicated. Repair circuit or replace harness.
522427.03- Front Wiper Park

328
Front wiper motor (M13) circuit is short to power or open. (Front wiper park switch is showing the park position for more than 1
second while wiper motor is active.)
Alarm Level:
Front Wiper Park Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Front wiper motor (M13). See Cab Harness (W14) Component Location . (Group 9015-10.)
Result:

Action:
Ignition OFF.
Disconnect front wiper motor (M13).
Apply 12 V to pin 3 and ground to pin 2 on front wiper motor (M13).
Result:

Action:
Ignition OFF.
Disconnect front wiper motor (M13) connector.
Check circuit A713 GRY for ground at pin 3 on front wiper motor (M13) connector.
Is voltage present?
Result:

( 5 ) Harness Check
Action:

X12, X13, and X14).
Result:
522427.04- Front Wiper Park

328
Front wiper motor (M13) circuit is short to ground. (Front wiper park switch is not showing the park position for more than 10
seconds.)
Alarm Level:
Front Wiper Park Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Ignition OFF.
Apply 12 V to pin 3 and ground to pin 2 on front wiper motor (M13).
Result:

NO:Replace front wiper motor (M13).
Action:
Ignition OFF.
Check circuit A713 GRY for ground at pin 3 on front wiper motor (M13) connector.
Is ground present?
Result:

( 5 ) Harness Check
Action:

X12, X13, and X14).
Result:
YES:Wire A014 GRY is short to circuit with continuity indicated. Repair circuit or replace harness.
522433.03- Rear Wiper

328
Rear wiper motor (M14) low speed circuit is short to power.
Alarm Level:
Rear Wiper Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Ignition ON.
Verify rear wipers are off.
Check circuit A414 GRY for voltage between pin 4 on rear wiper motor (M14) connector and machine ground.
Is system voltage (approximately 12 V) present?
Result:
YES:Circuit A414 GRY is short to power. Repair circuit or replace harness.

( 4 ) Harness Check
Action:

Disconnect vehicle control unit (VCU) connectors (X11, X12, X13, and X14).
Check for continuity between pin 4 (circuit A414 GRY) on VCU connector (X12) and all other pins on VCU connectors (X11, X12,
X13, and X14).
Result:

328
Rear wiper motor (M14) low speed circuit is open.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Apply 12 V to pins 1 and 2 of rear wiper motor (M14).
Ground pin 3 of rear wiper motor (M14).
Does rear wiper motor (M14) function?
Result:

( 4 ) Voltage Check
Action:
Rear wiper motor (M14) disconnected.

Switched power ON.
Check for voltage at pin 1 (wire A414 GRY) of rear wiper motor (M14) connector.
Result:

Action:
Switched power OFF.

Rear wiper motor (M14) disconnected.
Window wipers 10 A fuse (F18) removed.
Disconnect fuse box 1 connector (X25).
Pin H1 (wire A15 ORG) of VCU connector (X12) and pin 2 of rear wiper motor (M14) connector.
Pin C8 (wire P18 RED) of fuse box 1 connector (X25) and pin 1 of rear wiper motor (M14) connector.
Pin 3 (wire G09 BLK) of rear wiper motor (M14) connector and machine ground.
Result:

NO:Open in circuit. Repair or replace harness. See appropriate wiring diagram or schematic.
( 6 ) Harness Check
Action:
Switched power OFF.

Fuse box 1 connector (X25) connected
Right door wiper motor (M7) disconnected.
Window wipers 10 A fuse (F18) removed.
Vehicle control unit (VCU) 48-pin connector (J2) (X21) disconnected.
Switched power ON.
Pin 1 (wire P18 RED) of rear wiper motor (M14) connector for 0.0 V.
Pin 2 (wire A15 ORG) of rear wiper motor (M14) connector for 0.0 V.
Pin 3 (wire G09 BLK) of rear wiper motor (M14) connector for 0.0 V.
Result:
NO:Circuit is short to power. Repair or replace harness. See appropriate wiring diagram or schematic.

328
Rear wiper motor (M14) low speed circuit is short to ground.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Apply 12 V to pins 1 and 2 of rear wiper motor (M14).
Ground pin 3 of rear wiper motor (M14).
Does rear wiper motor (M14) function?
Result:

Action:
Ignition OFF.
Switched power ON.
Verify rear wipers are OFF.
Check circuit A414 GRY for voltage between pin 4 on rear wiper motor (M14) connector and machine ground.
Is system voltage (approximately 12 V) present?
Result:
YES:Circuit A414 GRY is short to power. Repair circuit or replace harness.

( 5 ) Harness Check
Action:

Check for continuity between pin 5 (circuit A414 GRY) on VCU connector (X12) and all other pins on VCU connectors (X11, X12,
X13, and X14).
Result:
YES:Circuit A12 ORG is short to circuit with continuity indicated. Repair circuit or replace harness.
522434.03- Front Wiper Low

328
Front wiper motor (M13) low speed circuit is short to power. (Above 7.4 V.)
Front Wiper Low Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Front wiper motor diode (V13). See Cab Harness (W14) Component Location . (Group 9015-10.)
Result:

Action:
Switched power OFF.

Pin 3 (A713 GRY) and pin 4 (A413 GRY) of motor (M13).

Result:
YES:Front wiper motor (M13) malfunction. Repair or replace motor.

( 4 ) Diode Check
Action:
Switched power OFF.

Remove front wiper diode (V13).
Check continuity by connecting positive (+) lead to pin A and negative (-) lead to pin B of diode.
Result:
YES:Diode malfunction. Replace front wiper diode (V13).

( 5 ) Harness Check
Action:

Front wiper diode (V13) connected.
Front wiper motor (M13) disconnected.
Disconnect VCU connectors (X11, X12, X13, and X14)
Pin 2 (wire A313 GRY) of VCU connector (X12) and all other pins of VCU connectors (X11, X12, X13, and X14).
Result:
YES:Circuit with continuity is short to power. Repair circuit or replace harness. See appropriate wiring diagram or schematic.

328
Front wiper motor (M13) low speed circuit open.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Apply 12 volts to pin 4 (A413 GRY) and ground pin 2 (wire G032 BLK) of front wiper motor (M13) .
Does motor operate?
Result:

NO:Front wiper motor (M13) malfunction. Repair or replace motor.
( 4 ) Diode Check
Action:
Switched power OFF.

Result:

NO:Diode malfunction. Replace front wiper diode (V13).
Action:
Switched power OFF.

Disconnect vehicle control unit (VCU) connector (X12 and X13).
Pin 2 (wire A313 GRY) of VCU connector (X12) and pin B of front wiper diode (V13).
Pin 4 (wire A413 GRY) of front wiper motor (M13) and pin A of front wiper diode (V13).
Pin 5 (wire A213 GRY) of front wiper motor (M13) and pin 5 of VCU connector (X12).
Pin 3 (wire A713 GRY) of front wiper motor (M13) and pin 21 of VCU connector (X13).
Pin 2 (wire G032 BLK) of front wiper motor (M13) and machine ground.
Pin 6 (wire G032 BLK) of front wiper motor (M13) and machine ground.
Result:
NO:Circuit without continuity is open. Repair or replace harness. See appropriate wiring diagram or schematic.

328
Front wiper motor (M13) low speed circuit is short to ground.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Pin 4 (A413 GRY) and pin 2 (wire G032 BLK) of motor (M13).
Result:

Action:
Switched power OFF.

Pin 2 (wire A313 GRY) of VCU connector (X12) and machine ground.
Result:
( 5 ) Harness Check
Action:

Result:
522435.03- Front Wiper Hi

328
Front wiper motor (M13) high speed circuit is short to power. (Above 7.4 V.)
Alarm Level:
Front Wiper Hi Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.


Result:

( 4 ) Diode Check
Action:
Switched power OFF.

Result:
YES:Diode malfunction. Replace front wiper diode (V13).

( 5 ) Harness Check
Action:

Disconnect VCU connectors (X11, X12, X13, and X14)
Result:

328
Front wiper motor (M13) high speed circuit is open.
Alarm Level:
Front Wiper High Speed Diagnostic Procedure

Action:
Result:
Action:
Ignition OFF.
Disconnect front wiper motor (M13). See Cab Harness (W14) Component Location or see Canopy Harness (W15) Component
Apply 12 volts to pin 4 on front wiper motor (M13).
Does motor operate?
Result:

NO:Front wiper motor is faulty. Replace motor.
Action:
Ignition OFF.
Disconnect vehicle control unit (VCU) connector 2 (X12). See Cab Harness (W14) Component Location or see Canopy Harness
(W15) Component Location
Check circuit A213 GRY for continuity between pin 4 on front wiper motor (M13) harness connector and pin 5 on VCU connector
(X12).
Result:

NO:Circuit A213 GRY open. Repair or replace harness. See appropriate wiring diagram or schematic.

328
Front wiper motor (M13) high speed circuit is short to ground.
Alarm Level:
Front Wiper High Speed Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Result:

Action:
Switched power OFF.

Result:
( 5 ) Harness Check
Action:

Result:
522438.03- Loader Coupler

328
Loader coupler unlock solenoid (Y29) circuit is short to power.
Alarm Level:
Loader Coupler Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Loader coupler unlock solenoid (Y29). See Loader Coupler Solenoid Harness (W26) Component Location . (Group
9015-10.)
Operator Station Floor Ground (W2). See Cab Harness (W14) Component Location or see Canopy Harness (W15)
(Group 9015-10.)
Result:

Action:
Ignition OFF.
Disconnect loader coupler unlock solenoid (Y29). See Loader Coupler Solenoid Harness (W26) Component Location . (Group
9015-10.)
Measure resistance between terminals 1 and 2 on loader coupler unlock solenoid (Y29).
Is resistance to specification?
Result:

NO:Loader coupler unlock solenoid (Y29) malfunction. Replace solenoid.
Action:
Ignition OFF.
9015-10.)
Ignition ON.
Check circuit H007 GRN for voltage at pin 1 on loader coupler unlock solenoid (Y29) connector.
Is voltage present?
Result:
YES:Circuit H007 GRN is short to power. Repair circuit or replace harness. See appropriate wiring diagram or schematic.
( 5 ) Harness Check
Action:

9015-10.)
Disconnect VCU connectors (X11, X12, X13, and X14). See Cab Harness (W14) Component Location or see Canopy Harness
Check for continuity between pin 51 (circuit H007 GRN) on VCU connector (X13) and all other pins on VCU connectors (X11,
X12, X13, and X14).
Result:
YES:Circuit H007 GRN is short to circuit that indicated continuity. Repair circuit or replace harness. See appropriate wiring

328
Loader coupler unlock solenoid (Y29) circuit is open.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
9015-10.)
(Group 9015-10.)
Result:

Action:
Ignition OFF.
Disconnect loader coupler unlock solenoid (Y29).
Result:

Action:
Ignition OFF.
Check circuit H007 GRN for continuity between pin 1 on loader coupler unlock solenoid (Y29) connector and pin 51 on VCU
connector X13.
Result:

NO:Circuit H007 GRN is open. Repair circuit or replace harness. See appropriate wiring diagram or schematic.

328
Loader coupler unlock solenoid (Y29) circuit is short to ground.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
9015-10.)
(Group 9015-10.)
Result:

Action:
Ignition OFF.
9015-10.)
Result:

Action:
Ignition OFF.
Check circuit H007 GRN for ground at pin 1 on loader coupler unlock solenoid (Y29) connector.
Is voltage present?
Result:
YES:Circuit H007 GRN is short to ground. Repair circuit or replace harness. See appropriate wiring diagram or schematic.
( 5 ) Harness Check
Action:

Disconnect vehicle control unit (VCU) connectors (X11, X12, X13, and X14).
Check for continuity between pin 51 (circuit H007 GRN) on VCU connector (X13) and all other pins on VCU connectors (X11,
X12, X13, and X14).
Result:
YES:Circuit H007 GRN is short to circuit that indicated continuity. Repair circuit or replace harness. See appropriate wiring
522797.03- Front Washer Pump

328
Front washer motor (M15) circuit is short to power.
Alarm Level:
Front Washer Pump Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Front washer motor (M15). See Cab Harness (W14) Component Location or see Canopy Harness (W15) Component
Result:

Action:
Switched power OFF.

Disconnect front washer motor (M15).
Result:
YES:Go to Short to Power.
NO:Replace front washer motor (M15).

( 4 ) Harness Check
Action:

Disconnect front washer pump (M15).
Check for continuity between pin 19 (circuit A515 GRY) on VCU connector (X13) and all other pins on connectors (X11, X12,
X13, and X14).
Result:

328
Front washer motor (M15) circuit is open.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Front washer motor (M15). See Cab Harness (W14) Component Location or see Canopy Harness (W15) Component
Result:

Action:
Switched power OFF.

Disconnect front washer motor (M15).
Result:
YES:Go to Short to Power.
NO:Replace front washer motor (M15).

( 4 ) Voltage Check
Action:
Front washer motor (M15) disconnected.

Switched power ON.
Check for voltage at pin 1 of front washer motor (M15) connector.
Result:

Action:
Battery disconnect switch OFF.

Pin 19 (wire A515 GRY) of VCU connector (X13) and pin 1 of front washer motor (M15) connector.
Pin 2 (wire G032 BLK) of front washer motor (M15) connector and machine ground.
Result:

NO:Open in circuit. Repair or replace harness. See appropriate wiring diagram or schematic.
( 6 ) Harness Check
Action:
Switched power OFF.

Switched power ON.
Pin 1 (wire A515 GRY) of front washer motor (M15) connector 0.0 V.
Pin 2 (wire G032 BLK) of front washer motor (M15) connector for 0.0 V.
Result:
NO:Circuit is short to power. Repair or replace harness. See appropriate wiring diagram or schematic.

328
Front washer motor (M15) circuit is short to ground.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Front and rear washer motor (M15). See Cab Harness (W14) Component Location or see Canopy Harness (W15)
Result:

Action:
Switched power OFF.

Disconnect front and rear washer motor (M15).
Result:
NO:Replace front and rear washer motor (M15).

Action:
Switched power OFF.

Front and rear washer motor (M15) disconnected.
Check for continuity between pin 19 of VCU connector (X13) and machine ground.
Result:

NO:Checks complete.
523597.03- Beacon Light Driver

328
Beacon light (E17) circuit is short to power
Alarm Level:
Beacon Light Driver Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Beacon light (E17). See Roof Harness (W17) Component Location . (Group 9015-10.)
Result:

Action:
Ignition OFF.
Disconnect beacon light (H17). See Roof Harness (W17) Component Location . (Group 9015-10.)
Apply 12 volts to pin 1 and ground to pin 2 on beacon light (H17).
Does beacon light come on?
Result:
NO:Replace beacon light.

Action:
Ignition OFF.
Disconnect beacon light (H17). See Roof Harness (W17) Component Location . (Group 9015-10.)
Check circuit L045 BRN for power at pin 1 of beacon light (H17) harness connector.
Is voltage present?
Result:
YES:Circuit L045 BRN is short to power. Repair circuit or replace harness.

( 5 ) Harness Check
Action:

Disconnect beacon light (H17).
Disconnect vehicle control unit (VCU) connectors (X11, X12, X13, and X14). See Cab Harness (W14) Component Location or see
Check for continuity between pin 1 (wire L045 BRN) on VCU connector (X13) and all other pins on VCU connectors (X11, X12,
X13, and X14).
Result:
YES:Circuit L045 BRN is short to circuit that indicated continuity. Repair circuit or replace harness.

328
Beacon light (E17) circuit is open.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Ignition OFF.
Disconnect rotating beacon (H17).
Does rotating beacon come on?
Result:

Action:

Disconnect beacon (H17).
Check circuit L045 BRN for continuity between pin 1 on VCU connector (X13) and pin 2 on rotating beacon (H17).
Result:
YES:Circuit L045 BRN is open. Repair circuit or replace harness. See appropriate wiring diagram or schematic.
( 5 ) Harness Check
Action:

X13, and X14).
Result:

328
Beacon light (E17) is short to ground.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Ignition OFF.
Does rotating beacon come on?
Result:

Action:
Ignition OFF.
Check circuit L045 BRN for ground at pin 1 of rotating beacon (H17) harness connector.
Is voltage present?
Result:
YES:Circuit L045 BRN is short to ground. Repair circuit or replace harness. See appropriate wiring diagram or schematic.
( 5 ) Harness Check
Action:

X13, and X14).
Result:
523911.03- Pump Control

328
Hydraulic pump control solenoid (Y56) circuit is short to power. (Above 7.4 V.)
Alarm Level:
Pump Control Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Hydraulic pump control solenoid (Y56). See Transmission Harness (W13) Component Location . (Group 9015-10.)
(Group 9015-10.)
Result:

( 3 ) Harness Check
Action:
Switched power OFF.

Disconnect:

Hydraulic pump control solenoid (Y56).
VCU connectors (X11, X12, X13, and X14).
Pin D4 (wire R056 GRN) of VCU connector (X11) and all other pins on VCU connectors (X11, X12, X13, and X14).
Pin K2 (wire H056 GRN) of VCU connector (X11) and all other pins on VCU connectors (X11, X12, X13, and X14).
Result:

328
Hydraulic pump control solenoid (Y56) circuit is short to ground.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Disconnect:

VCU connector (X11).
Pin D4 (wire R056 GRN) of VCU connector (X11) and machine ground.
Pin K2 (wire H056 GRN) of VCU connector (X11) and machine ground.
Result:
( 4 ) Harness Check
Action:
Switched power OFF.

Hydraulic pump control solenoid (Y56) disconnected.
Disconnect:

VCU connectors (X12, X13, and X14).
Result:

328
Hydraulic pump control solenoid (Y56) circuit is open.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Disconnect:

Pin D4 (wire R056 GRN) of VCU connector (X11) and pin 2 of solenoid (Y56).
Pin K2 (wire H056 GRN) of VCU connector (X11) and pin 1 of solenoid (Y56).
Result:
YES:Circuit without continuity is open. Repair circuit or replace harness. See appropriate wiring diagram or schematic.

328
Hydraulic pump control solenoid (Y56) high-side driver circuit is shorted to ground or low-side driver circuit is shorted to power.
Alarm Level:
Hydraulic Pump Control Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

Disconnect hydraulic pump control solenoid (Y56).
Measure resistance between pins 1 and 2 of solenoid (Y56).
Result:

NO:Replace solenoid.
Action:
Switched power OFF.

Hydraulic pump control solenoid (Y56) disconnected.
Check for continuity between pin K2 (wire H056 GRN) of VCU connector (X11) and machine ground.
Result:
YES:High side driver circuit is short to ground. Repair circuit or replace harness. See appropriate wiring diagram or schematic.
( 4 ) Harness Check
Action:
Switched power OFF.

Disconnect:

VCU connectors (X11, X12, X13, and X14).
Result:
YES:Circuit with continuity is short. Repair circuit or replace harness. See appropriate wiring diagram or schematic.

328
Hydraulic pump control solenoid (Y56) out of calibration.
Alarm Level:

Action:
523911.03—Pump Control
Are VCU pump control codes active?
Result:
YES:Clear active VCU pump control codes.

Action:
Calibrate machine. See Standard Display Monitor (SDM)—Service Menu . (Group 9015-16.)
Was machine calibration successful?
Result:

328
Hydraulic pump control solenoid (Y56) out of calibration. (Relief setting incorrect during calibration. Check that load sense relief
is correct and repeat calibration.)
Alarm Level:

Action:
Are VCU pump control codes active?
Result:
YES:Clear active VCU pump control codes.

Action:
Calibrate machine. See Standard Display Monitor (SDM)—Service Menu . (Group 9025-16.)
Was machine calibration successful?
Result:
523948.03- Ride Control

328
Ride control solenoid 1 (Y50) or ride control solenoid 2 (Y51) circuit is short to power.
Alarm Level:
Ride Control Diagnostic Procedure

Action:
Result:
Action:
Ignition OFF.
Disconnect ride control solenoids (Y50 and Y51). See Ride Control Solenoid Harness (W27) Component Location . (Group
9015-10.)
Measure resistance between terminals 1 and 2 on ride control solenoids (Y50 and Y51).
Result:

NO:Ride control solenoid (Y50 or Y51) malfunction. Replace solenoid.
Action:
Ignition OFF.
9015-10.)
Ignition ON.
Check for power on circuit H050 GRN at pin 1 on ride control solenoids (Y50 and Y51) harness connectors.
Is voltage present?
Result:
YES:Circuit H050 GRN is short to power. Repair or replace harness. See appropriate wiring diagram or schematic.
( 4 ) Harness Check
Action:

9015-10.)
Disconnect vehicle control unit (VCU) connector (X11, X12, X13, and X14). See Cab Harness (W14) Component Location or see
Check for continuity between pin 42 (circuit H050 GRN) of VCU connector (X21) and all other pins on VCU connectors (X11,
X12, X13, and X14).
Result:
YES:Circuit that indicated continuity to another pin is short. Repair circuit or replace harness. See appropriate wiring diagram
or schematic.

328
Ride control solenoid 1 (Y50) or ride control solenoid 2 (Y51) circuit is open.
Alarm Level:

Action:
Result:
Action:
Ignition OFF.
9015-10.)
Result:

Action:
Ignition OFF.
9015-10.)
Disconnect vehicle control unit (VCU) connector 3 (X13). See Cab Harness (W14) Component Location or see Canopy Harness
Check circuit H050 GRN for continuity between pin 1 on ride control solenoids (Y50 and Y51) harness connectors and pin 42 on
Is voltage present?
Result:
YES:Circuit H050 GRN is open. Repair or replace harness. See appropriate wiring diagram or schematic.

328
Ride control solenoid 1 (Y50) or ride control solenoid 2 (Y51) circuit is short to ground.
Alarm Level:
Check Service Code

Action:
Result:
Action:
Ignition OFF.
9015-10.)
Result:

Action:
Ignition OFF.
Disconnect ride control solenoids (Y50 and Y51).
Check for ground on circuit H050 GRN at pin 1 on ride control solenoids (Y50 and Y51) harness connectors.
Is ground present?
Result:
YES:Circuit H050 GRN is short to ground. Repair or replace harness. See appropriate wiring diagram or schematic.
( 4 ) Harness Check
Section 9001 - DIAGNOSTICS Group 50: Auxiliary Valve Control (AVC) Diagnostic Trouble Codes
Action:

Disconnect ride control solenoids (Y50 and Y51).
Disconnect vehicle control unit (VCU) connector (X11, X12, X13, and X14). See Cab Harness (W14) Component Location or see
Check for continuity between pin 42 (circuit H050 GRN) of VCU connector (X13) and all other pins on VCU connectors (X11,
X12, X13, and X14).
Result:
or schematic.
Group 50 - Auxiliary Valve Control (AVC) Diagnostic Trouble Codes

Auxiliary Valve Controller (AVC) Diagnostic Trouble Codes
Note: For in-depth diagnostics on all AVC diagnostic trouble codes, see specific code diagnostic procedure in this group.

286
Battery voltage input is above 15 V.
Alarm Level:

See Hydraulic System Circuit Theory of Operation . (Group 9015-15.)
See Sensor Circuit Test . (Group 9015-20.)

Action:
Result:
NO:Go to System Voltage Check.
Action:
Start engine.
Result:

Action:

Result:

286
Battery voltage input is below 11.7 V.
Alarm Level:


Action:
Switched power OFF.

Result:

Action:
Result:
Action:
Switched power OFF.

continuity.
(Group 9015-15.)
Result:

( 4 ) Fuse Check
Action:
Switched power OFF.

9015-10.)

VCU Switched Power 5 A Fuse (F33)
Result:

NO:Replace fuse(s).
( 5 ) Relay Check
Action:
Switched power OFF.

Apply 12 V to pin 1 of accessory relay (K20).
Apply ground to pin 1 of accessory relay (K20).
sss:
Did accessory relay (K20) “Click”
Check for continuity between pin 3 of accessory relay (K20) and pin 5 of accessory relay (K20).
Result:

NO:Replace accessory relay (K20).
( 6 ) Voltage Check
Action:
Switched power ON.

Engine RUNNING.
Result:

NO:Go to Alternator Check.
Action:

Result:
Action:
Switched power OFF.

Disconnect vehicle control unit (VCU) connector 2 (X12)
Pin L1 (wire P017 RED) of VCU connector (X11) and pin D8 of fuse and relay block (X3).
Pin M1 (wire P033 RED) of VCU connector (X11) and pin AA8 of fuse and relay block (X3).
Result:

286
The HVC (if TMC tractor), VCU, and SDM have a software checking routine that runs at power up. This routine ensures that the
appropriate version of software is installed on each controller for compatibility. If this fault occurs, it means the controller that
has triggered this fault sees one of the other controllers as being incompatible. The technician should record the software
version numbers for the VCU, SDM, and HVC and make sure they are the same MAJOR revision number.
Alarm Level:
Software Incorrect Diagnostic Procedure

Action:
Switched power ON. Using Service ADVISOR ™ or standard display monitor (SDM), clear diagnostic trouble codes (DTCs). Cycle
switched power.
Does DTC return?
Result:

NO:Checks complete.
Action:
Check software version numbers for HVC, SDM, and VCU.

Do controllers have the same major revision number?
Result:
286
VIN security mismatch.
Alarm Level:

Action:
Result:
Action:

Result:
286
VIN security option bytes are not configured (equal to 0).
Alarm Level:

Action:
Result:
NO:Go to Software Version Check.
Action:
Result:

286
Messages are missing or other controllers in CAN network are not completed in the required time.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

Result:

NO:Repair or replace circuit. See appropriate schematic or wiring diagram.
Action:
Switched power OFF.

Perform CAN resistor test. Perform Controller Area Network (CAN) Resistor Test . (Group 9015-20.)
Result:

NO:Repair or replace failed resistor(s).
Action:
Result:
286
The controller has experienced a JDOS Watchdog Timeout. This points to a software error and will automatically reset the
controller.
Alarm Level:
Cycle switched power. If code still exists, reprogram VCU.
002664.03- Ldr Aux Roller

286
One of loader auxiliary flow control switch (B44) circuits is shorted to power. (Above 4.75 V.)
Alarm Level:
Loader Auxiliary Roller Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Loader auxiliary flow control switch (B44). See Transmission Harness (W13) Component Location . (Group 9015-10.)
Loader control lever connector (X58). See Transmission Harness (W13) Component Location . (Group 9015-10.)
Result:

Action:
Switched power OFF.

Disconnect loader auxiliary flow control switch (B44).
Switched power ON.

Pin 14 (wire H140 GRN) of VCU connector (X12).

Result:

schematic.
( 4 ) Harness Check
Action:
Switched power OFF.

Disconnect vehicle control unit (VCU) connectors (X13 and X14).
Pin H3 (wire R053 BLK) of VCU connector (X11) and all other VCU connectors.
Pin J3 (wire P053 RED) of VCU connector (X11) and all other VCU connectors.
Pin 14 (wire H140 GRN) of VCU connector (X12) and all other VCU connectors.
Result:

286
One of loader auxiliary flow control switch (B44) circuit is shorted to ground. (Below 0.25 V.)
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

( 3 ) Voltage Check
Action:
Switched power OFF.

Switched power ON.
Check pin 9 (wire P053 RED) of loader control lever connector (X58) for voltage above 0.25 V.
Result:
Action:
Switched power OFF.

Pin 14 (wire H140 GRN) of VCU connector (X12) and machine ground.
Pin 26 (wire H040 GRN) of VCU connector (X12) and machine ground.
Result:
( 5 ) Harness Check
Action:
Switched power OFF.

Disconnect VCU connectors X13 and X14.
Result:

286
Opposing channels on the loader auxiliary flow control switch (B44) do not agree.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Pin H3 (wire R053 BLK) of VCU connector (X11) and pin 10 of loader control lever connector (X58).
Pin J3 (wire P053 RED) of VCU connector (X11) and pin 9 of loader control lever connector (X58).
Pin 14 (wire H140 GRN) of VCU connector (X12) and pin 12 of loader control lever connector (X58).
Result:

Action:
Switched power OFF.

Disconnect loader auxiliary flow control switch (B44).
Switched power ON.

Result:

schematic.
( 5 ) Harness Check
Action:
Switched power OFF.

VCU connectors X11 and X12 disconnected.
Disconnect vehicle control unit (VCU) connectors (X13) and (X14).
Result:

NO:Replace loader auxiliary flow control switch (B44). Reprogram controller.

286
Loader auxiliary flow control switch (B44) is faulted and invalid.
Machine Response:
Loader Auxiliary Function is Disabled.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.

Pin H3 (wire R053 BLK) of VCU connector (X11) and pin 10 of loader control lever connector (X58).
Pin J3 (wire P053 RED) of VCU connector (X11) and pin 9 of loader control lever connector (X58).
Result:

Action:
Switched power OFF.

Switched power ON.

Result:

schematic.
( 5 ) Harness Check
Action:
Switched power OFF.

VCU connectors (X11) and X12) disconnected.
Disconnect vehicle control unit (VCU) connectors X13 and X14.
Result:
YES:Circuit with continuity is short. Repair circuit or replace harness. See appropriate wiring diagram or schematic.
NO:Replace loader auxiliary flow control switch (B44). Reprogram controller.
002724.07- Left Joystick
286
The left joystick rocker switch (S95) data is logically not valid. Switch inputs do not match.
Alarm Level:

Left Joystick Diagnostic Procedure

Action:
Result:
NO:Repair or replace left joystick rocker switch (S95).

286
Sensor power supply 1 voltage is above 5.25 V.
Alarm Level:

Action:
Result:
NO:Go to Code Check
( 2 ) Code Check
Action:
Switched power ON.

Result:
YES:Clear codes.
Action:
Switched power OFF.

continuity.
Result:

Action:
Switched power OFF.
→NOTE:
Check voltage on VCU side of connector.

Switched power ON.
Check pins 3 and 6 (wire P055 RED) of seat position sensor (B9) connector for voltage.
Result:

( 5 ) Harness Check
Action:
Switched power OFF.

X13, and X14).
Result:

NO:Checks complete.

286
Sensor power supply 1 voltage is below 4.75 V.
Alarm Level:

Action:
Result:
NO:Go to Code Check
( 2 ) Code Check
Action:
Switched power ON.

Result:
YES:Clear codes.
Action:
Switched power OFF.

continuity.
Result:

( 4 ) Voltage Check
Action:
Ignition OFF.
Ignition ON.
Check for ground at pins 3 and 6 (wire P055 RED) on seat position sensor (B9) connector.
Is ground present?
Result:
( 5 ) Harness Check
Action:
Switched power OFF.

X13, and X14).
Result:

NO:Checks complete.
520542.03- CAN Bus

286
CAN high line test voltage above threshold.
Alarm Level:
See Controller Area Network (CAN) Circuit Test . (Group 9015-20.)
CAN Bus Diagnostic Procedure

Action:
Result:
Action:

Result:

Action:

Result:
YES:Reprogram controller.
520543.04- CAN Bus

286
CAN low line test voltage is below threshold.
Alarm Level:
See Controller Area Network (CAN) Circuit Test . (Group 9015-20.)
CAN Bus Diagnostic Procedure

Action:
Result:
Action:

Result:

Action:

Result:
YES:Reprogram controller.
523404.00- Loader Aux Press

286
Loader auxiliary calibration did not see a pressure drop when command was reduced.
Alarm Level:
Loader Auxiliary Pressure Drop Diagnostic Procedure

Action:
Result:
( 2 ) Loader Auxiliary Operation Check
Action:
View hydraulic system pressure in monitor. See Standard Display Monitor (SDM)—Diagnostics . (Group 9015-16.)
Activate loader auxiliary, hold function over relief in the direction that calibration did not pass, then release.
Does hydraulic system pressure ramp up then go back down to hydraulic tank return pressure when loader auxiliary flow
control switch (B44) is returned to neutral position?
Result:
YES:Loader auxiliary calibration software error. Program vehicle control unit (VCU).
( 3 ) Solenoid Check
Action:
→NOTE:
Rolling loader auxiliary flow switch (B44) forward activates loader auxiliary retract solenoid (Y21). Rolling
auxiliary flow switch backward activates loader auxiliary extend solenoid (Y20).
Check malfunctioned solenoid resistance. For location of solenoids, see Loader Auxiliary Solenoid Harness (W29) Component
Does solenoid (Y20 or Y21) meet resistance specifications? See Electrical Component Specifications . (Group 9015-20.)
Result:

NO:Replace solenoid valve.
( 4 ) Stuck Solenoid Check
Action:
Apply power (12V) and ground to appropriate loader auxiliary solenoid (Y20 or Y21).
Is there an audible click when applying and removing power, indicating the valve is shifting?
Result:

NO:Solenoid valve is sticking. Replace solenoid valve.
( 5 ) Stuck Loader Auxiliary Spool Check
Action:
Check loader auxiliary spool operation. See Loader and Stabilizer Control Valve Spool Disassemble and Assemble . (Group
3160.)
Is spool binding or stuck?
Result:
YES:Repair spool.
NO:Checks complete.
523404.01- Loader Aux Press

286
Loader auxiliary calibration does not see a stall during the current ramp.
Alarm Level:
Loader Auxiliary Pressure Drop Diagnostic Procedure

Action:
Result:
( 2 ) Loader Auxiliary Operation Check
Action:
View hydraulic system pressure in monitor. See Standard Display Monitor (SDM)—Diagnostics . (Group 9015-16.)
Activate loader auxiliary, hold function over relief in the direction that calibration did not pass, then release.
Does hydraulic system pressure reach loader auxiliary circuit relief pressure, then return to hydraulic tank return pressure
when loader auxiliary flow control switch (B44) is released to neutral position? See Circuit Relief Valve Test—With Remote
Pump for pressure specification. (Group 9025-25.)
Result:
YES:Loader auxiliary calibration software error. Program vehicle control unit (VCU).
( 3 ) Solenoid Check
Action:
→NOTE:
Rolling loader auxiliary flow switch (B44) forward activates loader auxiliary retract solenoid (Y21). Rolling
auxiliary flow switch backward activates loader auxiliary extend solenoid (Y20).
Check malfunctioned solenoid resistance. For location of solenoids, see Loader Auxiliary Solenoid Harness (W29) Component
Does solenoid (Y20 or Y21) meet resistance specifications? See Electrical Component Specifications . (Group 9015-20.)
Result:

NO:Replace solenoid valve.
( 4 ) Stuck Solenoid Check
Action:
Apply power (12V) and ground to appropriate loader auxiliary solenoid (Y20 or Y21).
Is there an audible click when applying and removing power, indicating the valve is shifting?
Result:

NO:Solenoid valve is sticking. Replace solenoid valve.
( 5 ) Loader Auxiliary Circuit Relief Check
Action:
Check loader auxiliary circuit relief valve. See Circuit Relief Valve Test—With Remote Pump . (Group 9025-25.)
Did the loader auxiliary circuit relief valve test good?
Result:
YES: Go to Stuck Loader Auxiliary Spool Check .

( 6 ) Supply Circuit Check Valve Check
Action:
→NOTE:
This check only applies to machines equipped with manual backhoe controls.
LEGEND:
1 Supply Circuit Check Valve
Backhoe Control Valve
Check supply circuit check valve.

Does the valve move and operate properly?
Result:

NO:Repair or replace check valve.
( 7 ) Loader Auxiliary Solenoid Filter Screen Check
Action:
LEGEND:
1 Screen
Loader Auxiliary Solenoid
Check screen (1) on loader auxiliary extend solenoid (Y20) and loader auxiliary retract solenoid (Y21).
Are screens clean and free of debris?
Result:

NO:Clean screen or replace solenoid.
( 8 ) Stuck Loader Auxiliary Spool Check
Action:
Check loader auxiliary spool operation. See Loader and Stabilizer Control Valve Spool Disassemble and Assemble . (Group
3160.)
Is spool binding or stuck?
Result:
YES:Repair spool.
NO:Checks complete.
523571.04- Valve Power 2

286
Power input voltage 2 for vehicle control unit (VCU) (A1) is below 11.7 V.
Alarm Level:

Valve Power 2 Diagnostic Procedure

Action:

Result:
YES:Diagnose and clear active VCU DTC 000168.04—Battery Voltage. See 000168.04—Battery Voltage . (Group 9001-40.)
NO:Go to Intermittent Check.
OK:
Action:
Result:
Action:
Switched power OFF.

continuity.
Loader control lever connector (X58). See Cab Harness (W14) Component Location . (Group 9015-10.)
Result:

( 4 ) Fuse Check
Action:
Switched power OFF.

Check following fuses for continuity and proper amperage rating. See Fuse and Relay Location and Specifications . (Group
9015-10.)
Main 250 A fuse (F1).

VCU switched power 5 A fuse (F33).
Result:

NO:Replace fuses.
( 5 ) Harness Check
Action:
Switched power OFF.

Loader control lever connector (X58) and vehicle control unit (VCU) connector (X11) disconnected.
Check continuity between:
Pin J3 (wire P053 RED) of VCU (X11) and pin 9 of X58.

Pin H3 (wire R053 BLK) of VCU (X11) and pin 10 of X58.
Pin 3 (wire G001 BLK) of VCU (X12) and machine ground.
Pin 4 (wire G001 BLK) of VCU (X12) and machine ground.
Pin J1 (wire G030 BLK) of VCU (X11) and machine ground.
Result:

286
Mechanical front wheel drive (MFWD) switch (S36) stuck closed at start-up for more than 20 seconds.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Mechanical front wheel drive (MFWD) switch (S36). See Transmission Harness (W13) Component Location . (Group
9015-10.)
Result:

Action:
Switched power OFF.

sss:
Is mechanical front wheel drive (MFWD) switch (S36) stuck ON?

Check for continuity between pin 5 (DK BLU wire) and pin 7 (DK GRN wire) of loader control lever connector (X58). Do not press
MFWD switch (S36).
Result:
YES:Switch malfunction. Repair or replace MFWD switch (S36).

Action:
Switched power OFF.

Check for 0.0 V at pin 38 (wire T011 BLU) of VCU connector (X13).
Result:

NO:Circuit is short to power. Repair circuit or replace harness. See appropriate wiring diagram or schematic.
( 5 ) Harness Check
Action:
Switched power OFF.

Check for continuity between pin 38 (wire T011 BLU) of VCU connector (X13) and pins of all VCU connectors.
Result:

286
Mechanical front wheel drive (MFWD) momentary switch (S37) stuck closed at start-up for more than 20 seconds.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Mechanical front wheel drive (MFWD) momentary switch (S37). See Transmission Harness (W13) Component Location .
(Group 9015-10.)
Result:

Action:
Switched power OFF.

sss:
Is mechanical front wheel drive (MFWD) momentary switch (S37) stuck ON?

Check for continuity between pin 4 (GRY wire) and pin 8 (LT GRN wire) of loader control lever connector (X58). Do not press
MFWD momentary switch (S37).
Result:
YES:Switch malfunction. Repair or replace MFWD momentary switch (S37).

Action:
Switched power OFF.

Check for continuity between pin 43 (wire T111 BLU) of VCU connector (X12) and machine ground.
Result:
( 5 ) Harness Check
Action:
Switched power OFF.

Check for continuity between pin 43 (wire T111 BLU) of VCU connector (X12) and remaining pins of all VCU connectors.
Result:
YES:Circuit with continuity is shorted. Repair circuit or replace harness. See appropriate wiring diagram or schematic.
523938.03- Loader Aux Sol A

286
Loader auxiliary retract solenoid (Y21) high side driver circuit is shorted to power.
Alarm Level:
Loader Auxiliary Solenoid Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Loader auxiliary retract solenoid (Y21). See Loader Auxiliary Solenoid Harness (W29) Component Location . (Group
9015-10.)
Loader auxiliary solenoid harness connector (X82). See Loader Auxiliary Solenoid Harness (W29) Component Location .
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Disconnect loader auxiliary retract solenoid (Y21).
Switched power ON.
Pin K3 (wire R271 BLK) of VCU connector (X11).

Pin M2 (wire H271 GRN) of VCU connector (X11).

Result:

schematic.
( 4 ) Harness Check
Action:
Switched power OFF.

VCU connectors (X11) disconnected.
Pin K3 (wire R271 BLK) of VCU connector (X11) and all other pins of VCU connectors.
Pin M2 (wire H271 GRN) of VCU connector (X11) and all other pins of VCU connectors.
Result:

286
Loader auxiliary retract solenoid (Y21) low side driver circuit is shorted to ground.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
9015-10.)
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Pin K3 (wire R271 BLK) of VCU connector (X11) and machine ground.
Pin M2 (wire H271 GRN) of VCU connector (X11) and machine ground.
Result:
( 4 ) Harness Check
Action:
Switched power OFF.

Loader auxiliary retract solenoid (Y21) disconnected
Result:

286
Loader auxiliary retract solenoid (Y21) circuit is open.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
9015-10.)
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Pin K3 (wire R271 BLK) of VCU connector (X11) and pin 2 of loader auxiliary retract solenoid (Y21).
Pin M2 (wire H271 GRN) of VCU connector (X11) and pin 1 of loader auxiliary retract solenoid (Y21).
Result:

286
Loader auxiliary retract solenoid (Y21) low side driver circuit shorted to power or high side driver circuit shorted to ground.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
9015-10.)
(Group 9015-10.)
Result:
YES:Go to Short Circuit Check—Low Side Driver.

( 3 ) Short Circuit Check—Low Side Driver
Action:
Switched power OFF.

Switched power ON.
Check pin K3 (wire R271 BLK) of VCU connector (X11) for 0.0 V.
Result:
YES:Go to Short Circuit Check—High Side Driver.

NO:Low side driver circuit is short to power. Repair circuit or replace harness. See appropriate wiring diagram or schematic.
( 4 ) Short Circuit Check—High Side Driver
Action:
Switched power OFF.

Loader auxiliary retract solenoid (Y21) disconnected.
Check for continuity between pin M2 (wire H271 GRN) of VCU connector (X11) and machine ground.
Result:
( 5 ) Harness Check
Action:
Switched power OFF.

VCU connectors (X11) disconnected.
Loader auxiliary retract solenoid (Y21) disconnected.
Result:

523939.03- Loader Aux Sol B

286
Loader auxiliary extend solenoid (Y20) high side driver circuit is shorted to power.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Loader auxiliary extend solenoid (Y20). See Loader Auxiliary Solenoid Harness (W29) Component Location . (Group
9015-10.)
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Disconnect loader auxiliary extend solenoid (Y20).
Switched power ON.
Pin K4 (wire R171 BLK) of VCU connector (X11).

Pin M3 (wire H171 GRN) of VCU connector (X11).

Result:

schematic.
( 4 ) Harness Check
Action:
Switched power OFF.

Loader auxiliary extend solenoid (Y20) disconnected.
Result:

286
Loader auxiliary extend solenoid (Y20) low side driver circuit is shorted to ground.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
9015-10.)
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Pin K4 (wire R171 BLK) of VCU connector (X11) and machine ground.
Pin M3 (wire H171 GRN) of VCU connector (X11) and machine ground.
Result:
( 4 ) Harness Check
Action:
Switched power OFF.

Result:

286
Loader auxiliary extend solenoid (Y20) circuit is open.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
9015-10.)
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Pin K4 (wire R171 BLK) of VCU connector (X11) and pin 2 of loader auxiliary extend solenoid (Y20).
Pin M3 (wire H171 GRN) of VCU connector (X11) and pin 1 of loader auxiliary extend solenoid (Y20).
Result:

286
Loader auxiliary extend solenoid (Y20) low side driver circuit shorted to power or high side driver circuit shorted to ground.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
9015-10.)
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Switched power ON.
Check pin K4 (wire R171 BLK) of VCU connector (X11) for 0.0 V.
Result:

Action:
Switched power OFF.

Check for continuity between pin M3 (wire H171 GRN) of VCU connector (X11) and machine ground.
Result:
( 5 ) Harness Check
Action:
Switched power OFF.

Result:

524010.03- Selective Flow

17
Selective flow control solenoid (Y53) is shorted to power.
Alarm Level:
See Wire Harness Test . (Group 9015-20.
Selective Flow Diagnostic Procedure

Action:
Result:
Action:
Switched power OFF.

continuity.
Selective flow control solenoid (Y53). Selective Flow Solenoid Harness (W28) Component Location . (Group 9015-10.)
Selective flow control solenoid harness connector (X54). Selective Flow Solenoid Harness (W28) Component Location .
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Selective flow control solenoid (Y53) disconnected.
Measure resistance between pins A and B of selective flow control solenoid (Y53).
Result:

NO:Replace selective flow control solenoid (Y53).
Action:
Switched power OFF.

Disconnect selective flow control solenoid (Y53).
Switched power ON.
Pin E4 (wire R153 BLK) of VCU connector (X11).

Pin L3 (wire H053 GRN) of VCU connector (X11).
Result:

schematic.
( 5 ) Harness Check
Action:
Switched power OFF.

Pin E4 (wire R153 BLK) of VCU connector (X11) and all other pins of VCU connectors.
Pin L3 (wire H053 GRN) of VCU connector (X11) and all other pins of VCU connectors.
Result:

286
Selective flow control solenoid (Y53) low side driver is shorted to ground.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Pin E4 (wire R153 BLK) of VCU connector (X11) and machine ground.
Pin L3 (wire H053 GRN) of VCU connector (X11) and machine ground.
Result:
( 4 ) Harness Check
Action:
Switched power OFF.

Result:

286
Selective flow control solenoid (Y53) is open circuit.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
(Group 9015-10.)
Result:

Action:
Switched power OFF.

Pin E4 (wire R153 BLK) of VCU connector (X11) and pin B of selective flow control solenoid (Y53).
Pin L3 (wire H053 GRN) of VCU connector (X11) and pin A of selective flow control solenoid (Y53).
Result:
NO:Circuit with out continuity is open. Repair circuit or replace harness. See appropriate wiring diagram or schematic.

17
Selective flow control solenoid (Y53) is shorted to ground on high side drive or shorted to power on low side drive.
Alarm Level:

Action:
Result:
Action:
Switched power OFF.

continuity.
Selective flow control solenoid (Y53). Selective Flow Solenoid Harness (W28) Component Location .(Group 9015-10.)
Selective flow control solenoid harness connector (X54). Selective Flow Solenoid Harness (W28) Component Location
.(Group 9015-10.)
Component Location .(Group 9015-10.)
Result:

Action:
Switched power OFF.

Measure resistance between pins A and B of selective flow control solenoid (Y53).
Result:

NO:Replace selective flow control solenoid (Y53).
Action:
Switched power OFF.

Switched power ON.
Check pin E4 (wire R153 BLK) of VCU connector (X11) for 0.0 V.
Result:

Action:
Switched power OFF.

Check for continuity between pin L3 (wire H053 GRN) of VCU connector (X11) and machine ground.
Result:
( 6 ) Harness Check
Action:
Switched power OFF.

Result:
524204.03- Loader Aux Switch
286
Loader auxiliary control enable switch (S51) circuit is short to power. (Low level only)
Alarm Level:
Section 9001 - DIAGNOSTICS Group 60: Sealed Switch Module (SSM) Diagnostic Trouble Codes
524204.05- Loader Aux Switch

286
Loader auxiliary control enable switch (S51) circuit is open. (Low level only)
Alarm Level:
Group 60 - Sealed Switch Module (SSM) Diagnostic Trouble Codes

Sealed Switch Module (SSM) Diagnostic Trouble Codes
See Standard Display Monitor (SDM)—Main Menu—Diagnostics—Codes . (Operator’s Manual.)
Note: For in-depth diagnostics on all SSM diagnostic trouble codes, see specific code diagnostic procedure in this group.
194
Sealed switch module (SSM) has timed out.
Watchdog Timeout Diagnostic Procedure

Alarm Level:
Action:
Switched power OFF.

Wait 20 seconds.
Press engine start switch once to turn on switched power.
Check for active SSM codes.
Is SSM code 000629.12 present?
Result:
NO:Checks complete.
002634.04- Ignition Relay

194
Ignition relay (K10) circuit is shorted to ground or overloaded.
Alarm Level:
Ignition Relay Out Voltage Low Diagnostic Procedure

Action:
Result:
YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20).
NO:Go to Ignition Relay Check.
( 2 ) Ignition Relay Check
Action:
Switched power OFF.

Remove ignition relay (K10). See Cab Harness (W14) Component Location or see Canopy Harness (W15) Component Location .
(Group 9015-10.)
Measure resistance across the coil (pins 1 and 2) of relay (K10).
Result:

Action:
Switched power OFF.

Disconnect the SSM connector (X40). See Cab Harness (W14) Component Location or see Canopy Harness (W15) Component
Check circuit U110 RED for ground at pin 3 on connector.
Is ground present?
Result:
YES:Circuit U110 RED is short to ground. Repair circuit or replace harness. See appropriate wiring diagram or schematic.
( 4 ) Harness Check
Action:
Switched power OFF.

Disconnect SSM connector (X40).
Disconnect ignition relay (K10) connector.
Check for continuity between pin 3 (circuit U110 RED) on SSM connector (X40) and all other pins of ignition relay connector
(K10).
Result:
or schematic.
Action:
→NOTE:
The sealed switch module (SSM) will not store diagnostic trouble codes; when ignition is cycled, the SSM
will reset and all codes will be lost.
Document all diagnostic codes.

Switched power OFF.
Wait 20 seconds.
Ignition ON.
Is DTC 002634.04 present?
Result:
YES:Replace SSM.
NO:Checks complete.
002634.05- Ignition Relay

194
Ignition relay (K10) circuit is open or shorted to power.
Alarm Level:
Ignition Relay Out Current Low Diagnostic Procedure

Action:
Result:
YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20).
NO:Go to Ignition Relay Check.
( 2 ) Ignition Relay Check
Action:
Switched power OFF.

Remove ignition relay (K10). See Cab Harness (W14) Component Location or see Canopy Harness (W15) Component Location .
(Group 9015-10.)
Measure resistance across the coil (pins 1 and 2) of relay (K10).
Result:

Action:

Disconnect the SSM connector (X40).
Disconnect the ignition relay (K10) connector.
Check circuit U110 RED for continuity between pin 3 of SSM connector (X40) and pin 1 of ignition relay connector (K10).
Check circuit G001 BLK for continuity between pin 2 of ignition relay connector (K10) and ground.
Result:
YES:Go to Reset Controller.

NO:Circuit without continuity indicated is open. Repair circuit or replace harness. See appropriate wiring diagram or schematic.
Action:
→NOTE:
The sealed switch module (SSM) will not store diagnostic trouble codes; when ignition is cycled, the SSM
will reset and all codes will be lost.
Switched power OFF.

Wait 20 seconds.
Ignition ON.
Is DTC 002634.05 present?
Result:
NO:Checks complete.
523850.04- SSM Button 15
194
Ride control switch on sealed switch module (SSM) is stuck.
Alarm Level:
Switch Stuck Diagnostic Procedure

Action:
Result:
Action:
Press engine stop switch to turn off switched power.

Wait 20 seconds.
Result:
YES:Sealed switch module (SSM) malfunction. Program SSM.

NO:Checks complete.
523850.09- SSM Button 15
194
No LED response for ride control switch on sealed switch module (SSM).
Alarm Level:
No LED Response Diagnostic Procedure

Action:
Result:
Action:

Wait 20 seconds.
Result:

NO:Checks complete.
Action:
Perform CAN circuit test to test CAN connection between SSM and vehicle control unit (VCU). See Controller Area Network
(CAN) Circuit Test . (Group 9015-20.)
Result:

523852.04- SSM Button 14
194
Backhoe control pattern switch on sealed switch module (SSM) is stuck.
Alarm Level:

Action:
Result:
Action:

Wait 20 seconds.
Result:
NO:Checks complete.
523852.09- SSM Button 14
194
No LED response for the backhoe control pattern switch on sealed switch module (SSM).
Alarm Level:

Action:
Result:
Action:

Wait 20 seconds.
Result:

NO:Checks complete.
Action:
Result:

523854.04- SSM Button 13
194
Auxiliary hydraulic switch on sealed switch module (SSM) is stuck.
Alarm Level:

Action:
Result:
Action:

Wait 20 seconds.
Result:

NO:Checks complete.
523854.09- SSM Button 13
194
No LED response for auxiliary hydraulic switch on sealed switch module (SSM).
Alarm Level:

Action:
Result:
Action:

Wait 20 seconds.
Result:

NO:Checks complete.
Action:
Result:

523855.04- SSM Button 12
194
Rear wiper switch on sealed switch module (SSM) is stuck.
Alarm Level:

Action:
Result:
Action:

Wait 20 seconds.
Result:

NO:Checks complete.
523855.09- SSM Button 12
194
No LED response for rear wiper switch on sealed switch module (SSM).
Alarm Level:

Action:
Result:
Action:

Wait 20 seconds.
Result:

NO:Checks complete.
Action:
Result:

523856.04- SSM Button 11
194
Front washer switch on sealed switch module (SSM) is stuck.
Alarm Level:

Action:
Result:
Action:

Wait 20 seconds.
Result:

NO:Checks complete.
523856.09- SSM Button 11

194
No LED response for the front washer switch on sealed switch module (SSM).
Alarm Level:

Action:
Result:
Action:

Wait 20 seconds.
Result:

NO:Checks complete.
Action:
Result:

523857.04- SSM Button 10
194
Front wiper switch on sealed switch module (SSM) is stuck.
Alarm Level:

Action:
Result:
Action:

Wait 20 seconds.
Result:

NO:Checks complete.
523857.09- SSM Button 10
194
No LED response for front wiper switch on sealed switch module (SSM).
Alarm Level:

Action:
Result:
Action:

Wait 20 seconds.
Result:

NO:Checks complete.
Action:
Result:

523858.04- SSM Button 9
194
Rear work light switch on sealed switch module (SSM) is stuck.
Alarm Level:

Action:
Result:
Action:

Wait 20 seconds.
Result:

NO:Checks complete.
523858.09- SSM Button 9
194
No LED response for rear work light switch on sealed switch module (SSM).
Alarm Level:

Action:
Result:
Action:

Wait 20 seconds.
Result:

NO:Checks complete.
Action:
Result:

523860.04- SSM Button 8
194
Front work light switch on sealed switch module (SSM) is stuck.
Alarm Level:

Action:
Result:
Action:

Wait 20 seconds.
Result:

NO:Checks complete.
523860.09- SSM Button 8

194
No LED response for the front work light switch on sealed switch module (SSM).
Alarm Level:

Action:
Result:
Action:

Wait 20 seconds.
Result:

NO:Checks complete.
Action:
Result:

523861.04- SSM Button 7
194
Keypad 1 switch on sealed switch module (SSM) is stuck.
Alarm Level:

Action:
Result:
Action:

Wait 20 seconds.
Result:

NO:Checks complete.
523861.09- SSM Button 7
194
No LED response for the keypad 1 switch on sealed switch module (SSM).
Alarm Level:

Action:
Result:
Action:

Wait 20 seconds.
Result:

NO:Checks complete.
Action:
Result:

523862.04- SSM Button 6
194
Loader coupler switch on sealed switch module (SSM) is stuck.
Alarm Level:

Action:
Result:
Action:

Wait 20 seconds.
Result:

NO:Checks complete.
523862.09- SSM Button 6
194
No LED response for the loader coupler switch on sealed switch module (SSM).
Alarm Level:

Action:
Result:
Action:

Wait 20 seconds.
Result:

NO:Checks complete.
Action:
Result:

523863.04- SSM Button 5
194
Hazard warning signal switch on sealed switch module (SSM) is stuck.
Alarm Level:

Action:
Result:
Action:

Wait 20 seconds.
Result:

NO:Checks complete.
523863.09- SSM Button 5

194
No LED response for hazard warning signal switch on sealed switch module (SSM).
Alarm Level:

Action:
Result:
Action:

Wait 20 seconds.
Result:

NO:Checks complete.
Action:
Result:

523864.04- SSM Button 4
194
Park brake switch on sealed switch module (SSM) is stuck.
Alarm Level:

Action:
Result:
Action:

Wait 20 seconds.
Result:

NO:Checks complete.
523864.09- SSM Button 4
194
No LED response for the park brake switch on sealed switch module (SSM).
Alarm Level:

Action:
Result:
Action:

Wait 20 seconds.
Result:

NO:Checks complete.
Action:
Result:

523865.04- SSM Button 3
194
Auto shift switch on sealed switch module (SSM) is stuck.
Alarm Level:

Action:
Result:
Action:

Wait 20 seconds.
Result:

NO:Checks complete.
523865.09- SSM Button 3
194
No LED response for auto shift switch on sealed switch module (SSM).
Alarm Level:

Action:
Result:
Action:

Wait 20 seconds.
Result:

NO:Checks complete.
Action:
Result:

523867.04- SSM Button 2
194
Engine stop switch on sealed switch module (SSM) is stuck.
Alarm Level:

Action:
Result:
Action:
→NOTE:
Use battery disconnect switch, if necessary, to cycle power to SSM to reset controller.

Wait 20 seconds.
Result:

NO:Checks complete.
523867.09- SSM Button 2
194
No LED response for the engine stop switch on sealed switch module (SSM).
Alarm Level:

Action:
Result:
Action:

Wait 20 seconds.
Result:

NO:Checks complete.
Action:
→NOTE:
Result:

523868.04- SSM Button 1
194
Engine start switch on sealed switch module (SSM) is stuck.
Alarm Level:

Action:
Result:
Action:
→NOTE:

Wait 20 seconds.
Result:

NO:Checks complete.
523868.09- SSM Button 1
194
No LED response for the engine start switch on sealed switch module (SSM).
Alarm Level:

Action:
Result:
Action:
→NOTE:

Wait 20 seconds.
OPERATIONAL CHECKOUT PROCEDURE (g) by Belgreen v2.0

Result:

NO:Checks complete.
Action:
Result:

Section 9005 - OPERATIONAL CHECKOUT PROCEDURE

Table of contents
Group 10 - Operational Checkout Procedure ....................................................................................... 1
Switched Power ON, Engine ON Checks ............................................................................................... 1

Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure
Group 10 - Operational Checkout Procedure

Operational Checkout Procedure
Use this check to make a quick check of machine operation by doing a walk-around inspection and performing specific checks
from operator’s seat.
Always check for diagnostic trouble codes and correct them before performing the operational checkout.
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.
If no problem is found, go to the next check. If a problem is indicated, an additional check or repair procedure will be
suggested.
No special tools are necessary to perform the checkout.
Diagnostic Trouble Code Check

( 1 ) Display and Clear Trouble Codes
Action:
Always check for diagnostic trouble codes and correct them before performing the operational checkout.
Diagnostic trouble codes can be displayed by using two methods:
Standard Display Monitor (SDM)

Service ADVISOR ™
Check for diagnostic trouble codes.

sss:
Are diagnostic trouble codes present?
Result:
YES:Correct all diagnostics trouble codes before proceeding. See Reading Diagnostic Trouble Codes (DTCs) . (Group 9015-20.)
NO:Proceed with operational checkout.
Switched Power OFF, Engine OFF Checks

( 1 ) Periodic Maintenance Decal Check
Action:
Periodic maintenance decal check.

sss:
Is periodic maintenance decal legible?
Result:

NO:Replace decal.
( 2 ) Cab Doors and Window Seals Check
Action:
Open and close doors and windows. Inspect seals.

sss:
Do cab doors and windows seal properly?
sss:
Do cab doors latch properly?
Result:

NO:Adjust doors and windows to close against seals properly. Replace seals as necessary.
NO:Adjust or replace latches as necessary.
( 3 ) Battery and Hour Meter Check
Action:
Switched power OFF position.
Hour and Voltage

Press SELECT button on standard display monitor (SDM), and hold until battery voltage and hour meter are displayed.
sss:
Does battery volts read a minimum of 12 volts?
Result:

NO:Test battery.
( 4 ) Dome Light Check
Action:
Press the outside edge of dome light lens to turn the dome light on.
sss:
Is dome light on?
Result:

NO:Check fuse and bulb. Check wiring. See Fuse and Relay Location and Specifications and see System Functional Schematic
and Section Legend . (Group 9015-10.)
( 5 ) Horn Check
Action:
Press horn button.

sss:
Does horn activate?
Result:

NO:Check fuse. See Fuse and Relay Location and Specifications . (Group 9015-10.)
NO:Check horn circuit. See System Functional Schematic and Section Legend . (Group 9015-10.)
( 6 ) Seat Belt Check
Action:
Does seat belt function correctly?
Result:

NO: See Use and Maintain Seat Belt . (Operator’s Manual.)
( 7 ) Seat Control Checks
Action:
→NOTE:
For seat adjustment procedures, see Seat Controls . (Operator′s Manual.)
Does seat raise and lower?

Does seat move forward and rearward easily and lock in position?
Does seat rotate from loader to backhoe position easily and lock in position?
Does seat back tilt forward and rearward easily and lock in position?
Result:

NO:Inspect linkage and repair.
( 8 ) Service Brake Pedal Stop Check
Action:
Pedal Stop
Unlock brake pedals.

Lift left and right brake pedals individually.
sss:
Does each pedal have a minimal amount of travel before cap screws contact stop?
→NOTE:
Gap between pedal stop screws and plate should be 0.127—0.381 mm (0.005—0.015 in).
This travel ensures that brake check valves are opened and brakes are released.
Result:

NO: See Service Brake Pedal Adjustment . (Group 9020-20.)
Switched Power ON, Engine OFF Checks

( 1 ) Standard Display Monitor (SDM) Check
Action:
→NOTE:
For full display of indicators and menu see Standard Display Monitor (SDM) . (Operator’s Manual.)
Press and release engine start switch on the sealed switch module (SSM) to energize machine (switched power on, engine off).
Observe monitor and note changes (bulbs, indicators, and gauges).
sss:
Does the display show the correct model number for a few seconds?
Does the display show FASTEN SEAT BELT for a few seconds?
Do all lights and backlighting come on?
Does the display show the voltage and hours symbol?
Do all gauge indicators point to maximum travel position and then move to their normal operating position?
Result:
YES:Continue check.
NO:Check standard display monitor (SDM) circuit. See Standard Display Monitor (SDM) Circuit Theory of Operation . (Group
9015-15.)
Action:
Switched power ON.

Observe monitor. Press the NEXT button.
sss:
Does the display show gear, engine speed, and hour meter?
Result:
YES:Continue check.
NO:Check standard display monitor (SDM) circuit. See Standard Display Monitor (SDM) Circuit Theory of Operation . (Group
9015-15.)
Action:
Switched power ON.

sss:
Does the display show gear, engine speed, and voltage?
Result:
YES:Continue check.
NO:Check SDM circuit. See Standard Display Monitor (SDM) Circuit Theory of Operation . (Group 9015-15.)
Action:
Switched power ON.

sss:
Does the display show gear, engine speed, and job timer hours?
Result:

NO:Check SDM circuit. See Standard Display Monitor (SDM) Circuit Theory of Operation . (Group 9015-15.)
( 2 ) Battery Disconnect Switch Check—If Equipped
Action:
Battery Disconnect Switch
Turn battery disconnect switch to the OFF position.

Switched power ON.
sss:
Do monitor indicator lights come on?
Result:
YES:Switch is malfunctioning. Check battery disconnect switch.

NO:Continue check.
Action:
Turn battery disconnect switch to the ON position.

Switched power ON.
sss:
Do monitor indicator lights come on?
Result:

NO:Switch is malfunctioning. Check battery disconnect switch.
( 3 ) Front Wiper and Washer Circuit Check
Action:
Front Wiper Switch
Front Washer Switch
Switched power ON.

Press front wiper switch on sealed switch module (SSM) and release to enable (one LED illuminated).
sss:
Does front wiper operate in intermittent mode?
Press wiper switch again and release to enable (two LED’s illuminated).
sss:
Does front wiper operate in slow mode?
Press wiper switch again and release to enable (three LED’s illuminated).
sss:
Does front wiper operate in fast mode?
IMPORTANT:
Washer motor may be damaged if washer switch is held for more than 20 seconds, or continually
operated with no fluid in the washer fluid tank.
Press washer switch on SSM and release to enable.

sss:
Does front wiper continue to operate?
sss:
Does front washer pump operate?
Result:

NO:Check circuit. See Cab Harness (W14) Wiring Diagram . (Group 9015-10.)
NO:Check washer hose for kinks or obstructions.
NO:Washer fluid reservoir may be empty.

( 4 ) Rear Wiper Check
Action:
Rear Wiper Switch
Switched power ON.

Press rear wiper switch on sealed switch module (SSM) and release to enable (one LED illuminated).
sss:
Does rear wiper operate intermittently?
Press wiper switch on SSM again and release (two LED’s illuminated).
sss:
Does rear wiper operate in regular mode?
Result:

NO:Check circuit. See Cab Harness (W14) Wiring Diagram . (Group 9015-10.)
( 5 ) Drive Lights Check
Action:
Drive Lights Switch
Switched power ON.

Press drive light switch on sealed switch module (SSM) and release to enable (one LED illuminated).
sss:
Are two front drive lights and two rear red lights on?
Press drive light switch on SSM again and release to enable (two LED’s illuminated).
sss:
Are four front drive lights and two rear red lights on?
Press drive light switch on SSM again and release to enable (three LED’s illuminated).
sss:
Are all lights off?
Result:

NO:Check wiring. See System Functional Schematic and Section Legend . (Group 9015-10.)
( 6 ) Rear Work Lights Check
Action:
Rear Work Lights
Switched power ON.

Press rear work light switch on sealed switch module (SSM) and release to enable (one LED illuminated).
sss:
Are two rear work lights on?
Press rear work light switch the second time and release to enable (two LED’s illuminated).
sss:
Are four rear work lights on?
Press rear work light switch the third time and release to enable (three LED’s illuminated).
sss:
Are four rear work lights and two side lights on?
Press rear work light switch fourth time and release to enable (one LED illuminated).
sss:
Are the two side work lights on?
Press rear work light switch fifth time and release (no LED’s illuminated).
sss:
Are all rear work lights off?
Result:

NO:Check wiring. See System Functional Schematic and Section Legend . (Group 9015-10.) See Cab Harness (W14) Component
Location and see Cab Harness (W14) Wiring Diagram . (Group 9015-10.)
( 7 ) Turn Signal Light Check
Action:
Switched power ON.

Press right side of turn signal light rocker switch down on steering wheel column.
sss:
Is right amber light flashing? Does right LED indicator flash in the rocker switch?
Press left side of turn signal light rocker switch down.

sss:
Is left amber light flashing? Does left LED indicator light on steering column flash?
Result:

NO:Check fuse and bulbs. See Fuse and Relay Location and Specifications . (Group 9015-10.)
( 8 ) Brake Light Switch Check
Action:
Switched power ON.

Depress and hold left brake pedal, then right brake pedal.
sss:
Does brake light come on when either pedal is depressed with switched power on?
Result:

( 9 ) Beacon Light Check—If Equipped
Action:
Switched power ON.

Turn beacon light switch ON.
sss:
Is beacon flashing?
Turn beacon light switch OFF.

sss:
Is beacon light off?
Result:

( 10 ) Hazard Warning Signal Light Check
Action:
Hazard Warning Signal Light Switch
Switched power ON.

Press the hazard warning signal light switch on sealed switch module (SSM).
sss:
Are four amber lights flashing (two front and two rear)?
Are both turn light indicator arrows flashing in turn signal rocker switch?
Result:

( 11 ) Blower Switch and Function Check—If Equipped
Action:
LEGEND:
1 Defroster, Heater, and Air Conditioner Switch
2 Blower Speed Control Switch
3 Temperature Control Knob
Defroster, Heater, and Air Conditioner Controls
Switched power ON.

Turn blower speed control switch (2) to LOW, MED, HIGH, and PURGE.
sss:
Does blower speed change as each different speed is selected?
Result:

NO:Check blower fuse (F44). See Fuse and Relay Location and Specifications . (Group 9015-10.)
NO: Perform Blower Motor Speed Switch Test . (Group 9031-25.) If blower switch is good, perform Blower Motor Resistor Test .
(Group 9031-25.)
( 12 ) Ride Control Electrical Check—If Equipped
Action:
Ride Control Switch
Switched power ON.

Press ride control switch on the sealed switch module (SSM) to turn enable ride control (LED illuminated in switch).
sss:
Does the ride control indicator symbol illuminate in the standard display monitor (SDM)?
Turn ride control switch OFF (LED not illuminated in switch).

sss:
Is the ride control LED indicator light symbol turned off in the SDM?
Result:

NO:Check ride control SSM switch and circuit. See System Functional Schematic and Section Legend , see Cab Harness (W14)
Wiring Diagram , and see Cab Harness (W14) Component Location . (Group 9015-10.) See Standard Display Monitor (SDM)
Circuit Theory of Operation . (Group 9015-15.)
NO:Check ride control circuit. See System Functional Schematic and Section Legend and see Ride Control Solenoid Harness
(W27) Wiring Diagram . (Group 9015-10.) See Cab Harness (W14) Wiring Diagram . (Group 9015-10.)
Switched Power ON, Engine ON Checks

( 1 ) Loader Boom Lock Check
Action:
Raise loader boom and install boom lock.

sss:
Does boom lock work properly?
Result:

NO:Repair or replace if necessary.
( 2 ) Park Brake Indicator and Switch Check
Action:
Fasten seat belt.

Operator′s seat facing loader position and locked.
Apply service brakes.
Start the engine.
Engine speed at slow idle.
sss:
Is the park brake indicator displayed on the standard display monitor (SDM)?
sss:
Is the park brake switch LED illuminated?
Release park brake.

sss:
Is the park brake indicator off on the SDM?
sss:
Is the park brake switch LED off?
Apply park brake.

Stop the engine.
Result:

NO:Check SDM park brake pressure switch circuit. See Standard Display Monitor (SDM) Circuit Theory of Operation . (Group
9015-15.) See Cab Harness (W14) Component Location and see Cab Harness (W14) Wiring Diagram . (Group 9015-10.) See
Transmission Harness (W13) Wiring Diagram and see Transmission Harness (W13) Component Location . (Group 9015-10.)
( 3 ) Start Circuit Check
Action:
Transmission Control Lever (TCL)

Fasten seat belt.
Move transmission control lever (TCL) to first gear forward (1F).
Start the engine.
→NOTE:
The engine will start with TCL in forward (F) or reverse (R) but the controller will automatically shift the
transmission to neutral (N).
sss:
Does the engine start?
Does standard display monitor (SDM) show RETURN TCL TO NEUTRAL?

Release park brake.
Neutral on Display
Move TCL to neutral.
→NOTE:
SDM will not show forward (F) or reverse (R) until the TCL is cycled to neutral and the park brake has
been released.
sss:
Does SDM show neutral (N)?
1F
TCL to first gear forward.
sss:
Does SDM show first forward (1F)?
Result:

NO:Check TCL gear range switch (S6) circuit. See Cab Harness (W14) Wiring Diagram . (Group 9015-10.) See Transmission
Control Circuit Theory of Operation and see Standard Display Monitor (SDM) Circuit Theory of Operation . (Group 9015-15.)
( 4 ) Reverse Warning Alarm Check
Action:
1R Transmission Control Lever (TCL)
1R Display

Release Park Brake.
Move transmission control lever (TCL) to first gear reverse (1R).
sss:
Does display show correct gear and direction?
Does the reverse warning alarm sound?
Result:

NO:Check reverse warning alarm circuit. See Transmission Harness (W13) Wiring Diagram and see Transmission Harness
( 5 ) Transmission Gearshift Detent Check
Action:
Transmission Control Lever (TCL)
Fasten seat belt.

Start the engine.
Release park brake.
Move transmission control lever (TCL) into forward (F).
Turn TCL to shift into each gear.
sss:
Does gear number align with pointer in each speed detent position?
Does twist handle remain in detented positions?
Does display indicate correct gear and direction?
Result:

NO:Replace TCL switch. See Transmission Control Lever (TCL) Remove and Install . (Group 0315.)
( 6 ) Autoshift Transmission Check—If Equipped
Action:
Autoshift Transmission Switch
→NOTE:
Autoshift Transmission mode allows the machine to automatically shift in gear range two through highest
gear range in forward and two through three in reverse but the transmission control lever’s (TCL) current
position determines the highest range or shift band autoshift will operate in. If the TCL is in forward (3F),
autoshift will only shift automatically between gears two and three.
Fasten seat belt.

Start the engine.
Press autoshift transmission switch on sealed switch module (SSM) and release to enable (two LED’s illuminated).
Release park brake.
Move transmission control lever (TCL) to forward (4).
Drive machine at various travel and engine speeds in forward.
sss:
Does the gear range show on the SDM?
sss:
Does machine automatically shift up and down in gears two through highest forward gear?
Move transmission control lever (TCL) to reverse (4).

Drive machine at various travel and engine speeds in reverse.
sss:
Does the gear range change on the SDM?
sss:
Does machine automatically shift up and down in gears two through three in reverse?
Result:

NO:Check autoshift circuit. See Standard Display Monitor (SDM) Circuit Theory of Operation . (Group 9015-15.) See
Transmission Control Circuit Theory of Operation . (Group 9015-15.)
( 7 ) Park Brake Function Check
Action:
Fasten seat belt.

Start the engine.
Operator′s seat facing loader position.
Release park brake.
Move transmission control lever (TCL) to third gear forward (3F).
Slowly increase engine speed just enough to allow machine to start to move a few feet.
Apply the park brake.
→NOTE:
Transmission will shift to neutral (N) as soon as park brake is applied.
sss:
Does park brake engage when park brake switch is pushed and does the machine stop?
Result:

NO:Check DTCs. See Reading Diagnostic Trouble Codes (DTCs) . (Group 9015-20.) Check park brake circuit. See Standard
Display Monitor (SDM) Circuit Theory of Operation . (Group 9015-15.)
( 8 ) Pilot Control Tower Operating/Stored Position Check—If Equipped
Action:
Move pilot control towers into operating position.

Release towers.
sss:
Do towers stay in operating position?
Move pilot control towers into stored position.

sss:
Do towers stay in stored position?
Result:

NO:Inspect pilot control towers. See Backhoe Pilot Control Tower Remove and Install . (Group 3315.)
( 9 ) Pilot Enable Switch Check—If Equipped
Action:
Run engine at slow idle.

Disable pilot controls and move control levers.
sss:
Do activated functions move?
Result:
NO:Continue with check.

YES:Check pilot control circuit. See System Functional Schematic and Section Legend . (Group 9015-10.) See Pilot Enable
Switch Harness (W31) Wiring Diagram . (Group 9015-10.)
( 10 ) Pilot Control Pattern Select Switch Check—If Equipped
Action:
Pilot Control Pattern Select Switch
Enable pilot controls.

Select backhoe option (LED illuminated) on the pilot control pattern select switch on the standard switch module (SSM).
Activate left and right pilot control levers forward and backward.
sss:
Does backhoe boom move when left pilot control lever is activated?
Does backhoe crowd move when right pilot control lever is activated?
Result:
YES:Continue with check.

NO:Check pattern select circuit. See System Functional Schematic and Section Legend . (Group 9015-10.) See Pilot Enable
Pattern Select Valve Harness (W30) Component Location or see Pilot Enable Pattern Select Valve Harness (W30) Wiring
Action:
Select excavator from the two position pattern select switch.

Activate left and right pilot control levers forward and backward.
sss:
Does backhoe crowd move when left pilot control lever is activated?
Does backhoe boom move when right pilot control lever is activated?
Result:

NO:Check pattern select circuit. See System Functional Schematic and Section Legend . (Group 9015-10.) See Pilot Enable
Pattern Select Valve Harness (W30) Component Location or see Pilot Enable Pattern Select Valve Harness (W30) Wiring
( 11 ) Backhoe Auxiliary Hydraulic Selective Flow Check—If Equipped
Action:
Selective Flow Control Momentary Switch
Operator’s seat facing backhoe position and locked.

Enable the following modes:
FOOT SWITCH MODE
sss:
Does backhoe auxiliary function with use of foot switch only?
CONTINUOUS MODE
sss:
Does backhoe auxiliary function continuously without use of foot switch?
OFF
sss:
Does backhoe auxiliary stop continuously functioning?
sss:
Is backhoe auxiliary foot switch function disabled?
Result:

NO:Check backhoe auxiliary hydraulic selective flow circuit. See System Functional Schematic and Section Legend . (Group
9015-10.) See Hydraulic System Circuit Theory of Operation . (Group 9015-15.)
( 12 ) Pilot Control Valve Check—If Equipped
Action:

Move pilot control levers in all directions.
sss:
Do levers move freely in all directions?
sss:
Do levers spring back to neutral when released?
Result:

NO:If pilot control levers bind during travel or do not return to neutral position, inspect controls and towers. See Backhoe Pilot
Control Tower Remove and Install . (Group 3315.)
( 13 ) Pilot Control Accumulator Check—If Equipped
Action:
Run engine at 1500 rpm.

Operators seat in backhoe position.
Disengage boom from boom lock.
Hold boom up function over relief for 10 seconds.
Turn engine off and switched power ON.
→NOTE:
Pilot enable switch must be cycled after switched power is turned back ON.
Cycle pilot enable switch to enable position.

Activate boom down function.
sss:
Does boom lower when boom down function is activated?
Result:

NO:Check pilot control manifold valve. See Pilot Control Valve Operation—If Equipped . (Group 9025-05.)
( 14 ) Backhoe Stabilizer Check
Action:

Operator′s seat facing backhoe position.
Activate stabilizer lever to lower and raise left stabilizer.
Activate stabilizer lever to lower and raise right stabilizer.
sss:
Do both stabilizers raise and lower?
Result:

NO: See Check Hydraulic Reservoir Oil Level . (Operator′s Manual.) See Loader and Stabilizer Control Valve Lockout Leakage
Test . (Group 9025-25.) See Loader and Stabilizer Control Valve Remove and Install . (Group 3160.)
( 15 ) Stabilizer Cylinder Check
Action:
Engine speed at approximately 1500 rpm.

Position loader bucket off the ground.
Operator′s seat facing backhoe position and locked.
Lower stabilizers to raise rear of machine off the ground.
sss:
Do cylinders extend and hold machine up?
Raise stabilizers.
sss:
Do cylinders retract and remain up?
Result:

NO:Check DTCs. See Reading Diagnostic Trouble Codes (DTCs) . (Group 9015-20.) Inspect stabilizer valve section and stabilizer
solenoids.
( 16 ) Brake System Leakage Check
Action:
Brake Pedals
Depress and hold left brake pedal, then right brake pedal.
sss:
Brake pedal must not feel spongy (caused by air in the system). Does pedal settle more than 25 mm (1.0 in) per minute?
Result:
YES:Bleed brake system. See Service Brake Bleed Procedure . (Group 9020-15.)
( 17 ) Brake Drag/Park Brake Check
Action:
Machine Position
Operator′s seat in loader position and locked.
Position machine on a gradual slope with front of machine facing downhill.
Lift loader bucket off the ground.
Transmission control lever (TCL) to neutral.
Differential lock not actuated.
Release park brake.
Release service brakes.
Let machine coast freely for several feet.
Apply park brake.
sss:
Did machine stop?
Release park brake.
→NOTE:
If machine does not move freely on slope, drive the machine for 5 minutes. Feel axle housing area to
locate which brake is dragging.
sss:
Did machine coast freely?
Result:

NO: Perform Park Brake Release Pressure Test . (Group 9020-25.) Perform Power Boost Service Brake Valve Leakage Test .
(Group 9020-25.)
( 18 ) Engine Speed Control Dial Check
Action:
Engine Speed Control Dial

Auto-idle off.
Lower all equipment to the ground.
Transmission control lever (TCL) in neutral.
Move engine speed control dial to slow idle, then to fast idle position.
→NOTE:
If equipped with economy mode option, it must be disabled (OFF) in the monitor to allow for maximum
fast idle (2400 rpm).
sss:
Does tachometer read 900 rpm (slow idle) and 2400 rpm (fast idle)?
Result:
YES:Continue check.
NO:Check DTCs. See Reading Diagnostic Trouble Codes (DTCs) . (Group 9015-20.) Check engine controller unit (ECU) circuit.
Action:

Operator’s seat facing backhoe position.
Move speed control dial to increase engine speed to 1200 rpm.
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device. Do not crawl
under machine while hydraulically supported.
Lower stabilizers to raise machine off the ground.

Mechanical front wheel drive (MFWD) not actuated.
Move TCL to first gear forward.
sss:
Does engine speed return to slow idle?
Result:
YES:Continue check.
Action:

Operator’s seat facing loader position.
TCL in neutral.
Move speed control dial to increase engine speed to 1200 rpm.
sss:
Does engine speed return to slow idle?
Result:
YES:Continue check.
Action:
Release service brakes.

sss:
Does engine speed return to 1200 rpm?
Result:

YES:Check DTCs. See Reading Diagnostic Trouble Codes (DTCs) . (Group 9015-20.) Check engine controller unit (ECU) circuit.
( 19 ) Engine Speed Control Pedal Check
Action:

Operator’s seat facing loader position and locked.
Move the foot throttle from slow idle to fast idle.
→NOTE:
sss:
Does tachometer read 900 rpm (slow idle) and 2400 rpm (fast idle)?
Result:

( 20 ) Auto-Idle Circuit Check—If Equipped
Action:
Enable auto-idle function in the standard display monitor (SDM) menu. See Standard Display Monitor (SDM)—Main
Menu—Setup . (Operator’s Manual)
Hydraulic functions in neutral.
Engine speed fast idle.
Warm hydraulic oil to operating temperature. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)
sss:
Does engine speed decrease after 4—6 seconds?
Result:
YES:Continue check.
NO:See engine control unit (ECU) circuit theory of operation (for machine engine type). (Group 9015-15.) See Vehicle Control
Unit (VCU) Circuit Theory of Operation . (Group 9015-15.) See Cab Harness (W14) Wiring Diagram . (Group 9015-10.)
Action:
Slowly actuate any boom backhoe function.

sss:
Does engine speed return to its original setting?
Result:

NO:See engine control unit (ECU) circuit theory of operation (for machine engine type). (Group 9015-15.) See Vehicle Control
Unit (VCU) Circuit Theory of Operation . (Group 9015-15.) See Cab Harness (W14) Wiring Diagram . (Group 9015-10.)
( 21 ) Loader Return-to-Dig Check
Action:

Raise loader boom to full height.
Lower loader boom by pulling the loader control lever all the way to left and let go of control lever to enable return-to-dig.
sss:
Does bucket roll back from dump position to dig position and control lever return to neutral position?
Result:

NO: See Loader Operation . (Operator′s Manual.)
( 22 ) Transmission Clutch Disconnect Circuit Check
Action:
Fasten seat belt. Operator’s seat facing loader position and locked.
Engine speed approximately 2000 rpm.
Raise loader bucket off the ground.
Shift transmission into fourth gear.
Release park brake.
Shift transmission control lever (TCL) to forward (3).
sss:
Does engine rpm drop (approximately 50 rpm) when the TCL is shifted into forward (F)?
Press clutch disconnect switch on loader control lever and note sound of engine.
sss:
Does engine rpm increase when the clutch disconnect button is pressed?
Result:

NO:Check harness circuit. See Cab Harness (W14) Wiring Diagram and See Cab Harness (W14) Component Location . (Group
9015-10.)
( 23 ) Differential Lock Check
Action:
Differential Lock Check
Raise machine off the ground with loader and stabilizers.

Unlock the brake pedals.
Turn mechanical front wheel drive (MFWD) switch OFF (if equipped).
Release park brake.
Press differential lock foot switch.
→NOTE:
Differential lock speed limit option limits engagement (enabling the option) when engine is operated over
1000 rpm. See Standard Display Monitor (SDM)—Main Menu—Setup . (Operator’s Manual.)
Operate machine at 1000 rpm maximum in first forward (1F).

Apply one brake pedal.

sss:
Do both rear wheels stop?
Result:

NO:Check differential lock pressure. See Differential Lock Pressure Test . (Group 9020-25.)
( 24 ) Front Wheel Alignment (Toe-In) Check
Action:
Toe-In
Drive machine in fourth gear forward on a surface with loose material.
sss:
Is material from behind front wheels thrown excessively inward or outward?
Result:
YES: See Toe-In Check and Adjust . (Group 9020-20.)

( 25 ) Mechanical Front Wheel Drive (MFWD) Driving Check—If Equipped
Action:
MFWD Switch
CAUTION:
Raise machine off the ground using loader and stabilizers.

Release park brake.

Shift transmission to first gear and operate engine at approximately 1500 rpm.
Move transmission control lever (TCL) to forward (F) position.
Turn on mechanical front wheel drive (MFWD) switch.
sss:
Do the front wheels turn?
Turn OFF MFWD.

sss:
Do the front wheels stop turning?
Result:

NO: See No Power to Mechanical Front Wheel Drive (MFWD) or see No Power to One Wheel of Mechanical Front Wheel Drive
(MFWD) . (Group 9020-15.)
( 26 ) Mechanical Front Wheel Drive (MFWD) Differential Check—If Equipped
Action:
MFWD Switch
CAUTION:
Raise machine off the ground using loader and stabilizers.

Release park brake.
Shift transmission in first gear forward (1F).
Engage mechanical front wheel drive (MFWD).
Lower front wheels to just contact ground.
sss:
Does at least one front wheel turn?
Result:

NO: See No Power to Mechanical Front Wheel Drive (MFWD) or see No Power to One Wheel of Mechanical Front Wheel Drive
(MFWD) . (Group 9020-15.)
( 27 ) Sideshift Frame Lock Check
Action:
Side Shift Frame Lock Check
Operate engine at slow idle.

Lock backhoe in transport position.
Depress sideshift lock foot switch.
sss:
Does sideshift frame drop slightly as locking pistons retract?
Result:
YES:Continue check.
NO:Sideshift frame lock does not release. Check fuse (F47). See Fuse and Relay Location and Specifications . (Group 9015-10.)
Inspect wiring from switch to valve solenoid. See System Functional Schematic and Section Legend . (Group 9015-10.) See
Boom Lock/Sideshift Harness (W37) Wiring Diagram and see Boom Lock/Sideshift Harness (W37) Component Location . (Group
9015-10.)
Action:
Release switch to ON position.

Hold boom up function over relief.
sss:
Does sideshift frame raise slightly when backhoe valve is held over relief?
Result:
YES:Continue check.
NO:Sideshift frame will not lock. Remove and inspect check valve and solenoid seals. See Boom Lock/Sideshift Harness (W37)
Component Location . (Group 9015-10.
Action:
Return boom lever to neutral position.

sss:
Does sideshift frame remain locked in position for 1 minute minimum?
Result:

NO:Sideshift frame does not remain locked. See System Functional Schematic and Section Legend . (Group 9015-10.)
( 28 ) Boom Lock Check
Action:
Boom Lock Switch
Engage park brake.

Put transmission control lever (TCL) in neutral (N).
Operate engine at slow idle.
Move boom control back in the boom raise (over relief) position.
Depress boom lock foot switch.
sss:
Are both locks in the raised and released position?
Result:
YES:Continue check.
NO:Check fuse (F47). See Fuse and Relay Location and Specifications . (Group 9015-10.)
NO:Check sideshift switch (S34), solenoid (Y34), and circuit. See Boom Lock/Sideshift Harness (W37) Wiring Diagram and see
Boom Lock/Sideshift Harness (W37) Component Location . (Group 9015-10.)
Action:
Release Boom Lock Foot Switch
Release boom lock foot switch.

sss:
Are both locks in the engaged position?
Result:
YES:Go to the next check.

NO:Inspect and repair boom lock cylinder return springs.
( 29 ) Steering System Checks
Action:

Raise the loader bucket off the ground with the bottom level with the ground.
CAUTION:
Raise rear of machine off the ground using stabilizers.

Operate engine at approximately 1000 rpm.
Turn the steering wheel full left to full right several times.
→NOTE:
Internal leakage or a sticking steering valve spool can cause wheels to continue to move after steering
wheel is stopped.
sss:
Did the front wheels move smoothly in both directions? When the steering wheel was stopped, did the wheels stop moving?
Result:

NO:Wheels did NOT move smoothly in both directions. Wheels continued to move after steering wheel was stopped. See
Machine Turns When Steering Valve is in Neutral . (Group 9025-15.)
( 30 ) Cylinder Cushion Check
Action:

Operator’s seat facing backhoe position.
CAUTION:
Raise rear of machine off the ground.

Boom must be lowered from the transport position.
Activate backhoe swing left and right.
Make a note of the sound and speed as cylinders near end of their stroke.
sss:
Does swing speed decrease near the end of the cylinder stroke?
Repeat check using backhoe boom raise function.
Result:

NO:Remove and repair cylinder cushion.
( 31 ) Backhoe and Loader Function Drift Check
CAUTION:
Make sure area is clear and large enough to operate all functions of machine.
→NOTE:
All systems must be warmed up to operating range to get accurate test results.
Action:
Perform Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)

Hydraulic Oil Temperature 60—70°C
140—160°F

Position backhoe fully extended with bucket at a 45° angle to the ground.
Lower boom until the bucket cutting edge is 50 mm (2.0 in) off the ground.
Position loader bucket the same distance off of the ground as backhoe bucket.
Observe both bucket cutting edges for 1 minute.
sss:
Are both bucket cutting edges still off the ground after 1 minute?
Result:

NO: Perform Function Drift Test . (Group 9025-25.)
( 32 ) Ride Control System Check—If Equipped
Action:
Ride Control Switch
Run engine at fast idle.

Press ride control switch on sealed switch module (SSM) and release to enable ride control ON (LED illuminated).
Operator’s seat facing loader position and locked.
Raise loader boom to maximum height.
Power boom down half way to the ground.
Stop suddenly by releasing the joystick.
sss:
Is boom cushioned when joystick is released?
Result:

NO:Check accumulator charge. See Ride Control Accumulator Charge Check Procedure . (Group 9025-20.)
( 33 ) Cycle Times Check
CAUTION:
Make sure area is clear and large enough to operate all functions of machine.
IMPORTANT:
Warm hydraulic oil to operating temperature for this check.
Action:
Engine at fast idle.
→NOTE:
Record cycle time for each function.

Does machine perform within specifications?
Loader Boom Raise (bucket flat on ground-to-full height) Maximum Cycle Time (seconds) 5.5 (seconds)
Loader Boom Lower—Powered (full height-to-bucket flat on ground) Maximum Cycle Time 2.2 (seconds)
Loader Boom Lower—Float (full height-to-bucket flat on ground) Maximum Cycle Time 2.2 (seconds)
Loader Bucket Dump (boom just above ground Maximum Cycle Time 2.4 (seconds)
Loader Bucket Curl (boom just above ground) Maximum Cycle Time 2.6 (seconds)
Backhoe Boom Raise (backhoe at maximum reach, bucket teeth on ground-to-boom at cushion) Maximum Cycle Time 2.9 (seconds)
Backhoe Boom Lower (backhoe at maximum reach, bucket teeth on ground-to-boom at cushion) Maximum Cycle Time 2.9 (seconds)
Crowd In (boom in transport position) Maximum Cycle Time 3.1 (seconds)
Crowd Out (boom in transport position) Maximum Cycle Time 2.7 (seconds)
Backhoe Bucket Dump Maximum Cycle Time 2.4 (seconds)
Backhoe Bucket Curl Maximum Cycle Time 2.8 (seconds)
Backhoe Swing (boom raised to cushion, bucket curled, dipperstick parallel to ground cylinder-cushion-to-cylinder-
Maximum Cycle Time 3.3 (seconds)
cushion [180°])
Extendible Dipperstick Extend—If Equipped Maximum Cycle Time 2.4 (seconds)
Extendible Dipperstick Retract—If Equipped Maximum Cycle Time 2.6 (seconds)
Right Stabilizer Down (full up-to-ground level) Maximum Cycle Time 2.5 (seconds)
Right Stabilizer Up (ground level-to-full up) Maximum Cycle Time 2.5 (seconds)
Left Stabilizer Down (full up-to-ground level) Maximum Cycle Time 2.5 (seconds)
Left Stabilizer Up (ground level-to-full up) Maximum Cycle Time 2.5 (seconds)
Steering Right to Left Turns 2.3 to 3
Steering Left to Right Turns 2.3 to 3
Steering Right to Left (MFWD) Turns 2.3 to 3
Steering Left to Right (MFWD) Turns 2.3 to 3
Does machine perform within specifications?
Result:
YES:Operational checkout complete.
ENGINE (g) by Belgreen v2.0
NO:Check hydraulic oil level.

NO: See Hydraulic Pump Flow Test . (Group 9025-25.)
Section 9010 - ENGINE

Table of contents
Group 05 - Theory of Operation ............................................................................................................. 1
John Deere Engine Operation ............................................................................................................... 1
Engine Cooling System Operation ........................................................................................................ 1
Cold Start Aid System Operation—If Equipped ..................................................................................... 3
Group 15 - Diagnostic Information ........................................................................................................ 4
John Deere Engine Operation ............................................................................................................... 4
Engine Identification ............................................................................................................................. 5
Engine Cooling System Component Location ....................................................................................... 8
Engine Fuel System Component Location .......................................................................................... 10
Engine Intake and Exhaust Component Location ............................................................................... 14
Group 20 - Adjustments ........................................................................................................................ 18
John Deere Engine Operation ............................................................................................................. 18
Group 25 - Tests ..................................................................................................................................... 19
John Deere Engine Operation ............................................................................................................. 19
Fluid Sampling Procedure—If Equipped .............................................................................................. 20
Engine Speed Check ........................................................................................................................... 24
Air in Fuel Test .................................................................................................................................... 25
Engine Thermostat Test ..................................................................................................................... 25
Thermal Bypass Valve Test ................................................................................................................ 26
Intake Manifold Pressure—Turbocharger Boost .................................................................................. 27

Section 9010 - ENGINE Group 05: Theory of Operation

John Deere Engine Operation
This machine uses one of the following engines:
John Deere PowerTech™ E diesel engine model 4045HT054

John Deere PowerTech™ diesel engine model 4045TT096
To identify engine model, see Engine Identification . (Group 9010-15.)

For theory of operation on John Deere PowerTech ™ engines not contained in this group, see the following:
Engine 4045HT054 and 4045HT086
See General Engine Operation . (CTM104).

See Head Gasket Joint Construction and Operation . (CTM104).
See Cooling System Operation . (CTM104).
See Lubrication System Operation . (CTM104).
See Fuel System Operation . (CTM502).
See Electronic Injector (EI) Operation . (CTM502).
See High-Pressure Fuel Pump Operation . (CTM502).
See High-Pressure Fuel System Operation . (CTM502).
See Low-Pressure Fuel Pump Operation . (CTM502).
See Low-Pressure Fuel System Operation . (CTM502).
See Air Intake and Exhaust System Operation . (CTM104).
See EGR Valve Operation . (CTM104).
For additional engine information on John Deere engines and components, see the following component technical manuals
(CTM).
See Powertech™ 4.5L & 6.8L Diesel Engines—Base Engine . (CTM104.)

See Powertech™ E 4.5L & 6.8L Diesel Engines—Level 16 Electronic Fuel System with Denso HPCR . (CTM502.)
Engine 4045TT096

See Fuel System Operation . (CTM331.)
See Electronic Injector (EI) Operation . (CTM331.)
See High-Pressure Fuel Pump Operation . (CTM331.)
See High-Pressure Fuel System Operation . (CTM331.)
See Low-Pressure Fuel Pump Operation . (CTM331.)
See Low-Pressure Fuel System Operation . (CTM331.)
(CTM).

See Powertech™ 4.5L & 6.8L Diesel Engines—Level 12 Electronic Fuel System with Stanadyne DE10 Pump . (CTM331.)
Engine Cooling System Operation

The machine’s cooling package contains:
Radiator
Hydraulic/transmission radiator
Air conditioner condenser
The radiator is mounted behind the hydraulic/transmission radiator in the cooling package. It is first to receive fan air. It also
has higher coolant flow than the hydraulic/transmission radiator.
The machine is equipped with a direct drive fan. Direct drive fans operate at a consistent speed with the engine at all times.
Section 9010 - ENGINE Group 05: Theory of Operation
Direct drive machines must increase engine speed in order to increase cooling performance.
The engine cooling system shares coolant with the hydraulic and transmission cooling systems. Hydraulic and transmission oil
cooling is accomplished by means of fluid-to-fluid coolers. The hydraulic and transmission oil coolers are remote mounted away
from the cooling package, below the operator′s station.
The water pump circulates coolant through the engine. Once achieving normal operating temperature, a thermostat opens to
allow coolant to pass through the radiator, back to the water pump.
The thermal bypass valve speeds hydraulic warm-up, maintains the oil at a more consistent set point, and makes for quicker
stabilization of engine, transmission, and hydraulic temperatures. It works similarly to a thermostat but is not contained in the
engine. When the thermal bypass valve opens, coolant flows from the water pump through the hydraulic/transmission radiator
to remote mounted hydraulic and transmission oil coolers located on the right side inner frame rail. Coolant returns from the
hydraulic and transmission oil coolers to the water pump.
For additional information, see the following:
Power Train Overview . (Group 9020-05.)

Hydraulic System Operation . (Group 9025-05.)
Air Conditioning System Cycle Of Operation . (Group 9031-05.)
Machines with engine model 4045HT054 or 4045HT086 add a fuel cooler and a charge air cooler to the cooling package.
The fuel cooler is an air-to-fluid cooler. Fuel from the fuel tank is circulated through the fuel cooler before it arrives at the high
pressure fuel pump. The lower fuel temperatures help reduce overall combustion temperatures and emissions.
The charge air cooler is an air-to-air cooler. Charge air from the turbocharger is forced through the charge air cooler where it is
cooled before it reaches the intake manifold. This cooler air increases horsepower while assisting in the reduction of emissions.
Section 9010 - ENGINE Group 15: Diagnostic Information
Cold Start Aid System Operation—If Equipped
Auto-Ether Injection System

LEGEND:
1 Intake Manifold
2 Ether Canister
Y15 Start Aid Solenoid
The cold start aid system used on this machine is auto-ether injection. Ether injection helps to start the engine in cold weather
by injecting a specific amount of ether into the intake manifold (1).
When the ignition is ON and the engine control unit (ECU) detects the fuel temperature is below a specified temperature, the
start aid solenoid (Y15) energizes, and ether flows from the canister (2) to the intake manifold (1) and mixes with intake air. For
more information on the electrical control of auto-ether injection, see Start and Charge Circuit Theory of Operation . (Group
9015-15.)
When the ether/air mixture reaches the combustion chamber, it mixes with diesel fuel. Ether ignites at a lower temperature
than diesel fuel, therefore, inside the combustion chamber the ether ignites first, heating the diesel fuel and aiding combustion.




(CTM).

Engine 4045TT096

(CTM).

Engine Identification
This machine is equipped one of the following engine models: 4045HT054, 4045HT086, and 4045TT096. Use the following
information to identify engine model.
Engine Serial and Model Number Identification

LEGEND:
1 Engine Serial Number Plate
2 Engine Serial Number
3 Engine Model Number
Engine Serial Number Plate Location
Engine Serial Number Plate Example
Engine serial number plate (1) is located on right rear of engine block.
Fifth character of engine model number (3) can be used to identify engine aspiration method.
Engine Model Number
Engine Model Number
4045 H T054 Turbocharged and air-to-air aftercooled
4045 H T086 Turbocharged and air-to-air aftercooled
4045 T T096 Turbocharged, no aftercooling
Engine Component Identification

LEGEND:
4 Charge Air Cooler
4045HT054 and 4045HT086 Engine (front view)
4045TT096 Engine (front view)
Machines equipped with 4045HT054 and 4045HT086 engines utilize a charge air cooler (4) located near top front of cooling
package.
Machines equipped with 4045TT096 engines do not utilize a charge air cooler in the cooling package.
Engines 4045HT054 and 4045HT086 are very similar. Key differences between the two engines are:
LEGEND:
5 Exhaust Manifold
4045HT054 Engine
4045HT086 Engine
Camshaft
Turbocharger
Exhaust Manifold
Fuel Injectors
Software
The exhaust manifold geometry is the only external component that visually distinguishes these two engines.
Engine Cooling System Component Location

Engine Model 4045HT054 and 4045HT086
Engine Cooling System Component Location (engine model 4045HT054 and 4045HT086)
LEGEND:
1 Hydraulic Oil Cooler-to-Transmission Oil Cooler Hose
2 Hydraulic Oil Cooler-to-Hydraulic Reservoir Hose
3 Transmission Oil Cooler-to-Transmission Hose
4 Thermal Bypass Valve
5 Upper Radiator Hose
6 Hydraulic/Transmission Radiator-to-Thermal Bypass Valve Hose
7 Surge Tank Overflow Hose
8 Hydraulic/Transmission Radiator-to-Surge Tank Hose
9 Surge Tank
10 Thermal Bypass Valve-to-Hydraulic/Transmission Radiator Hose
11 Surge Tank-to-Thermostat Housing Hose
12 Surge Tank-to-Coolant Pump Housing Hose
13 Hydraulic/Transmission Radiator
14 Radiator
15 Fan
16 Lower Radiator Hose
17 Thermal Bypass Valve-to-Oil Cooler Housing Hose
18 Thermal Bypass Valve-to-Hydraulic Oil Cooler Hose
19 Transmission Oil Cooler-to-Coolant Pump Hose
21 Transmission Oil Cooler
22 Hydraulic Oil Cooler
Engine Model 4045TT096
Engine Cooling System Component Location (engine model 4045TT096)

LEGEND:
1 Hydraulic Oil Cooler-to-Transmission Oil Cooler Hose
2 Hydraulic Oil Cooler-to-Hydraulic Reservoir Hose
4 Thermal Bypass Valve
5 Upper Radiator Hose
6 Hydraulic/Transmission Radiator-to-Thermal Bypass Valve Hose
7 Surge Tank Overflow Hose
8 Hydraulic/Transmission Radiator-to-Surge Tank Hose
9 Surge Tank
11 Surge Tank-to-Hydraulic/Transmission Radiator Hose
12 Surge Tank-to-Coolant Pump Housing Hose
13 Hydraulic/Transmission Radiator
14 Radiator
15 Fan
16 Lower Radiator Hose
17 Thermal Bypass Valve-to-Oil Cooler Housing Hose
19 Transmission Oil Cooler-to-Coolant Pump Hose
Engine Fuel System Component Location

Engine Model 4045HT054 and 4045HT086
Engine Fuel System Components (engine model 4045HT054 and 4045HT086) (1 of 2)

LEGEND:
1 Fuel Cooler-to-High Pressure Fuel Pump Hose
2 High Pressure Fuel Pump
3 Final Fuel Filter-to-High Pressure Fuel Pump Line
5 Fuel Injector (4 used)
6 Fuel Injector-to-Fuel Injector Line (3 used)
7 High Pressure Common Rail-to-Fuel Injector Line
8 High Pressure Common Rail-to-High Pressure Fuel Pump Line
9 High Pressure Fuel Pump-to-High Pressure Common Rail Line
10 High Pressure Fuel Pump-to-Final Fuel Filter Line
12 Final Fuel Filter
13 Fuel Cooler
14 Fuel Sender-to-Fuel Cooler Hose
18 Fuel Tank Vent-to-Fuel Breather Hose
19 Fuel Sender-to-Auxillary Fuel Filter Hose
20 Auxillary Fuel Filter
21 Auxillary Fuel Filter-to-Primary Fuel Filter Hose
23 Fuel Transfer Pump
25 Fuel Leak-Off Line
26 High Pressure Common Rail-to-Fuel Leak-Off Line
27 High Pressure Common Rail
Engine Fuel System Components (engine model 4045HT054 and 4045HT086) (2 of 2)

LEGEND:
1 Fuel Cooler-to-High Pressure Fuel Pump Hose
3 Final Fuel Filter-to-High Pressure Fuel Pump Line
10 High Pressure Fuel Pump-to-Final Fuel Filter Line
11 Fuel Tank Breather
13 Fuel Cooler
14 Fuel Sender-to-Fuel Cooler Hose
15 Fuel Tank
16 Fuel Tank Vent
17 Fuel Sender
18 Fuel Tank Vent-to-Fuel Breather Hose
19 Fuel Sender-to-Auxillary Fuel Filter Hose
20 Auxillary Fuel Filter
21 Auxillary Fuel Filter-to-Primary Fuel Filter Hose
22 Primary Fuel Filter-to-Final Fuel Filter Hose
24 Primary Fuel Filter
Engine Model 4045TT096
Engine Fuel System Components (engine model 4045TT096) (1 of 2)

LEGEND:
1 High Pressure Fuel Pump
2 Primary Fuel Filter-to-High Pressure Fuel Pump Line
3 Fuel Injector Leak-Off-to-High Pressure Fuel Pump Line
4 Fuel Injector (4 used)
5 Fuel Injector Leak-Off Line
6 Fuel Tank Vent-to-Fuel Tank Breather Hose
8 Fuel Transfer Pump-to-Final Fuel Filter Hose
16 Fuel Sender-to-Final Fuel Filter Hose
17 High Pressure Fuel Pump-to-Fuel Injector Line (4 used)
18 Fuel Injector-to-Fuel Injector Line (3 used)
Engine Fuel System Components (engine model 4045TT096) (2 of 2)

LEGEND:
2 Primary Fuel Filter-to-High Pressure Fuel Pump Line
5 Fuel Injector Leak-Off Line
8 Fuel Transfer Pump-to-Final Fuel Filter Hose
9 Primary Fuel Filter-to-Fuel Transfer Pump Line
12 Fuel Tank Breather
13 Fuel Tank
14 Fuel Tank Vent
15 Fuel Sender
16 Fuel Sender-to-Final Fuel Filter Hose
Engine Intake and Exhaust Component Location

Engine Intake and Exhaust Component Location (4045HT054 and 4045HT086) (1 of 2)

LEGEND:
1 Charge Air Cooler
2 Air Cleaner
3 Charge Air Cooler-to-Air Intake Tube
4 Exhaust Stack
5 Muffler
6 Exhaust Manifold
7 Turbocharger
8 Air Cleaner-to-Turbocharger Tube
9 Turbocharger-to-Charge Air Cooler Tube
Engine Intake and Exhaust Component Location (4045HT054 and 4045HT086) (2 of 2)

LEGEND:
1 Charge Air Cooler
2 Air Cleaner
3 Charge Air Cooler-to-Air Intake Tube
4 Exhaust Stack
5 Muffler
7 Turbocharger
9 Turbocharger-to-Charge Air Cooler Tube
10 Air Intake
Engine 4045TT096
Engine Intake and Exhaust Component Location (4045TT096) (1 of 2)

LEGEND:
1 Exhaust Manifold
2 Muffler
3 Turbocharger
4 Air Cleaner
5 Exhaust Stack
Section 9010 - ENGINE Group 20: Adjustments
Engine Intake and Exhaust Component Location (4045TT096) (2 of 2)

LEGEND:
2 Muffler
3 Turbocharger
4 Air Cleaner
5 Exhaust Stack
7 Turbocharger-to-Air Intake Tube
8 Air Intake
Section 9010 - ENGINE Group 25: Tests



(CTM).

Engine 4045TT096

(CTM).

Group 25 - Tests



(CTM).

Engine 4045TT096

(CTM).

Fluid Sampling Procedure—If Equipped

Specifications
SPECIFICATIONS
Engine Speed Slow Idle
100 mL
System Fluid Purge Volume (approximate)
3.4 oz.
75 mL
Fluid Sample Volume (approximate)
2.5 oz.
This procedure is recommended for obtaining oil samples using the John Deere sampling valve. A cap probe, plastic bag, and
oil sampling kit for the appropriate system are needed for this procedure. Part numbers for the required items can be found at
the end of this procedure.
Sample fluid systems at the following intervals:
Each system at every oil change before changing oil

Engine oil: 250 hours (125 hours for machines above 1829 m (6000 ft.) elevation)
Engine coolant: 500 hours
Hydraulic oil: 500 hours
Transmission oil: 500 hours
Power train oil (axles, gear cases): 500 hours
Machine Preparation
[1] - Start the machine and warm system to normal operating temperature. Operate machine functions so that the fluid is
agitated throughout the system.
[2] - Once the system has reached operating temperature, operate engine at slow idle.
[3] - Locate sample valve on unit and clean the area around the valve before removing dust cap, to reduce fluid sample
contamination. See Fluid Sampling Test Ports—If Equipped. (Operator′s Manual.)
[4] - Once the area has been cleaned, remove the dust cap from the valve.
Priming Sample Valve
Oil must be purged from the system to ensure that a representative sample is collected in the test collection bottle. The
amount of waste oil is the distance of the sampling valve from the flow of the system. It is recommended one full sample
bottle, equal to 100 mL (3.4 oz.), be purged from a remotely mounted valve before collecting the sample.
[1] - Connect probe to sample valve by placing the probe end into the valve port.
[2] -
System Fluid Purge (excavator shown)

Press and hold the probe to release an appropriate amount of fluid into a waste container.
System Fluid Purge Volume (approximate) 100 mL
3.4 oz.
[3] - Properly dispose of collected waste fluid.
[4] - To increase the oil flow and obtain a representative sample, accelerate the flow of the system by increasing the engine
speed to fast idle.
Obtaining Fluid Sample
[1] -
→NOTE:
This step is best done in a clean environment, rather than at the sample site.
Place the sample bottle from the sample kit into plastic bag. Seal plastic bag.
Place Sample Bottle in Plastic Bag
[2] -
Remove Lid of Sample Bottle (in plastic bag)

Remove the lid from the sample container, while keeping bottle inside plastic bag. Move the lid aside within the plastic bag, so
that the bottle opening is accessible.
When collecting hydraulic or power train oil samples, be careful to hold the sheet of plastic (located under the lid) to the top of
the bottle. Keep the protective plastic in place when the lid is taken off.
[3] -
→NOTE:
The plastic bag creates a protective covering for the sample so that external contaminants are not
introduced into the fluid sample.
Holding bag tight across bottle, puncture hole in bag with cap probe line and insert line about 13 mm (0.5 in.) into the sample
bottle.
Puncture Plastic Bag with Cap Probe Line
[4] -
Collect Sample Fluid (excavator shown)

Hold the cap probe line inside the bottle. Press, and hold the cap probe to the valve to release the sample fluid into the bottle.
[5] - Fill the sample bottle about 3/4 full of fluid.

Fluid Sample Volume (approximate) 75 mL
2.5 oz.
[6] - After a representative sample is obtained, remove the tube and return the lid to the container. Leave the lid and bottle
inside the plastic bag and the protective sheet attached underneath the lid (if applicable).
When properly performed, sample oil is warm, indicating that all stagnant fluid was removed during the purge process and not
sent to the lab.
[7] -
→NOTE:
Use cap probes for only one sampling procedure.
Install the dust cap to the sample valve, and properly dispose of the cap probe.
[8] - Fill out the sample information form completely, and submit the form and sample to the designated regional lab for
testing.
Service Equipment and Tools
Fluid Analysis Sampling Materials Summary
Part Number Description
AT317904 Engine Test Kit
AT303189 Hydraulic and Power Train Test Kit
AT180344 Diesel Fuel Test Kit
AT183016 Coolant Test Kit
TY26349 6 mm (1/4 in.) Suction Pump Tubing, 30 m (100 ft.).
AT308579 120 mL (4 oz.) Sample Bottle
AT315231 Poly Cap Probe
AT321211 Probe Style Sample Valve with Attached Cap, -4 SAE O-ring
AT306111 Probe Style Sample Valve with Attached Cap, -6 SAE O-ring
TY26363 Probe Style Sample Valve with Attached Cap, 1/4"-20 NPT
AT306133 Probe Style Sample Valve with Attached Cap, 1/8"-27 NPT
AT320593 Probe Style Sample Valve with Attached Cap, -6 ORFS Female
TY26364 90° Push Button Sample Valve with attached Cap, 1/8"-27 NPT
TY26365 Sample Valve Actuator Tubing Adaptor Fitting, KST Series Probe
Not applicable Plastic Bag
Engine Speed Check

LEGEND:
27 Display Monitor Screen
Display Monitor Screen
Specifications
SPECIFICATIONS
80°C
Engine Coolant Temperature
176°F
Engine Slow Idle Speed 880—900 rpm
Engine Fast Idle Speed 2350—2400 rpm
[1] -
→NOTE:
ECONOMY MODE must be set to OFF in standard display monitor (SDM) to allow machine to reach
standard fast idle.
If equipped, disable ECONOMY MODE. See Standard Display Monitor (SDM)—Machine Options . (Group 9015-16.)
[2] - View engine coolant temperature in monitor. See Standard Display Monitor (SDM)—Diagnostics . (Group 9015-16.)
[3] - Run engine until engine coolant is to specification.

Engine Coolant Temperature 80°C
176°F
[4] - Run engine at slow idle.

Engine Slow Idle Speed 880—900 rpm
[5] - Check display monitor screen (27) to see if slow idle rpm is within specification.
[6] - Run engine at fast idle.

Engine Fast Idle Speed 2350—2400 rpm
[7] - Check display monitor screen (27) to see if fast idle rpm is within specification.
[8] -
→NOTE:
Engine slow idle and fast idle settings cannot be adjusted.
If slow or fast idle is out of specification, check the following:
Check diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes (DTCs) . (Group 9015-20.)
Check air cleaner elements. See Inspecting and Cleaning Dusty Secondary and Primary Element . (Operator′s Manual.)
Check for kinked or pinched fuel hoses (supply and return). See Engine Fuel System Component Location . (Group
9010-15.)
Check fuel tank breather filter and hose. See Engine Fuel System Component Location . (Group 9010-15.)
Check fuel filter and system. See Engine Fuel System Component Location . (Group 9010-15.)
Check throttle position sensor. See Electrical Component Specifications . (Group 9015-20.)
To identify engine as a 4045HT054, 4045HT086, or 4045TT096 see Engine Identification . (Group 9010-15).
For machines with 4045HT054 or 4045HT086 engines:
Check engine control unit (ECU). See Electronic Control Unit (ECU) System Operation . (CTM502.)
For machines with 4045TT096 engines:
Check engine control unit (ECU). See Electronic Control Unit (ECU) . (CTM331.)
Air in Fuel Test

To identify engine as a 4045HT054, 4045HT086, or 4045TT096 see Engine Identification . (Group 9010-15).
For machines with 4045HT054 or 4045HT086 engines:
To check for air in fuel, see Test for Air in Fuel . (CTM502.)
For machines with 4045TT096 engines:
To check for air in fuel, see Test for Air in Fuel . (CTM331.)
Engine Thermostat Test

Test opening temperature of the engine thermostat. See Inspect Thermostat and Test Opening Temperature . (CTM104.)
Thermostat Initial Opening Temperature—Range 79.5—83.5°C
175—182°F
Thermostat Full Open Temperature—Nominal 94.5°C
202°F
Thermal Bypass Valve Test
Thermostat Opening Temperature Test
Specifications
SPECIFICATIONS
70—78°C
Thermostat Initial Opening Temperature—Range
158—172°F
88°C
Thermostat Full Open Temperature—Nominal
190°F
[1] - Remove thermostat from thermal bypass valve.
[2] - Heat water in a container.
[3] -
CAUTION:
DO NOT allow thermostat or thermometer to rest against the side or bottom of container when heating
water. Either may rupture if overheated.
Suspend thermostat and a thermometer in the container of water.
[4] - Stir the water as it heats. Observe opening action of thermostat and compare temperature with specification.
Thermostat Initial Opening Temperature—Range 70—78°C
158—172°F
Thermostat Full Open Temperature—Nominal 88°C
190°F
[5] - Remove thermostat and observe its closing action as it cools. In ambient air the thermostat will close completely. Closing
action will be smooth and slow.
[6] - Replace thermostat if operation does not meet specification.

Intake Manifold Pressure—Turbocharger Boost

Specifications
SPECIFICATIONS
60—70°C
Engine Temperature
140—160°F
Engine Rated Speed 2200 rpm
83—103 kPa
Turbocharger Boost Pressure (engines 4045HT054, 4045HT086) 0.83—1.03 bar
12—15 psi
48—62 kPa
Turbocharger Boost Pressure (engine 4045TT096) 0.48—0.62 bar
7—9 psi
Essential Tools
ESSENTIAL TOOLS
JT07248 Turbocharger Boost Test Kit
IMPORTANT:
On power shift transmissions ONLY, never operate machine equipped with mechanical front wheel drive
(MFWD) with front wheels (axle) on the ground, rear wheels (axle) off the ground and transmission in
fourth gear forward. Damage to the mechanical front wheel drive (MFWD) will occur.
→NOTE:
Boost specifications are based on use of No. 2 fuel. If using No. 1 fuel, reduce boost specifications by 7%.
Start Aid Tube (shown installed)
Turbocharger Boost Pressure Test

LEGEND:
1 Starting Aid Tube
2 Adapter (JT07248 Turbocharger Boost Test Kit)
3 Gauge (JT07248 Turbocharger Boost Test Kit)
[1] - Identify engine model number. See Engine Identification . (Group 9010-15.)
[2] - Remove plug or starting aid tube (1) if equipped.
[3] - Install adapter (2) and gauge (3).

Turbocharger Boost Test Kit
JT07248
Used to check turbocharger boost pressure.
[4] - Apply park brake and put transmission control lever (TCL) in neutral. Run engine until it is at normal operating
temperature.
Engine Temperature 60—70°C
140—160°F
[5] -
→NOTE:
ECONOMY MODE must be set to OFF to allow machine to reach standard fast idle.
If equipped, disable ECONOMY MODE. See Engagement and Monitor Unit (EMU)—Machine Options or see Standard Display
Monitor (SDM)—Machine Options . (Group 9015-16.)
[6] - Run engine at fast idle using loader hydraulics to load engine down to rated speed. Read turbocharger boost pressure.
Engine Rated Speed 2200 rpm
Turbocharger Boost Pressure (engines 4045HT054, 4045HT086) 83—103 kPa
0.83—1.03 bar
12—15 psi
Turbocharger Boost Pressure (engine 4045TT096) 48—62 kPa
0.48—0.62 bar
7—9 psi
[7] - If engine speed does not drop to specification, use following procedure to apply additional load to engine.
a. Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 9000-01.)
b. Lower stabilizers and loader to raise wheels off ground.
c. Put machine in second gear and transmission control lever (TCL) in forward or reverse.
IMPORTANT:
Possible damage to machine may occur if brakes are applied too long. Circulate hydraulic fluid if
temperature exceeds 99°C (210°F).
Run engine at fast idle. Apply service brakes to load engine down to rated speed.
[8] - Record highest boost pressure at rated speed.
[9] - Repeat test several times.
[10] - If boost pressure is too high, remove and test fuel injection pump for high fuel delivery.
[11] - If boost pressure is too low, check for the following:
Restricted air filter elements.
ELECTRICAL SYSTEM (g) by Belgreen v2.0
Restricted fuel filter elements.

Incorrect fast idle adjustment.
Incorrect injection pump timing.
Exhaust manifold leaks.
Intake manifold leaks.
Malfunctioning fuel transfer pump.
Low compression pressure.
Malfunctioning fuel injection nozzle.
Carbon buildup in turbocharger.
Turbocharger compressor or turbine wheel rubbing housing.
Low fuel injection pump fuel delivery. Remove and test fuel injection pump for low fuel delivery.
Section 9015 - ELECTRICAL SYSTEM

Table of contents
Group 05 - System Information ............................................................................................................. 1
Electrical Diagram Information ............................................................................................................. 1
Electrical Schematic Symbols ............................................................................................................... 5
Group 10 - System Diagrams ................................................................................................................. 8
Fuse and Relay Location and Specifications ......................................................................................... 8
System Functional Schematic, Wiring Diagram, and Component Location Legend ............................ 11
System Functional Schematic and Section Legend ............................................................................ 15
Engine Harness (W10) Component Location ...................................................................................... 57
Engine Harness (W10) Wiring Diagram .............................................................................................. 62
Transmission Harness (W13) Component Location ............................................................................ 67
Transmission Harness (W13) Wiring Diagram .................................................................................... 69
Cab Harness (W14) Component Location ........................................................................................... 71
Cab Harness (W14) Wiring Diagram ................................................................................................... 74
Roof Harness (W17) Component Location .......................................................................................... 83
Roof Harness (W17) Wiring Diagram .................................................................................................. 85
Radio Harness (W18) Component Location ........................................................................................ 87
Radio Harness (W18) Wiring Diagram ................................................................................................ 88
Heater and Air Conditioner Harness (W19) Component Location ....................................................... 89
Heater and Air Conditioner Harness (W19) Wiring Diagram ............................................................... 90
Pilot Control, Selective Flow and Ride Control Harness (W20) Component Location .......................... 91
Pilot Control, Selective Flow and Ride Control Harness (W20) Wiring Diagram .................................. 93
Selective Flow and Ride Control Harness (W21) Component Location ............................................... 95
Selective Flow and Ride Control Harness (W21) Wiring Diagram ....................................................... 97
Fuel Lift Pump Relay Harness (W22) Component Location ................................................................. 99
Fuel Lift Pump Relay Harness (W22) Wiring Diagram ....................................................................... 100
Start Aid Switch Harness (W24) Component Location ...................................................................... 101
Start Aid Switch Harness (W24) Wiring Diagram .............................................................................. 102
Ride Control Solenoid Harness (W27) Component Location ............................................................. 103
Ride Control Solenoid Harness (W27) Wiring Diagram ..................................................................... 104
Selective Flow Solenoid Harness (W28) Component Location .......................................................... 105
Selective Flow Solenoid Harness (W28) Wiring Diagram .................................................................. 106
Loader Auxiliary Solenoid Harness (W29) Component Location ....................................................... 107
Loader Auxiliary Solenoid Harness (W29) Wiring Diagram ............................................................... 108
Pilot Enable Pattern Select Valve Harness (W30) Component Location ............................................ 109
Pilot Enable Pattern Select Valve Harness (W30) Wiring Diagram .................................................... 111
Pilot Enable Switch Harness (W31) Component Location ................................................................. 112
Pilot Enable Switch Harness (W31) Wiring Diagram ......................................................................... 113
Return-to-Dig Harness (W32) Component Location .......................................................................... 114
Return-to-Dig Harness (W32) Wiring Diagram .................................................................................. 115
Boom Lock/Sideshift Harness (W37) Component Location—(S.N. —232969) ................................... 116
Boom Lock/Sideshift Harness (W37) Wiring Diagram—(S.N. —232969) ........................................... 118
Rear Frame Harness (W38) Component Location ............................................................................. 119
Rear Frame Harness (W38) Wiring Diagram ..................................................................................... 122
Air Conditioner Compressor Clutch Harness (W39) Component Location ......................................... 126
Air Conditioner Compressor Clutch Harness (W39) Wiring Diagram ................................................. 127
Blower Mode Door Motor Harness (W40) Component Location ........................................................ 127
Blower Mode Door Motor Harness (W40) Wiring Diagram ................................................................ 128
Sideshift/Boom Lock Switch Harness (W42) Component Location—(S.N. 235590— ) ....................... 128
Sideshift/Boom Lock Switch Harness (W42) Wiring Diagram—(S.N. 235590— ) ............................... 129
Modular Telematics Gateway (MTG) Harness (W6002) Component Location ................................... 130

Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram ........................................... 132
Satellite (SAT) Harness (W6003) Component Location ..................................................................... 133
Satellite (SAT) Harness (W6003) Wiring Diagram ............................................................................. 134
Group 15 - Sub-System Diagnostics ................................................................................................. 135
Start and Charge Circuit Theory of Operation .................................................................................. 135
Controller Area Network (CAN) Circuit Theory of Operation ............................................................. 144
Engine Control Unit (ECU) Circuit Theory of Operation ..................................................................... 149
Vehicle Control Unit (VCU) Circuit Theory of Operation .................................................................... 158
Transmission Control Circuit Theory of Operation ............................................................................ 167
Hydraulic System Circuit Theory of Operation .................................................................................. 172
Horn, Lights, and Beacon Circuit Theory of Operation ...................................................................... 176
Wiper and Washer Circuit Theory of Operation ................................................................................ 180
Standard Display Monitor (SDM) Circuit Theory of Operation ........................................................... 182
Group 16 - Monitor Operation ............................................................................................................ 184
Standard Display Monitor (SDM)—Service Menu .............................................................................. 184
Standard Display Monitor (SDM)—Clear Codes ................................................................................. 184
Standard Display Monitor (SDM)—Diagnostics ................................................................................. 185
Standard Display Monitor (SDM)—Main Menu Visible or Hidden ....................................................... 188
Standard Display Monitor (SDM)—Restore Monitor Defaults ............................................................ 188
Standard Display Monitor (SDM)—Machine Options ......................................................................... 190
Standard Display Monitor (SDM)—Setting Hour Meter ...................................................................... 194
Security System Enable-Disable ....................................................................................................... 196
Security System Configuration ......................................................................................................... 198
Security System Operation ............................................................................................................... 201
Group 20 - References ......................................................................................................................... 202
Electrical Component Specifications ................................................................................................. 202
Service ADVISOR™ Connection Procedure ....................................................................................... 204
JDLink™ Connection Procedure ........................................................................................................ 205
Reading Diagnostic Trouble Codes (DTCs) ....................................................................................... 206
Diagnostic Trouble Code (DTC) Monitor Messages ........................................................................... 209
Intermittent Diagnostic Trouble Code (DTC) Diagnostics ................................................................. 211
Controller Area Network (CAN) Diagnostics ...................................................................................... 213
Controller Area Network (CAN) Resistor Test .................................................................................... 221
Alternator Test .................................................................................................................................. 222
Wire Harness Test ............................................................................................................................ 223
Sensor Circuit Test ........................................................................................................................... 223
Crank Position Sensor Test ............................................................................................................... 225
Transmission Control Circuit Test ..................................................................................................... 226
Transmission Solenoid Circuit Test ................................................................................................... 227
Transmission Control Lever (TCL) Test ............................................................................................. 228
Transmission Solenoid Check ........................................................................................................... 229
Throttle Position Sensor Test ............................................................................................................ 230
Engine Speed Control Pedal Test Diagnostic Procedure ................................................................... 231
Vehicle Control Unit (VCU) Output Test ............................................................................................ 232
Seat Position Sensor Remove and Install .......................................................................................... 233
Controller Remove and Install .......................................................................................................... 234

Section 9015 - ELECTRICAL SYSTEM Group 05: System Information
Group 05 - System Information

Electrical Diagram Information
Explanation of Wire Markings
→NOTE:
All system functional schematics, circuit schematics, and wiring diagrams are shown with key switch in
the OFF position.
System Functional Schematic Diagram
System Functional Schematic Example

LEGEND:
1 Continuity Chart
2 Power Wires
3 Routing Location Information
4 Wire Identification
5 Ground Wires
7 Section Number
8 Component Name
9 Component Identification Number
10 Component Schematic Symbol
11 Connector Identification Number
12 Connector
13 Connector Pin Information
The system functional schematic is made up of equal sections to simplify searching the schematic. Each section of the system
functional schematic is assigned a number (7). The system functional schematic is formatted with power supply wires (2)
shown near the top of the drawing and ground wires (5) near the bottom. The schematic may contain some harness or
connector information.
When connector information is shown, it will be displayed as a double chevron (12) with a component identification number
(11) corresponding to the connector identification number. Connector pin information (13) will be displayed in a text size
smaller than that of the connector identification number.
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).
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. The
section and component identification number are given in the first line of information and any pin information for the
component is given in parenthesis in the second line. In this example, power is going TO section 23, component B14 on pin C4.
Wiring Diagram
Wiring Diagram Example

LEGEND:
1 Component Identification Number

2 Connector
3 Connector End 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
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 end 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.
Connector End View Diagram
The connector end view diagram is a pictorial end view of the component connectors showing the number of pins in the
connector and the wire color and identifier of the wire in every connector. Each component will be identified by the same
identification letter/number and description used in the system functional schematic diagram.
Electrical Schematic Symbols
Electrical Schematic Symbols
LEGEND:
1 Battery
2 Wire Splice
3 Fuse
4 Circuit Breaker
5 Fusible Link
6 Power Outlet
7 Alternator
8 Air Conditioner Compressor
9 Compressor
10 Liquid Pump
11 Antenna
12 Diode
13 Zener Diode
14 Capacitor
15 Magnet
16 Flasher
17 Buzzer
18 Horn
19 Alarm
20 Electromagnet
21 Internal Ground
22 Single Point Ground
23 External Ground
24 Sensor
25 Sensor with Normally Open Switch
26 Speed Sensor
27 Rotary Sensor
28 Single Element Bulb
29 Dual Element Bulb
30 Solenoid Operated Hydraulic Valve with Suppression Diode
31 Solenoid Normally Open
32 Solenoid Normally Closed
33 Starter Motor
34 Starter Motor
35 DC Motor
36 DC Stepping Motor
37 Wiper Motor
38 Blower Motor
39 Servo Motor
40 Speedometer
41 Tachometer
42 Temperature Gauge
43 Liquid Level Gauge
44 Gauge
45 Hourmeter
46 Resistor
47 Variable Resistor
48 Manually Adjusted Variable Resistor
49 Multi-Pin Connector
50 Single Pin Connector
51 Connector
52 4 Pin Relay
53 5 Pin Relay
54 5 Pin Relay with Internal Suppression Diode
55 5 Pin Relay with Internal Suppression Resistor
56 Key Switch
57 Temperature Switch Normally Open
58 Temperature Switch Normally Closed
59 Pressure Switch Normally Open
60 Pressure Switch Normally Closed
61 Liquid Level Switch Normally Open
62 Liquid Level Switch Normally Closed
63 Momentary Switch Normally Open
64 Momentary Switch Normally Closed
65 Toggle Switch Normally Open
66 Toggle Switch Normally Closed
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
67 2 Way Toggle Switch Normally Open

68 2 Way Toggle Switch Normally Closed
69 Manual Switch Operation
70 Push Switch Operation
71 Pull Switch Operation
72 Turn Switch Operation
73 Toggle Switch Operation
74 Pedal Switch Operation
75 Key Switch Operation
76 Detent Switch Operation
77 Temperature Sensor
78 Solar Sensor
79 Pressure Sensor
80 Liquid Level Sensor
Group 10 - System Diagrams

Fuse and Relay Location and Specifications
Fuse and Relay Box

LEGEND:
F11 Power Port Unswitched Power 15 A Fuse
F12 Horn/ Service ADVISOR ™ Unswitched Power 10 A Fuse
F13 Optional Equipment Unswitched Power 15 A Fuse
F15 Monitor Unswitched Power 5 A Fuse
F17 Sealed Switch Module (SSM) 7.5 A Fuse
F18 Radio 10 A Fuse
F20 Air Conditioner Control 7.5 A Fuse
F30 Monitor Switched Power 5 A Fuse
F31 Return-To-Dig 15 A Fuse
F33 VCU Switched Power 5 A Fuse
F34 Optional Equipment Switched Power 15 A Fuse
F35 Transmission Control 5 A Fuse
F42 Dome Light/Radio Switched Power 15 A Fuse
F43 Air Seat 15 A Fuse
F44 Blower Motor/Temperature Control 30 A Fuse
F45 Power Port Switched Power 15 A Fuse
X1 Service ADVISOR ™ Diagnostic Connector
IMPORTANT:
Install fuse with correct amperage rating to prevent electrical system damage from overload.
The fuse panel is located in right-hand console of operator’s station.
Engine Load Center—Engine 4045HT054 and 4045HT086
The engine load center is located on left side of the engine along the frame rail.
Engine Load Center (4045HT054 and 4045HT086)

LEGEND:
F3 Key Switch 10 A Fuse
F4 ECU Unswitched Power 20 A Fuse
F21 Fuel Lift Pump 15 A Fuse
F22 Start Aid 15 A Fuse
K25 Start Aid Relay
V4 Alternator Excitation Diode
Engine Load Center—Engine 4045TT096
The engine load center is located on left side of the engine along the frame rail.
Engine Load Center (4045TT096)

LEGEND:
F3 Key Switch 10 A Fuse
F23 Fuel Filter Heater 20 A Fuse (if equipped)
K25 Start Aid Relay
K26 Fuel Filter Heater Relay (if equipped)
LEGEND:
F1 Main 250 A Fuse
Main 250 A Fuse Location

LEGEND:
F71 JDLink ™ Ground 7.5 A Fuse
JDLink ™ Fuse Location
System Functional Schematic, Wiring Diagram, and Component Location

Legend
A1—Vehicle Control Unit (VCU) ( SE14 , SE16 , SE19 , SE23 , SE27 )
A2—Engine Control Unit (ECU) ( SE5 , SE8 )( W10 )
A3—Standard Display Monitor (SDM) ( SE15 )( W14 )
A9—Radio ( SE30 )( W18 )
A74—Sealed Switch Module (SSM) ( SE13 )( W14 )
A6000—Modular Telematics Gateway (MTG) Control Unit ( SE4 )( W6002 )
A6002—Satellite (SAT) Module Control Unit ( SE5 )( W6003 )
B2—Air Conditioner Freeze Control Switch ( SE27 )( W19 )
B3—Air Conditioner High/Low Pressure Switch ( SE27 )( W19 )
B6—Torque Converter Oil Temperature Sensor ( SE18 )( W13 )
B7—Engine Oil Pressure Switch ( SE7 )( W10 )
B8—Fuel Level Sensor ( SE14 )( W13 )
B9—Seat Position Sensor ( SE19 )( W14 )
B10—Hydraulic Oil Temperature Sensor ( SE20 )( W13 )
B12—Hydraulic Oil Filter Restriction Switch ( SE20 )( W13 )
B13—Park Brake Pressure Switch ( SE18 )( W13 )
B14—Transmission Output Speed Sensor ( SE18 )( W13 )
B15—Engine Coolant Temperature Sensor ( SE7 )( W10 )
B17—Fuel Temperature Sensor ( SE7 )( W10 )
B18—Manifold Air Temperature Sensor ( SE7 )( W10 )
B19—Crankshaft Position Sensor ( SE8 )( W10 )
B20—Engine Speed Control Pedal ( SE6 )( W14 )
B21—Engine Speed Control Dial ( SE6 )( W14 )
B26—Hydraulic System Pressure Sensor ( SE20 )( W13 )
B30—Right Speaker ( SE30 )( W18 )
B31—Left Speaker ( SE30 )( W18 )
B44—Loader Auxiliary Flow Control Switch ( SE19 )( W14 )
B60—Water-in-Fuel Sensor ( SE7 )( W10 )
B61—Fuel Filter Heater Temperature Switch ( SE9 )( W10 )
B109—Air Filter Restriction Switch ( SE7 )( W10 )
E1—Left Rear Work Light ( SE24 )( W17 )
E2—Left Rear Work Light (if equipped) ( SE24 )( W17 )
E3—Right Rear Work Light (if equipped) ( SE24 )( W17 )
E4—Right Rear Work Light ( SE24 )( W17 )
E5—Left Front Work Light (if equipped) ( SE24 )( W17 )
E6—Right Front Work Light (if equipped) ( SE23 )( W17 )
E7—Left Front Work Light ( SE23 )( W17 )
E8—Right Front Work Light ( SE23 )( W17 )
E15—Left Docking Light ( SE24 )( W17 )
E16—Right Docking Light ( SE24 )( W17 )
E17—Beacon Light ( SE23 )( W17 )
E20—Dome Light ( SE30 )( W14 )
E23—Left Backup Light ( SE22 )( W38 )
E24—Right Backup Light ( SE22 )( W38 )
E31—Left Front Drive Light ( SE23 )( W17 )
E32—Right Front Drive Light ( SE23 )( W17 )
E33—Left Front Marker Light ( SE23 )( W17 )
E34—Right Front Marker Light ( SE23 )( W17 )
E35—Left Front Turn Signal ( SE23 )( W17 )
E36—Right Front Turn Signal ( SE22 )( W17 )
E37—Left Brake/Tail Light ( SE22 )( W38 )
E38—Right Rear Turn Signal ( SE22 )( W38 )
E39—Left Rear Turn Signal ( SE22 )( W38 )
E40—Right Brake/Tail Light ( SE22 )( W38 )
E41—License Plate Light ( SE22 )( W38 )
E45—Left Rear Light Assembly ( SE22 )( W38 )
E46—Right Rear Light Assembly ( SE22 )( W38 )
E47—Left Tail Light ( SE22 )

E48—Right Tail Light ( SE22 )
F1—Main 250 A Fuse ( SE1 )( W10 )
F4—ECU Unswitched Power 10 A Fuse ( SE5 )
F11—Power Port Unswitched Power 15 A Fuse ( SE1 )
F12—Horn/Service ADVISOR Unswitched Power 10 A Fuse ( SE1 )
F13—Optional Unswitched Power 15 A Fuse ( SE2 )
F15—Monitor Unswitched Power 5 A Fuse ( SE2 )
F17—Sealed Switch Module (SSM) 7.5 A Fuse ( SE2 )
F18—Radio 10 A Fuse ( SE2 )
F20—Air Conditioner Control 7.5 A Fuse ( SE25 )
F22—Start Aid 15 A Fuse ( SE6 )
F23—Fuel Filter Heater 20 A Fuse ( SE9 )( W10 )
F30—Monitor Switched Power 5 A Fuse ( SE3 )
F31—Return-to-Dig/Alternator Excitation 15 A Fuse ( SE3 )
F33—VCU Switched Power 5 A Fuse ( SE3 )
F34—Optional Equipment Switched Power 15 A Fuse ( SE3 )
F35—Transmission Control 5 A Fuse ( SE3 )
F42—Dome Light/Radio Switched Power 15 A Fuse ( SE2 )
F43—Air Seat 15 A Fuse ( SE2 )
F44—Blower Motor/Temperature Control 30 A Fuse ( SE3 )
F45—Power Port Switched Power 15 A Fuse ( SE3 )
F47—Boom and Sideshift Lock/Optional Equipment 15 A Fuse (S.N. —232969) ( SE3 )( W14 )
F47—Boom/Sideshift Lock/Rear Tail Lights/Optional Equipment 15 A Fuse (S.N. 235590—) ( SE3 )( W14 )
F71—JDLink™ Ground 7.5 A Fuse ( SE4 )( W6002 )
G1—Battery 1 ( SE1 )
G2—Battery 2 ( SE1 )
G4—Alternator ( SE1 )( W10 )
H1—Monitor Alarm ( SE14 )( W14 )
H3—Backup Alarm ( SE18 )( W13 )
H40—Horn ( SE28 )( W10 )
K5—Starter Relay ( SE1 )( W10 )
K10—Ignition Relay ( SE3 )( W14 )
K13—Sideshift/Boom Lock/Rear Light Relay ( SE22 )( W38 )
K20—Accessory Relay ( SE2 )( W14 )
K25—Start Aid Relay ( SE6 )( W10 )
K26—Fuel Filter Heater Relay ( SE9 )( W10 )
M1—Starter Motor ( SE1 )( W10 )
M9—Temperature Control Motor ( SE25 )( W14 )
M10—Blower Motor ( SE25 )( W14 )
M11—Blower Mode Door Motor ( SE25 )( W14 )
M13—Front Wiper Motor ( SE27 )( W14 )
M14—Rear Wiper Motor ( SE27 )( W14 )
M15—Front Washer Motor ( SE27 )( W14 )
M45—Air Seat Motor ( SE28 )( W14 )
R5—CAN Termination Resistor 1 ( SE4 )( W10 ) ( W6002 )
R6—CAN Termination Resistor 2 ( SE15 )( W14 )
R10—Blower Motor Speed Resistor ( SE25 )( W14 )
R20—Temperature Control Resistor ( SE25 )( W14 )
R26—Fuel Filter Heater ( SE9 )( W10 )
S2—Battery Disconnect Switch ( SE1 )
S5—Forward, Neutral, Reverse (FNR) Switch ( SE16 )( W14 )
S6—Gear Select Switch ( SE16 )( W14 )
S8—Clutch Disconnect Switch ( SE17 )( W14 )
S9—Air Conditioner Mode Switch ( SE26 )( W14 )
S10—Differential Lock Switch ( SE16 )( W14 )
S11—Mechanical Front Wheel Drive (MFWD) Switch ( SE17 )( W14 )
S12—Return-to-Dig Switch ( SE29 )( W32 )
S14—Rear Wiper Enable Switch ( SE27 )( W14 )
S19—Drive Light High/Low Switch ( SE23 )( W14 )
S26—Brake Light Switch 1 ( SE22 )( W14 )
S27—Brake Light Switch 2 ( SE22 )( W14 )

S30—Turn Signal Switch ( SE22 )( W14 )
S34—Sideshift Lock Switch ( SE29 )( W37 , W42 )
S35—Boom Lock Switch ( SE29 )( W37 , W42 )
S36—Mechanical Front Wheel Drive (MFWD) Switch ( SE16 )( W14 )
S37—Mechanical Front Wheel Drive (MFWD) Momentary Switch ( SE16 )( W14 )
S38—Clutch Disconnect Switch ( SE16 )( W14 )
S40—Horn Switch ( SE28 )( W14 )
S42—Blower Motor Speed Switch ( SE25 )( W14 )
S45—Air Seat Switch ( SE28 )( W14 )
S46—Start Aid Switch ( SE6 )( W24 )
S47—Beacon Switch ( SE22 )( W14 )
S52—Pilot Enable Switch ( SE19 )( W31 )
S54—Auxiliary Hydraulic Foot Switch ( SE19 )( W14 )
V4—Alternator Excitation Diode ( SE1 )
V12—Return-to-Dig Solenoid Diode ( SE28 )( W32 )
V13—Front Wiper Motor Diode ( SE27 )( W14 )
V19—Air Conditioner Compressor Clutch Diode ( SE26 )( W39 )
W1—Frame Ground Near Starter Motor ( SE1 , SE5 , SE6 , SE9 , SE18 , SE26 , SE28 )( W10 , W13 )
W2—Operator Station Floor Ground ( SE2 , SE13 , SE15 , SE16 , SE19 , SE22 , SE25 , SE27 , SE28 , SE30 )( W14 )
W3—Roof Ground ( SE24 )( W17 )
W4—Battery Ground ( SE1 )
X1—Service ADVISOR™ Diagnostic Connector ( SE15 )( W14 )
X4—Standard Display Monitor (SDM) Connector ( SE15 )( W14 )
X9—Cab Harness-to-Radio Harness Connector ( SE30 )( W14 , W18 )
X10—Engine Control Unit (ECU) Connector ( SE5 , SE8 )( W10 )
X11—Vehicle Control Unit (VCU) Connector 1 ( SE14 , SE16 , SE19 , SE23 )( W14 )
X12—Vehicle Control Unit (VCU) Connector 2 ( SE14 , SE16 , SE19 , SE23 , SE27 )( W14 )
X13—Vehicle Control Unit (VCU) Connector 3 ( SE14 , SE16 , SE19 , SE23 , SE27 )( W14 )
X14—Vehicle Control Unit (VCU) Connector 4 ( SE14 )( W14 )
X20—Engine Harness-to-Cab/Canopy Harness Connector ( SE1 , SE3 , SE5 , SE6 , SE13 , SE26 , SE28 )( W10 , W14 )
X21—Transmission Harness-to-Cab/Canopy Harness Connector ( SE14 , SE17 , SE20 , SE28 )( W13 , W14 )
X26—Cab/Canopy Harness-to-Roof Harness Connector ( SE23 )( W17 )
X31—Right Front Drive Light/Turn Signal Connector ( SE23 )( W17 )
X32—Left Front Drive Light/Turn Signal Connector ( SE23 )( W17 )
X33—Rear Frame Harness Connector ( SE22 , SE29 )( W14 , W38 )
X34—Boom Lock/Sideshift Harness Connector ( SE29 )( W38 )
X38—Left Power Port ( SE30 )( W14 )
X39—Right Power Port ( SE30 )( W14 )
X40—Sealed Switch Module (SSM) Connector ( SE13 )( W14 )
X46—Cab Harness-to-Air Conditioner Harness Connector ( SE26 )( W14 , W19 , W24 )
X47—Blower Mode Door Motor Harness Connector ( SE25 )( W14 , W40 )
X48—Transmission Control Lever (TCL) Connector ( SE16 )( W14 )
X49—Start Aid Switch Harness Connector ( SE6 )( W10 , W24 )
X52—Pilot Control Console Harness Connector ( SE19 , SE20 )( W14 )( W30 )
X53—Pilot Enable Switch Harness Connector ( SE19 )( W30 , W31 )
X54—Selective Flow Control Solenoid Harness Connector ( SE21 )( W14 , W28 )
X58—Loader Control Lever Connector ( SE16 , SE19 )( W14 )
X60—Side Console Option Connector ( SE28 )( W14 )
X62—Operator Station Option Connector ( SE29 )( W14 )
X66—Air Conditioner Compressor Clutch Harness Connector ( SE26 )( W10 )
X67—Return-to-Dig Harness Connector ( SE28 )( W13 , W32 )
X68—Ride Control Solenoid Harness Connector ( SE21 )( W27 )
X81—Loader Coupler Solenoid Harness Connector ( SE21 )( W14 , W26 )
X82—Loader Auxiliary Solenoid Harness Connector ( SE21 )( W14 )
X101—Modular Telematics Gateway (MTG) 3-Pin Connector ( SE4 )( W10 )
X102—Modular Telematics Gateway (MTG) CAN 1 Connector ( SE4 )( W10 )
X123A—Sideshift/Boom Lock Switch Harness Connector A ( SE29 )( W42 )
X123B—Sideshift/Boom Lock Switch Harness Connector B ( SE29 )( W42 )
X6014—Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector ( SE4 )
X6015—Satellite (SAT) Module Control Unit 48-Pin Connector ( SE5 )
Y1—Transmission Forward Direction Solenoid ( SE18 )( W13 )

Y2—Transmission Reverse Direction Solenoid ( SE17 )( W13 )
Y3—Transmission Speed Solenoid 1 ( SE18 )( W13 )
Y7—Park Brake Release Solenoid ( SE17 )( W13 )
Y10—Differential Lock Solenoid ( SE18 )( W13 )
Y11—Mechanical Front Wheel Drive (MFWD) Solenoid ( SE17 )( W13 )
Y12—Return-to-Dig Solenoid ( SE28 )( W32 )
Y15—Start Aid Solenoid ( SE6 )( W10 )
Y16—Fuel Injection Pump Solenoid ( SE8 )( W10 )
Y19—Air Conditioner Compressor Clutch Solenoid ( SE26 )( W39 )
Y20—Loader Auxiliary Extend Solenoid ( SE21 )( W29 )
Y21—Loader Auxiliary Retract Solenoid ( SE21 )( W29 )
Y29—Loader Coupler Unlock Solenoid ( SE21 )( W26 )
Y30—Loader Coupler Pressure Solenoid ( SE21 )( W26 )
Y34—Sideshift Lock Solenoid ( SE29 )( W37 )
Y35—Boom Lock Solenoid ( SE29 )( W37 )
Y50—Ride Control Solenoid 1 ( SE21 )( W27 )
Y51—Ride Control Solenoid 2 ( SE21 )( W27 )
Y52—Pilot Enable Solenoid ( SE20 )( W30 )
Y53—Selective Flow Control Solenoid ( SE21 )( W28 )
Y56—Hydraulic Pump Control Solenoid ( SE20 )( W13 )
Y58—Pattern Select Solenoid 1 ( SE20 )( W30 )
Y59—Pattern Select Solenoid 2 ( SE21 )( W30 )
System Functional Schematic and Section Legend

→NOTE:
SE1—Starting and Charging Circuit
“SE1” indicates section number of system functional schematic where circuit is located.
“Starting and Charging Circuit” indicates circuit name.

SE2—Fuse Power Distribution Circuit
SE4—Modular Telematics Gateway (MTG) Control Unit Circuit
SE5—Satellite (SAT) Module Control Unit Circuit
SE6—Engine Control Unit (ECU) Circuit
SE13—CAN/Sealed Switch Module (SSM) Circuit
SE14—Vehicle Control Unit Circuit
SE15—Service Advisor/Standard Display Monitor Circuit
SE20—Pilot Enable Circuit
SE21—Loader Coupler/Single Lever Loader Control with Auxiliary/ Selective Flow/Ride Control Circuit
SE22 (S.N.—232969)—Beacon/Hazard Light Circuit
SE23 (S.N.—232969)—Brake/Drive/Work Light Circuit
SE22 (S.N 235590—)—Beacon/Hazard Light Circuit
SE23 (S.N 235590—)—Brake/Drive/Work Light Circuit
SE25—Blower Motor Circuit
SE26—Air Conditioner Circuit
SE27—Wiper/Washer Circuit
SE28—Air Seat/Return-to-Dig Circuit
SE29—Boom Lock/Sideshift Lock Circuit
SE30—Power Port/Radio Circuit
System Functional Schematic and Section Legend—Engines 4045HT054, 4045HT086
System Functional Schematic (SE1—SE3)
LEGEND:
F1 Main 250 A Fuse
F11 Radio/Power Port Unswitched Power 15 A Fuse
F18 Radio 10 A Fuse
F31 Return-to-Dig/Alternator Excitation 15 A Fuse
F47 Boom/Sideshift Lock/Optional Equipment Switched Power 15 A Fuse (S.N. —232969)
F47 Boom/Sideshift Lock/Rear Tail Light/Optional Equipment Switched Power 15 A Fuse (S.N. 235590— )
G1 Battery 1
G2 Battery 2
G4 Alternator
K5 Starter Relay
K10 Ignition Relay
K20 Accessory Relay
M1 Starter Motor
S2 Battery Disconnect Switch
W1 Frame Ground Near Starter Motor
W2 Operator Station Floor Ground
X20 Engine Harness-to-Cab/Canopy Harness Connector
LEGEND:
1 Without JDLink ™
2 With JDLink ™
A2 Engine Control Unit (ECU)
A6000 Modular Telematics Gateway (MTG) Control Unit
A6002 Satellite (SAT) Module Control Unit
B20 Engine Speed Control Pedal
B21 Engine Speed Control Dial
K25 Start Aid Relay
R5 CAN Termination Resistor 1
S46 Start Aid Switch
X41 ECU 32-Pin Connector
X49 Start Aid Switch Harness Connector
X101 Modular Telematics Gateway (MTG) 3-Pin Connector
X102 Modular Telematics Gateway (MTG) CAN 1 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
LEGEND:
B11 Fuel Rail Pressure Sensor
B15 Engine Coolant Temperature Sensor
B17 Fuel Temperature Sensor
B18 Manifold Air Temperature Sensor
B19 Crankshaft Position Sensor
B23 Engine Oil Pressure Sensor
B24 Camshaft Position Sensor
B60 Water-in-Fuel Sensor
B109 Air Filter Restriction Switch
K17 Fuel Lift Pump Relay
M17 Fuel Lift Pump
X50 Engine Harness-to-Electronic Injector Harness Connector
X86 Fuel Lift Pump Relay Harness Connector
Y17 Suction Control Valve
Y41 Electronic Fuel Injector (cylinder 1)
LEGEND:
A1 Vehicle Control Unit (VCU)
A3 Standard Display Monitor (SDM)
A74 Sealed Switch Module (SSM) (OC3)
B8 Fuel Level Sensor
H1 Monitor Alarm
X4 Standard Display Monitor (SDM) Connector
X11 Vehicle Control Unit (VCU) Connector 1
X21 Transmission Harness-to-Cab/Canopy Harness Connector
X40 Sealed Switch Module (SSM) Connector
LEGEND:
B6 Torque Converter Oil Temperature Sensor
B13 Park Brake Pressure Switch
B14 Transmission Output Speed Sensor
H3 Backup Alarm
S5 Forward, Neutral, Reverse (FNR) Switch
S6 Gear Select Switch
S8 Clutch Disconnect Switch
S10 Differential Lock Switch
S11 Mechanical Front Wheel Drive (MFWD) Switch
S37 Mechanical Front Wheel Drive (MFWD) Momentary Switch
X48 Transmission Control Lever (TCL) Connector
X58 Loader Control Lever Connector
Y1 Transmission Forward Direction Solenoid
Y2 Transmission Reverse Direction Solenoid
Y3 Transmission Speed Solenoid 1
Y7 Park Brake Release Solenoid
Y10 Differential Lock Solenoid
Y11 Mechanical Front Wheel Drive (MFWD) Solenoid
LEGEND:
B9 Seat Position Sensor
B10 Hydraulic Oil Temperature Sensor
B12 Hydraulic Oil Filter Restriction Switch
B26 Hydraulic System Pressure Sensor
B44 Loader Auxiliary Flow Control Switch
S52 Pilot Enable Switch
S54 Auxiliary Hydraulic Foot Switch
X52 Pilot Control Console Harness Connector
X53 Pilot Enable Switch Harness Connector
X57 Loader Auxiliary Control Harness 2-Pin Connector
X68 Ride Control Solenoid Harness Connector
X81 Loader Coupler Solenoid Harness Connector
X82 Loader Auxiliary Solenoid Harness Connector
Y20 Loader Auxiliary Extend Solenoid
Y21 Loader Auxiliary Retract Solenoid
Y29 Loader Coupler Unlock Solenoid
Y30 Loader Coupler Pressure Solenoid
Y50 Ride Control Solenoid 1
Y52 Pilot Enable Solenoid
Y53 Selective Flow Control Solenoid
Y56 Hydraulic Pump Control Solenoid
Y58 Pattern Select Solenoid 1
System Functional Schematic (S.N. —232969) (SE22—SE24)
LEGEND:
E1 Left Rear Work Light
E2 Left Rear Work Light (if equipped)
E3 Right Rear Work Light (if equipped)
E4 Right Rear Work Light
E5 Left Front Work Light (if equipped)
E6 Right Front Work Light (if equipped)
E7 Left Front Work Light
E8 Right Front Work Light
E15 Left Docking Light
E16 Right Docking Light
E17 Beacon Light
E23 Left Backup Light
E24 Right Backup Light
E31 Left Front Drive Light
E32 Right Front Drive Light
E33 Left Front Marker Light
E34 Right Front Marker Light
E35 Left Front Turn Signal
E36 Right Front Turn Signal
E37 Left Brake/Tail Light
E38 Right Rear Turn Signal
E39 Left Rear Turn Signal
E40 Right Brake/Tail Light
E41 License Plate Light
S19 Drive Light High/Low Switch
S26 Brake Light Pressure Switch 1
S30 Turn Signal Switch
S47 Beacon Light Switch
W3 Roof Ground
X26 Cab/Canopy Harness-to-Roof Harness Connector
X31 Right Front Drive Light/Turn Signal Connector
X32 Left Front Drive Light/Turn Signal Connector
X33 Rear Frame Harness Connector
X36 Not Used
System Functional Schematic (S.N. 235590— ) (SE22—SE24)
LEGEND:
E17 Beacon Light
E37 Left Brake Light
E40 Right Brake Light
E45 Left Rear Light Assembly
E46 Right Rear Light Assembly
E47 Left Tail Light
E48 Right Tail Light
K13 Sideshift/Boom Lock/Rear Light Relay
W3 Roof Ground
X36 Not Used
LEGEND:
B2 Air Conditioner Freeze Control Switch
B3 Air Conditioner High/Low Pressure Switch
M9 Temperature Control Motor
M10 Blower Motor
M11 Blower Mode Door Motor
M13 Front Wiper Motor
M14 Rear Wiper Motor
M15 Front Washer Motor
R10 Blower Motor Speed Resistor
R20 Temperature Control Resistor
S9 Air Conditioner Mode Switch
S14 Rear Wiper Enable Switch
S42 Blower Motor Speed Switch
V13 Front Wiper Motor Diode
V19 Air Conditioner Compressor Clutch Diode
X46 Cab Harness-to-Air Conditioner Harness Connector
X47 Blower Mode Door Motor Harness Connector
X66 Air Conditioner Compressor Clutch Harness Connector
Y19 Air Conditioner Compressor Clutch Solenoid
LEGEND:
A9 Radio
B30 Right Speaker
B31 Left Speaker
E20 Dome Light
H40 Horn
M45 Air Seat Motor
S12 Return-to-Dig Switch
S34 Sideshift Lock Switch
S35 Boom Lock Switch
S40 Horn Switch
S45 Air Seat Switch
V12 Return-to-Dig Solenoid Diode
X9 Cab Harness-to-Radio Harness Connector
X34 Boom Lock/Sideshift Harness Connector
X38 Left Power Port
X39 Right Power Port
X60 Side Console Option Connector
X62 Operator Station Option Connector
X67 Return-to-Dig Harness Connector
X123A Sideshift/Boom Lock Switch Harness Connector A (manual controls)
X123B Sideshift/Boom Lock Switch Harness Connector B (manual controls)
Y12 Return-to-Dig Solenoid
Y34 Sideshift Lock Solenoid
Y35 Boom Lock Solenoid
System Functional Schematic and Section Legend—Engine 4045HT096
→NOTE:
“SE1” indicates section number of system functional schematic where circuit is located.
“Starting and Charging Circuit” indicates circuit name.

SE4—Modular Telematics Gateway (MTG) Control Unit Circuit
SE5—Satellite (SAT) Module Control Unit Circuit
SE13—CAN/Sealed Switch Module (SSM) Circuit
SE15—Service Advisor/Standard Display Monitor Circuit
SE20—Pilot Enable Circuit
SE21—Loader Coupler/Single Lever Loader Control with Auxiliary/ Selective Flow/Ride Control Circuit
SE22 (S.N.—232969)—Beacon/Hazard Light Circuit
SE22 (S.N 235590—)—Beacon/Hazard Light Circuit
SE25—Blower Motor Circuit

SE26—Air Conditioner Circuit
SE27—Wiper/Washer Circuit
SE28—Air Seat/Return-to-Dig Circuit
SE29—Boom Lock/Sideshift Lock Circuit
SE30—Power Port/Radio Circuit
LEGEND:
F1 Main 250 A Fuse
F11 Radio/Power Port Unswitched Power 15 A Fuse
F18 Radio 10 A Fuse
F31 Return-to-Dig/Alternator Excitation 15 A Fuse
F47 Boom/Sideshift Lock/Optional Equipment Switched Power 15 A Fuse (S.N. —232969)
F47 Boom/Sideshift Lock/Rear Tail Light/Optional Equipment Switched Power 15 A Fuse (S.N. 235590— )
G1 Battery 1
G2 Battery 2
G4 Alternator
K5 Starter Relay
K10 Ignition Relay
K20 Accessory Relay
M1 Starter Motor
S2 Battery Disconnect Switch
LEGEND:
1 Without JDLink ™
2 With JDLink ™
K25 Start Aid Relay
X10 Engine Control Unit (ECU) Connector
LEGEND:
B7 Engine Oil Pressure Switch
B61 Fuel Filter Heater Temperature Switch
F23 Fuel Filter Heater 20 A Fuse
K26 Fuel Filter Heater Relay
R26 Fuel Filter Heater
Y16 Fuel Injection Pump Solenoid
LEGEND:
A74 Sealed Switch Module (SSM) (OC3)
H1 Monitor Alarm
LEGEND:
H3 Backup Alarm
LEGEND:
B10 Hydraulic Oil Temperature Sensor
System Functional Schematic (S.N. —232969) (SE22—SE24)
LEGEND:
E17 Beacon Light
S47 Beacon Switch
W3 Roof Ground
System Functional Schematic (S.N. 235590— ) (SE22—SE24)
LEGEND:
E17 Beacon Light
E37 Left Brake Light
E40 Right Brake Light
E45 Left Rear Light Assembly
E46 Right Rear Light Assembly
E47 Left Tail Light
E48 Right Tail Light
S47 Beacon Switch
W3 Roof Ground
LEGEND:
M10 Blower Motor
LEGEND:
A9 Radio
B30 Right Speaker
B31 Left Speaker
E20 Dome Light
H40 Horn
M45 Air Seat Motor
S40 Horn Switch
S45 Air Seat Switch
V12 Return-to-Dig Solenoid Diode
X38 Left Power Port
Engine Harness (W10) Component Location

Engine Harness (W10) Component Location (4045HT054 and 4045HT086)
LEGEND:
B18 Manifold Air Temperature (MAT) Sensor
F1 Main 250 A Fuse
G4 Alternator
H40 Horn
K5 Starter Relay
M1 Starter Motor
M17 Fuel Lift Pump
W10 Engine Harness
W39 Air Conditioner Compressor Clutch Harness
X18 Battery Load Center
Y17 Suction Control Valve (SCV)
Engine 4045TT096
Engine Harness (W10) Component Location (4045TT096)
LEGEND:
B61 Fuel Filter Heater Temperature Switch (if equipped)
F1 Main 250 A Fuse
G4 Alternator
H40 Horn
K5 Starter Relay
M1 Starter Motor
R26 Fuel Filter Heater (if equipped)
W10 Engine Harness
W39 Air Conditioner Compressor Clutch Harness
Engine Harness (W10) Wiring Diagram

Engine Harness (W10) Wiring Diagram (4045HT054 and 4045HT086)
LEGEND:
F1 Main 250 A Fuse
G4 Alternator
H40 Horn
K5 Starter Relay
M1 Starter Motor
M17 Fuel Lift Pump
X24 Engine Load Center Power Connector
X630 G002 BLK Splice
X632 M012 YEL Splice
X633 M013 LT GRN Splice
X634 P004 RED Splice
X636 R002 BLK Splice
Engine 4045TT096
Engine Harness (W10) Wiring Diagram (4045TT096)
LEGEND:
F1 Main 250 A Fuse
G4 Alternator
H40 Horn
K5 Starter Relay
M1 Starter Motor
X10 ECU Connector
X24 Engine Load Center Power Connector
X642 M013 LT GRN Splice
Transmission Harness (W13) Component Location
Transmission Harness (W13) Component Location
LEGEND:
B10 Not Used
H3 Backup Alarm
W13 Transmission Harness
Transmission Harness (W13) Wiring Diagram
Transmission Harness (W13) Wiring Diagram
LEGEND:
B10 Not Used
H3 Backup Alarm
X685 G011 BLK Splice 1
Cab Harness (W14) Component Location
Cab Harness (W14) Component Location
LEGEND:
1 Single Lever Loader Auxiliary Control Lever Configuration
A74 Sealed Switch Module (SSM)
E20 Dome Light
H1 Monitor Alarm
K10 Ignition Relay
K20 Accessory Relay
M10 Blower Motor
M45 Air Seat Motor
S5 Forward, Neutral, and Reverse (FNR) Switch
S11 Mechanical Front Wheel Drive (MFWD) Switch (without single lever loader control)
S40 Horn Switch
S45 Air Seat Switch
S47 Beacon Switch
W2 Operator’s Station Floor Ground
W14 Cab Harness
W40 Blower Mode Door Motor Harness
X3 Fuse and Relay Block
X6 Cab/Canopy Harness Battery Power Connector
X38 Left Power Port
X54 Selective Flow Control Solenoid Harness Connector
X62 Operator’s Station Option Connector

X81 Not Used
Cab Harness (W14) Wiring Diagram
LEGEND:
1 Continued on Sheet 2
LEGEND:
M45 Air Seat Motor
X6 Cab/Canopy Harness Battery Power Connector
X81 Not Used
X551 U110 RED Splice
X554 Sensor Return BLK Splice
X557 P001 RED Splice 2
X558 T011 BLU Splice
X559 L055 BRN Splice
LEGEND:
H1 Monitor Alarm
M10 Blower Motor
S11 Not Used
S40 Horn Switch
S45 Air Seat Switch
S47 Beacon Switch
X38 Left Power Port
X566 R002 BLK Splice 4
X567 M013 LT GRN Splice 4
X568 M012 YEL Splice 4
X578 A013 GRY Splice
LEGEND:
E20 Dome Light
K10 Ignition Relay
K20 Accessory Relay
Roof Harness (W17) Component Location
Roof Harness (W17) Component Location

LEGEND:
E17 Beacon Light

W3 Roof Ground
W17 Roof Harness
Roof Harness (W17) Wiring Diagram
Roof Harness (W17) Wiring Diagram
LEGEND:
E17 Beacon Light
W3 Roof Ground
Radio Harness (W18) Component Location
Radio Harness (W18) Component Location

LEGEND:
A9 Radio
B30 Right Speaker
B31 Left Speaker
W18 Roof Harness
Radio Harness (W18) Wiring Diagram
Radio Harness (W18) Wiring Diagram

LEGEND:
A9 Radio
B30 Right Speaker
B31 Left Speaker
Heater and Air Conditioner Harness (W19) Component Location
Heater and Air Conditioner Harness (W19) Component Location

LEGEND:
W19 Heater and Air Conditioner Harness
Heater and Air Conditioner Harness (W19) Wiring Diagram
Heater and Air Conditioner Harness (W19) Wiring Diagram

LEGEND:
Pilot Control, Selective Flow and Ride Control Harness (W20)

Component Location
Pilot Control, Selective Flow and Ride Control Harness (W20) Component Location
LEGEND:
S50 Ride Control Switch
S53 Selective Flow Control Switch

S58 Pattern Select Switch
W20 Pilot Control, Selective Flow and Ride Control Harness
X25 Optional Equipment Fuse and Relay Block
X60A Side Console Option Connector A
X60B Side Console Option Connector B
X64 Hydraulic Option Connector
Pilot Control, Selective Flow and Ride Control Harness (W20) Wiring Diagram
Pilot Control, Selective Flow and Ride Control Harness (W20) Wiring Diagram
LEGEND:
S54 Selective Flow Control Foot Switch
S58 Pattern Select Switch
X730 H001 GRN Splice
Selective Flow and Ride Control Harness (W21) Component Location
Selective Flow and Ride Control Harness (W21) Component Location

LEGEND:
W21 Selective Flow and Ride Control Harness

Selective Flow and Ride Control Harness (W21) Wiring Diagram
Selective Flow and Ride Control Harness (W21) Wiring Diagram
LEGEND:
S54 Selective Flow Control Foot Switch
Fuel Lift Pump Relay Harness (W22) Component Location
Fuel Lift Pump Relay Harness (W22) Component Location

LEGEND:
W22 Fuel Lift Pump Relay Harness
Fuel Lift Pump Relay Harness (W22) Wiring Diagram
Fuel Lift Pump Relay Harness (W22) Wiring Diagram

LEGEND:
Start Aid Switch Harness (W24) Component Location
Start Aid Switch Harness (W24) Component Location

LEGEND:
W24 Start Aid Switch Harness
Start Aid Switch Harness (W24) Wiring Diagram
Start Aid Switch Harness (W24) Wiring Diagram

LEGEND:
Ride Control Solenoid Harness (W27) Component Location
Ride Control Solenoid Harness (W27) Component Location

LEGEND:
W27 Ride Control Solenoid Harness
Ride Control Solenoid Harness (W27) Wiring Diagram
Ride Control Solenoid Harness (W27) Wiring Diagram

LEGEND:
Selective Flow Solenoid Harness (W28) Component Location
Selective Flow Solenoid Harness (W28) Component Location

LEGEND:
W28 Selective Flow Solenoid Harness
Selective Flow Solenoid Harness (W28) Wiring Diagram
Selective Flow Solenoid Harness (W28) Wiring Diagram

LEGEND:
Loader Auxiliary Solenoid Harness (W29) Component Location
Loader Auxiliary Control Harness (W29) Component Location

LEGEND:
W29 Loader Auxiliary Solenoid Harness
Loader Auxiliary Solenoid Harness (W29) Wiring Diagram
Loader Auxiliary Control Harness (W29) Wiring Diagram

LEGEND:
Pilot Enable Pattern Select Valve Harness (W30) Component Location
PIlot Enable Pattern Select Valve Harness (W30) Component Location

LEGEND:
W30 Pilot Enable Pattern Select Valve Harness
W31 Pilot Enable Switch Harness

Pilot Enable Pattern Select Valve Harness (W30) Wiring Diagram
Pilot Enable Pattern Select Valve Harness (W30) Wiring Diagram

LEGEND:

Pilot Enable Switch Harness (W31) Component Location
For Pilot Enable Switch Harness (W31) Component Location, see Pilot Enable Pattern Select Valve Harness (W30) Component
Pilot Enable Switch Harness (W31) Wiring Diagram
Pilot Enable Switch Harness (W31) Wiring Diagram

LEGEND:
Return-to-Dig Harness (W32) Component Location
Return-to-Dig Harness (W32) Component Location

LEGEND:
W32 Return-to-Dig Harness
X67 Return-to-Dig Harness-to-Transmission Harness Connector
Return-to-Dig Harness (W32) Wiring Diagram
Return-to-Dig Harness (W32) Wiring Diagram

LEGEND:
Boom Lock/Sideshift Harness (W37) Component Location—(S.N.

—232969)
Boom Lock/Sideshift Harness (W37) Component Location (S.N. —232969)

LEGEND:
W37 Boom Lock/Sideshift Harness

Boom Lock/Sideshift Harness (W37) Wiring Diagram—(S.N. —232969)
Boom Lock/Sideshift Harness (W27) Wiring Diagram (S.N. —232969)

LEGEND:
X34 Boom Lock/Sideshift Harness-to-Cab Harness Connector
Rear Frame Harness (W38) Component Location

Rear Frame Harness (W38) Component Location—(S.N. —232969)
Rear Frame Harness (W38) Component Location (S.N. —232969)

LEGEND:

W38 Rear Frame Harness
X36 Beacon Light Connector
Rear Frame Harness (W38) Component Location—(S.N. 235590— )
Rear Frame Harness (W38) Component Location (S.N. 235590— )

LEGEND:
1 Pilot Control Configuration
E45 Left Rear Turn Signal/Brake/Tail/Backup Light
E46 Right Rear Turn Signal/Brake/Tail/Backup Light

W42 Sideshift/Boom Lock Switch Harness (manual controls only)
X123A Sideshift/Boom Lock Switch Harness Connector A (manual controls only)
X123B Sideshift/Boom Lock Switch Harness Connector B (manual controls only)
Rear Frame Harness (W38) Wiring Diagram

Rear Frame Harness (W38) Wiring Diagram—(S.N. —232969)
Rear Frame Harness (W38) Wiring Diagram (S.N. —232969)
LEGEND:
Rear Frame Harness (W38) Wiring Diagram—(S.N. 235590— )
Rear Frame Harness (W38) Wiring Diagram (S.N. 235590— )
LEGEND:
E45 Left Rear Turn Signal/Brake/Tail/Backup Light
E46 Right Rear Turn Signal/Brake/Tail/Backup Light
Air Conditioner Compressor Clutch Harness (W39) Component Location
For Air Conditioner Compressor Clutch Harness (W39) Component Location see Engine Harness (W10) Component Location .
(Group 9015—10.)
Air Conditioner Compressor Clutch Harness (W39) Wiring Diagram
Air Conditioner Compressor Clutch Harness (W39) Wiring Diagram

LEGEND:
Blower Mode Door Motor Harness (W40) Component Location
For blower mode door motor harness (W40) component location, see Cab Harness (W14) Component Location . (Group
9015-10.)
Blower Mode Door Motor Harness (W40) Wiring Diagram
Blower Mode Door Motor Harness (W40) Wiring Diagram

LEGEND:
Sideshift/Boom Lock Switch Harness (W42) Component Location—(S.N.
235590— )
For Sideshift/Boom Lock Switch Harness (W42) Component Location—(S.N. 235590— ) see Rear Frame Harness (W38)
Sideshift/Boom Lock Switch Harness (W42) Wiring Diagram—(S.N.

235590— )
Sideshift/Boom Lock Switch Harness (W42) Wiring Diagram—(S.N. 235590— )

LEGEND:
X123A Sideshift/Boom Lock Switch Harness Connector A
X123B Sideshift/Boom Lock Switch Harness Connector B
Modular Telematics Gateway (MTG) Harness (W6002) Component Location
Modular Telematics Gateway (MTG) Harness (W6002) Component Location
LEGEND:
A6001 GPS/Cellular Antenna
A6003 Satellite (SAT) Antenna
G1 Battery 1
W6002 Modular Telematics Gateway (MTG) Harness
W6003 Satellite (SAT) Harness
Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram
Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram
LEGEND:
F71 JDLink™ Ground 7.5 A Fuse
G1 Battery 1
X616 M013 GRN Splice
X6020 Not Used
X6021 Not Used
X6022 Not Used
X6023 Not Used
Satellite (SAT) Harness (W6003) Component Location
For satellite (SAT) harness (W6003) component location, see Modular Telematics Gateway (MTG) Harness (W6002) Component
Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
Satellite (SAT) Harness (W6003) Wiring Diagram
Satellite (SAT) Harness (W6003) Wiring Diagram

LEGEND:
Group 15 - Sub-System Diagnostics

Start and Charge Circuit Theory of Operation
Start and Charge Circuit Theory of Operation—Engines 4045HT054, 4045HT086
Start and Charge Circuit Schematic (4045HT054, 4045HT086)
LEGEND:
F1 Main 250 A Fuse
F31 Alternator Excitation/Return-to-Dig 15 A Fuse
G1 Battery 1
G2 Battery 2 (if equipped)
G4 Alternator
K5 Starter Relay
K10 Ignition Relay
K25 Start Aid Relay
M1 Starter Motor
M17 Fuel Lift Pump
S2 Battery Disconnect Switch (if equipped)
X4 Standard Display Monitor (SDM) Connector 1
Unswitched power is supplied to the following components:
Vehicle Control Unit (VCU) (A1)

Sealed Switch Module (SSM) (A74) (from Sealed Switch Module (SSM) 7.5 A Fuse [F17])
Engine Control Unit (ECU) (A2) (from ECU Unswitched Power 40 A Fuse [F4])
Alternator (G4)
Starter Relay (K5)
Ignition Relay (K10)
Starter Motor (M1)
Fuel Lift Pump Relay (K17) (from fuel lift pump 15 A fuse [F21])
Ignition (Switched) Power ON

Engine start switch is located on sealed switch module (SSM) (A74). When engine start switch is pressed once, current flows
from terminal 3 of SSM to coil of ignition relay (K10), energizing the relay. With ignition relay energized, current flows through
ignition relay to vehicle control unit (VCU) (A1), powering up VCU. For more information on VCU, see Vehicle Control Unit (VCU)
Switched power is also provided to engine control unit (ECU) (A2) and standard display monitor (SDM) (A3). For power-up
information on ECU and SDM, see the theory of operation of specific component:
For more information on ECU, see Engine Control Unit (ECU) Circuit Theory of Operation (Group 9015-15.)
For more information on SDM, see Standard Display Monitor (SDM) Circuit Theory of Operation . (Group 9015-15.)
When powered up, SSM sends a message across controller area network (CAN) to VCU stating engine start switch has been
pressed. VCU acknowledges by sending a message back to SSM, causing ignition (switched) power status light emitting diode
LED to illuminate.
For more information on CAN circuit, see Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.)
Security System
Upon ignition power-up, VCU sends a request across CAN data line to ECU to check lock/unlock status of ECU. If ECU indicates it
is locked, then VCU enables security if not already enabled.
If a valid PIN is not entered within 5 minutes after ignition power-up, VCU turns off ignition (switched) power.
When proper PIN is entered, VCU sends an unlock request to ECU. ECU saves unlocked state in nonvolatile memory,
acknowledges unlock request, and allows engine to start (and run) until ignition (switched) power is turned off using engine
stop switch on SSM.
When a PIN is required to start engine and security configuration menu is not set to LOCK AT SHUTDOWN, engine can be
restarted without re-entering the PIN if the engine is started within 5 or 60 minutes (depending on setting) of stopping engine.
If ignition is powered up, but engine is not started for 60 minutes after turning on ignition (switched) power, VCU removes
ignition (switched) power.
If ECU indicates it is unlocked and security is not enabled, pressing the engine start switch again starts engine.
Engine Start
When engine start switch is pressed a second time and held down, SSM sends a message across controller area network (CAN)
to request VCU to begin start process.
When VCU receives start request and determines message from CAN is valid. VCU then forwards engine start request to ECU.
VCU also sends a message back to SSM, causing engine crank status LED to illuminate. Engine crank status LED is only
illuminated when engine start switch is held down.
→NOTE:
VCU uses the following engine speed thresholds to determine if engine is running or not running:
300 rpm or less—Not running

600 rpm or more—Running
To determine engine speed, VCU uses crankshaft position sensor (B19) information from ECU.
To prevent overheating starter motor, ECU is equipped with a timer that affects engine cranking. Timer consists of both a 30-
second timer that is active during engine cranking and a 60-second timer that becomes active after each crank cycle.
When ECU receives start signal from VCU, ECU checks status of 60-second timer. It also checks for a signal from crankshaft
position sensor (B19) representing engine speed. If engine speed is less than 300 rpm and 60-second timer is not active,
current is provided at pin K4 of ECU connector (X42) to coil of starter relay (K5), energizing the relay.
With start relay energized, unswitched battery current flows to starter motor solenoid, activating starter motor (M1).
At the same time, ECU activates 30-second timer. If engine start switch is held down for more than 30 seconds, ECU interrupts
current flow to coil of start relay, which automatically stops cranking of engine.
As starter motor cranks engine, crankshaft position sensor (B19) provides a signal representing engine speed to pins D4 and B4
of ECU connector (X41). The ECU uses this signal to verify that crankshaft is turning. ECU then sends a signal from pin M3 of
ECU connector (X42) energizing fuel lift pump relay (K17) and allowing current to flow to fuel lift pump (M17). This provides
pressurized fuel to electronic fuel injectors. At the same time, ECU allows current to flow to electronic fuel injectors to start fuel
injection process and thus, start the engine. For more information on the ECU, fuel lift pump, and electronic fuel injectors, see
Engine Control Unit (ECU) Circuit Theory of Operation . (Group 9015-15.)
When ECU detects engine speed is equal to or greater than 600 rpm, it interrupts current flow to coil of starter relay,
automatically stopping cranking of engine. It does this even if engine start switch is still held down (VCU still sends start
request to ECU).
If engine start switch is pressed and held while 60-second timer is active, ECU prevents current from flowing to the coil of
starter relay. Starter cannot be activated until 60 seconds elapses.
Engine Stop
Once engine stop switch has been pressed, SSM sends a message across CAN to VCU requesting to begin engine shutdown
process. VCU then returns a message commanding SSM to turn off left LED on start switch.
→NOTE:
If SSM stop switch is pressed again or held for more than 1 second at any time, SSM removes ignition
relay output regardless of VCU command.
VCU also observes vehicle speed via transmission speed sensor (B14). If it is determined that vehicle speed is invalid or greater
than 0.5 km/h and current gear is not set to neutral, VCU sets current gear to neutral, set a park brake apply timer to 15
seconds and sound an audible alarm.
A pop-up appears on SDM showing PARK BRAKE APPLY timer and decrements for 15 seconds.
Once timer expires or vehicle speed becomes 0.5 km/h or less VCU sends a shutdown request to SSM to turn off ignition
(switched) power.
If it is determined that vehicle speed is less than 0.5 km/h and engine stop switch has been pressed.
VCU also checks turbocharger cool down timer from ECU to see if turbocharger cool down is required.
If value in ECU for turbocharger cool down timer is zero, then VCU commands SSM to turn off ignition (switched) power relay. If
value is greater than zero, VCU captures that value and sets it as turbocharger cool down timer, disables engine speed control
dial, and sets park brake.
When cool down timer starts, SDM responds with a single beep, displays ENGINE SHUTDOWN timer and decrements for a value
determined by ECU no greater than 120 seconds.
Once turbocharger cool down timer has reached zero, VCU commands SSM to remove power from ignition (switched) power
relay.
Cold Start Aid
Ether injection is provided as an optional cold start aid for cold weather start-ups. When ignition is in ON or START position (1 or
2 LEDs illuminated on SSM start button) and momentary start aid switch (S46) is pressedd, start aid relay (K25) is energized
allowing current to flow through start aid 15 A fuse (F22) to start aid solenoid (Y15). Therefore energizing solenoid and injecting
ether into intake manifold.
Charge Circuit
Alternator (G4) provides power to all machine circuits and charges batteries when engine is running. Terminal B+ of alternator
is connected to battery positive (+) terminal at all times. When engine is running, current flows from ignition relay (K10)
through alternator excitation/return-to-dig 15 A fuse and alternator excitation diode (V4) to D+ terminal of alternator. Current
then flows through alternator field windings, causing excitation of windings. For more information, see Alternator Test . (Group
9015-20.)
Battery voltage at pin A of SDM 16-pin connector (X4) is used to display battery voltage.
When VCU detects system voltage less than 11.7 volts or greater than 15.5 volts for 5 seconds when engine is running, VCU
sends a message across CAN data line to SDM, causing engine alternator voltage indicator to appear.
Start and Charge Circuit Theory of Operation—Engine 4045TT096
Start and Charge Circuit Theory of Operation (4045TT096)
LEGEND:
F1 Main 250 A Fuse
F23 Fuel Filter Heater 20 A Fuse (if equipped)
G1 Battery 1
G4 Alternator
H1 Monitor Alarm
K5 Starter Relay
K10 Ignition Relay
K25 Start Aid Relay
K26 Fuel Filter Heater Relay (if equipped)
M1 Starter Motor
Unswitched power is supplied to the following components:

Sealed Switch Module (SSM) (A74) (from sealed switch module (SSM) 7.5 A fuse [F17])
Standard Display Monitor (SDM) (A3) (from monitor unswitched power 5 A fuse [F15])
Engine Control Unit (ECU) (A2) (from ECU unswitched power 40 A fuse [F4])
Alternator (G4)
Starter Relay (K5)
Starter Motor (M1)
Ignition (Switched) Power ON

Engine start switch is located on sealed switch module (SSM) (A74). When engine start switch is pressed once, current flows
from terminal 3 of SSM to coil of ignition relay (K10), energizing the relay. With ignition relay energized, current flows through
ignition relay to vehicle control unit (VCU) (A1), powering up VCU. For more information on VCU, see Vehicle Control Unit (VCU)
Switched power is also provided to engine control unit (ECU) (A2) and standard display monitor (SDM) (A3). For power-up
information on ECU and SDM, see theory of operation of specific component:
For more information on ECU, see Engine Control Unit (ECU) Circuit Theory of Operation (Group 9015-15.)
For more information on SDM, Standard Display Monitor (SDM) Circuit Theory of Operation . (Group 9015-15.)
When powered up, SSM sends a message across controller area network (CAN) to VCU stating that engine start switch has
been pressed. VCU acknowledges by sending a message back to SSM, causing ignition (switched) power status light emitting
diode (LED) to illuminate.

For more information on CAN circuit, Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.)
Security System
Upon ignition power-up, VCU sends a request across CAN data line to ECU to check lock/unlock status of ECU. If ECU indicates
that it is locked, then VCU enables security if not already enabled.
If a valid PIN is not entered within 5 minutes after ignition power-up, VCU remove ignition (switched) power.
When proper PIN is entered, VCU sends an unlock request to ECU. ECU saves unlocked state in nonvolatile memory,
acknowledges unlock request, and allows engine to start (and run) until ignition (switched) power is removed using engine stop
switch on SSM.
When a PIN is required to start engine and security configuration menu is not set to LOCK AT SHUTDOWN, engine can be
restarted without re-entering PIN if engine is started within 5 or 60 minutes (depending on setting) of stopping engine.
If ignition is powered up, but engine is not started for 60 minutes after turning on ignition (switched) power, VCU removes
ignition (switched) power.
If ECU indicates it is unlocked and security is not enabled, then pressing engine start switch again starts engine.
Engine Start
When engine start switch is pressed a second time and held down, SSM sends a message across controller area network (CAN)
to request VCU to begin start process.
When VCU receives start request and determines message from CAN is valid. VCU then forwards engine start request to ECU.
VCU also sends a message back to SSM, causing engine crank status LED to illuminate. Engine crank status LED is only
illuminated when engine start switch is held down.
→NOTE:
VCU uses the following engine speed thresholds to determine if engine is running or not running:
300 rpm or less—Not running

600 rpm or more—Running
To determine engine speed, VCU uses crankshaft position sensor (B19) information from ECU.
To prevent overheating starter motor, VCU is equipped with a timer that affects engine cranking. Timer consists of both a 30-
second timer that is active during engine cranking and a 60-second timer that becomes active after each crank cycle.
When VCU receives start signal from SSM, it checks status of 60-second timer. It also checks ECU for a signal from crankshaft
position sensor (B19) representing engine speed. If engine speed is less than 300 rpm and 60-second timer is not active,
current is provided at pin 7 of VCU connector (X10) to coil of starter relay (K5), energizing the relay.
With starter relay energized, unswitched battery current flows to starter motor solenoid, activating starter motor (M1).
At the same time, VCU activates 30-second timer. If engine start switch is held down for more than 30 seconds, VCU interrupts
current flow to coil of starter relay, which automatically stops cranking of engine.
As starter motor cranks engine, crankshaft position sensor (B19) provides a signal representing engine speed to pins D2 and B2
of ECU connector (X10). n The ECU uses this signal to verify that crankshaft is turning. ECU then sends a signal from pin K2 of
ECU connector (X10) energizing fuel injection pump solenoid (Y16) and allowing fuel to flow to cylinders. For more information
on ECU see Engine Control Unit (ECU) Circuit Theory of Operation . (Group 9015-15.)
When VCU receives a message from ECU indicating engine speed is equal to or greater than 600 rpm, VCU interrupts current
flow to coil of starter relay, automatically stopping cranking of engine. It does this even if engine start switch is still held down.
If engine start switch is pressed and held while the 60-second timer is active, VCU prevents current from flowing to coil of
starter relay. Starter cannot be activated until the 60 seconds elapses.
Engine Stop
Once engine stop switch has been pressed, SSM sends a message across CAN to VCU requesting to begin engine shutdown
process. VCU then returns a message commanding SSM to turn off the left LED on start switch.
→NOTE:
If SSM stop switch is pressed again or held for more than 1 second at any time, SSM removes ignition
relay output regardless of VCU command.
VCU also observes vehicle speed via transmission speed sensor. If it is determined that vehicle speed is invalid or greater than
0.5 km/h and current gear is not set to neutral, VCU sets current gear to neutral, sets a park brake apply timer to 15 seconds
and sounds an audible alarm.
A pop-up appears on SDM showing PARK BRAKE APPLY timer and decrements for 15 seconds.
Once timer expires or vehicle speed becomes 0.5 km/h or less, VCU sends a shutdown request to SSM to remove ignition
power.
VCU also checks turbocharger cool down timer from ECU to see if turbocharger cool down is required.
If value in ECU for turbocharger cool down timer is zero, then VCU commands SSM to turn off ignition (switched) power relay. If
value is greater than zero, VCU captures that value and sets it as turbocharger cool down timer, disables engine speed control
dial, and sets park brake.
When cool down timer starts, SDM responds with a single beep, displays ENGINE SHUTDOWN timer and decrements for a value
determined by ECU no greater than 120 seconds.
Once turbocharger cool down timer has reached zero, VCU commands SSM to turn off the ignition (switched) power relay.
Cold Start Aid
Ether injection is provided as an optional cold start aid for cold weather start-ups. When start switch is pressed (1 or 2 lights
illuminated on SSM start switch) and momentary start aid switch (S46) is pressed, start aid relay (K25) is energized allowing
current to flow through start aid 15 A fuse (F22) to start aid solenoid (Y15). Energizing the solenoid and injecting ether into
intake manifold.
Charge Circuit
Alternator (G4) provides power to all machine circuits and charges batteries when engine is running. terminal B+ of alternator
is connected to battery positive (+) terminal at all times. When the engine is running, current flows from ignition relay (K10)
through alternator excitation/return-to-dig 15 A fuse (F31) and alternator excitation diode (V4) to D+ terminal of alternator.
Current then flows through alternator field windings, causing excitation of windings. For more information, see Alternator Test .
(Group 9015-20.)
Battery voltage at pin A of SDM 16-pin connector (X4) is also used to display battery voltage.
When VCU detects system voltage less than 11.7 volts or greater than 15.5 volts for 5 seconds when engine is running, VCU
sends a message across CAN data line to SDM, causing the engine alternator voltage indicator to appear.
Controller Area Network (CAN) Circuit Theory of Operation
Controller Area Network (CAN) Circuit (engines 4045HT054, 4045HT086)
LEGEND:
1 Unswitched Battery Power
W10 Engine Harness
W14 Cab Harness
W15 Canopy Harness
W6002 Modular Telematics Gateway (MTG) Harness (if equipped)
Controller Area Network (CAN) Circuit (engine 4045TT096)
LEGEND:
W10 Engine Harness
W14 Cab Harness
W15 Canopy Harness
This machine utilizes a controller area network (CAN) on which devices communicate. The vehicle control unit (VCU) (A1),
engine control unit (ECU) (A2), standard display monitor (SDM) (A3), and sealed switch module (SSM) (A74) are connected to
the CAN. Operations and functions of these individual devices are covered separately.
For the JDLink ™ MTG, see System Overview in JDLink™ (MTG) Diagnosis and Test Manual. (TM114519.)
The devices on the CAN network are communicating at a high-speed frequency, which makes the networks susceptible to
interference caused by many electrical sources. The devices on the CAN are connected via three wires weaved together called
a twisted triple. The twisted triple consists of a high-voltage signal wire, a low-voltage signal wire, and a ground wire. This
method reduces interference and helps the devices communicate with minimal errors.
CAN termination resistors R5 and R6 are 120 ohm resistors that are connected on opposite ends of the network to avoid signal
errors. The Service ADVISOR ™ diagnostic connector (X1) is provided for machine diagnostic purposes. Additionally, some
messages can be viewed on-board using the standard display monitor (SDM). For connection information, see Service
ADVISOR™ Connection Procedure . (Group 9015-20.)
Engine Control Unit (ECU) Circuit Theory of Operation

Engine Control Unit (ECU) Circuit Schematic—Engines 4045HT054, 4045HT086
Engine Control Unit (ECU) Circuit Schematic (4045HT054, 4045HT086)
LEGEND:
1 Switched Battery Power
3 Controller Area Network (CAN)
K5 Starter Relay
M17 Fuel Lift Pump
W10 Engine Harness
W14 Cab Harness
W15 Canopy Harness
W22 Fuel Lift Pump Relay Harness
Engine Control Unit (ECU) (A2)
ECU utilizes information received from various sensors to determine the correct amount of fuel and injection timing based on
load, temperatures, and operator input. Some data calculated by ECU is transmitted across controller area network (CAN)
system to vehicle control unit (VCU). VCU forwards much of the information across CAN system to standard display monitor
(SDM) where it is displayed on appropriate screen. For more information concerning CAN system, see Controller Area Network
(CAN) Circuit Theory of Operation . (Group 9015-15.)
For more information concerning CAN system, see Controller Area Network (CAN) Circuit Theory of Operation . (Group
9015-15.)
For information concerning VCU, see Vehicle Control Unit (VCU) Circuit Theory of Operation . (Group 9015-15.)
For information concerning SDM, see Standard Display Monitor (SDM) Circuit Theory of Operation . (Group 9015-15.)
ECU also detects malfunctions in sensors and sensor circuits, or abnormal operating conditions. When this happens, ECU
generates a diagnostic trouble code (DTC). See Engine Control Unit (ECU) Diagnostic Trouble Codes . (Group 9001-20.)
Whenever an engine DTC occurs, information is captured or recorded. Information generated is called a Snapshot. Snapshot
information is categorized in two types: Snapshot Capture and Snapshot Recording. For more information, see Snapshot
Instructions . (CTM502.)
ECU contains a barometric air pressure sensor that is located inside the ECU. This sensor is used to determine pressure of
ambient air at the mounting location of ECU. Barometric air pressure sensor helps ECU determine air density for calculating
correct air/fuel ratio. This sensor cannot be repaired or replaced without replacing ECU.
ECU also contains a temperature sensor that is located inside ECU. This sensor is used to determine internal temperature of
ECU. If ECU temperature exceeds specification, ECU limits speed of engine in an attempt to protect it from permanent damage.
This sensor cannot be repaired or replaced without replacing ECU.
Ground is provided at pins L2, L3, and M2 of ECU 48-pin connector (X42).
Unswitched battery power is available at pins L1, L4, M1, and M4 of ECU 48-pin connector (X42), through fuse (F4).
When engine start switch is pressed once, current flows from pin 3 of SSM connector (X40) to coil of ignition relay and to pin B2
of ECU 48-pin connector (X42), causing ECU to power up.
Engine Speed Control
Operator controls engine speed with an engine speed control pedal, an engine speed control dial, or a combination of both.
When operator is facing forward (loader position), operator primarily uses engine speed control pedal to control engine speed.
When operator is facing rear (backhoe position), operator primarily uses engine speed control dial to control engine speed.
Engine Speed Control Pedal (B20): ECU observes desired engine speed from engine speed control pedal (B20) based on
engine speed control pedal position. ECU supplies 5 volts from pin A3 of ECU 48-pin connector (X42) and a ground
reference from pin C3 of ECU 48-pin connector (X42). Engine speed control pedal sends an analog signal representing
pedal position to pin A4 of ECU 48-pin connector (X42). This signal represents desired engine speed, that ECU compares
with values recorded during self-calibration. ECU detects this signal and responds by increasing or decreasing engine
speed accordingly
Engine Speed Control Dial (B21): ECU observes desired engine speed from engine speed control dial (B21) based on
engine speed control dial position. Engine speed control dial is a potentiometer that receives 5 volts from pin A3 of ECU
48-pin connector (X42) and a ground reference from pin C3 of ECU 48-pin connector (X42). Turning engine speed control
dial varies amount of voltage sent to pin F3 of ECU 48-pin connector (X42). This signal represents desired engine speed,
that ECU compares with values recorded during self-calibration. ECU detects this signal and responds by increasing or
decreasing engine speed accordingly. At engine start, regardless of current engine speed control dial position, ECU does
not allow engine speed control dial to control engine speed until it receives input from VCU. VCU sends a CAN message to
ECU to either disable engine speed control dial or enable engine speed control dial based on certain conditions. For more
information, see Vehicle Control Unit (VCU) Circuit Theory of Operation . (Group 9015-15.)
Turbocharger Cool Down

The turbocharger cool down feature allows the turbo to cool before the engine is shutdown.
When engine stop switch is pressed VCU checks turbocharger cool down timer from ECU to see if turbocharger cool down is
required. If value in ECU for turbocharger cool down timer is zero, then VCU commands SSM to turn off ignition (switched)
power relay. If value is greater than zero, VCU captures that value and sets it as turbocharger cool down timer, disables engine
speed control dial, and sets park brake. When cool down timer starts, SDM responds with a single beep, displays ENGINE
SHUTDOWN timer and decrements for a value determined by ECU no greater than 120 seconds. Once turbocharger cool down
timer has reached zero, VCU commands SSM to turn off ignition (switched) power relay.
→NOTE:
If SSM engine stop switch is pressed again or held for more than 1 second at any time, SSM turns off
ignition relay output even if turbocharger cool down is required. If engine is shutdown before
turbocharger cool down timer reaches zero a diagnostic trouble code (DTC) is set.
Fuel Rail Pressure Sensor (B11)

ECU supplies a 5 volt reference voltage and ground to fuel rail pressure sensor at pins E2 and D3 of ECU 32-pin connector
(X41). Fuel rail pressure sensor sends an analog signal representing fuel rail pressure to pin E3 of ECU 32-pin connector (X41).
ECU utiilzes this signal to monitor high pressure side of fuel system and apply derate conditions when needed. If ECU observes
a value that is out of valid range, ECU derates engine to 50% of full power. Engine returns to full power when fuel rail pressure
is in range. For information on engine deration, see Engine Derate and Shutdown Protection and 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 Sensor (B15)
ECU observes resistance from engine coolant temperature sensor at pins D2 and C4 of ECU 32-pin connector (X41). ECU
transmits engine coolant temperature information across CAN system to vehicle control unit (VCU).
VCU relays the message to standard display monitor (SDM) so SDM can determine position of needle on engine coolant
temperature gauge and moves it accordingly. It also activates a warning indicator when coolant temperature becomes too
high. See Standard Display Monitor (SDM) . (Operator′s Manual.)
Engine coolant temperature can also be displayed in SDM service menu. See Standard Display Monitor (SDM)—Diagnostics .
(Group 9015-16.)
ECU utilizes signal from engine coolant temperature sensor to monitor coolant temperature and apply derate conditions when
needed. If engine coolant temperature reaches 111°C (232°F), ECU derates engine 5% per minute to 80% of full power. If
coolant temperature reaches 113°C (236°F), ECU derates engine 20% per minute to 40% of full power. Engine returns to full
power (at a rate of 5% per minute) when engine coolant temperature drops below derate threshold temperature. If ECU
observes a value that is out of valid range, a default temperature of 90°C (194°F) is utilized. For information on engine
deration, see Engine Derate and Shutdown Protection and see OEM Engines - Derate Specifications . (CTM502.)
For information on how temperature sensors operate, see Measuring Temperature . (CTM502.)
Fuel Temperature Sensor (B17)
ECU observes resistance from fuel temperature sensor at pins D2 and F4 of ECU 32-pin connector (X41). ECU transmits fuel
temperature information across CAN system to VCU so it can be displayed in SDM service menu.
ECU monitors signal from fuel temperature sensor (B17) to apply derate conditions when needed. If ECU observes fuel
temperature above 100°C (220°F), ECU derated engine 5% per minute up to 80% of full power. Engine returns to full power (at
a rate of 5% per minute) when fuel temperature drops below derate threshold temperature. If ECU observes a value that is out
of valid range, a default temperature of 40°C (104°F) is utilized. High fuel temperature engine protection is disabled. For
information on engine deration, see Engine Derate and Shutdown Protection and see OEM Engines - Derate Specifications .
(CTM502.)
Manifold Air Temperature (MAT) Sensor (B18)
ECU observes resistance from MAT sensor at pins C2 and D2 of ECU 32-pin connector (X41). ECU transmits MAT sensor
information across CAN system to VCU so it can be displayed in SDM service menu. See Standard Display Monitor
(SDM)—Diagnostics . (Group 9015-16.)
If ECU observes a manifold air temperature above 89°C (192°F), ECU derates engine 5% per minute up to 80% of full power.
Engine returns to full power (at a rate of 5% per minute) when manifold air temperature falls below derate temperature. For
information on engine deration, see Engine Derate and Shutdown Protection and see OEM Engines - Derate Specifications .
(CTM502.)
For more information on MAT sensor, see Electrical Component Specifications . (Group 9015-20.)
Crankshaft Position Sensor (B19)
ECU detects signal from crankshaft position sensor at pins B4 and D4 of ECU 32-pin connector (X41). ECU determines when
number 1 cylinder is at top dead center. ECU also calculates engine (crankshaft) speed and sends this information across CAN
system to VCU. VCU then forwards this information to SDM to be displayed as engine rpm.
If ECU detects an invalid signal (“noisy,” invalid pattern, or missing pulse) from crankshaft position sensor, ECU derates engine
20% per minute up to 50% of full power. Engine returns to full power (at the rate of 20% per minute) when ECU detects a valid
crankshaft position sensor signal.
For information on how speed sensors operate, see Measuring Speed . (CTM502.)
Camshaft Position Sensor (B24)
ECU detects signal from camshaft position sensor at pins A4 and E4 of ECU 32-pin connector (X41). ECU determines which
cylinder is approaching top dead center.
For information on how speed sensors operate, see Measuring Speed . (CTM502.)
Engine Oil Pressure Sensor (B23)
ECU supplies a 5-volt reference voltage and ground to engine oil pressure sensor at pins F3 and D2 of ECU 32-pin connector
(X41). Engine oil pressure sensor sends an analog signal representing engine oil pressure to pin A3 of ECU 32-pin connector
(X41).
ECU transmits engine oil pressure information across CAN system to SDM. The SDM utilizes this information to determine the
position of the needle on the engine oil pressure gauge and moves the needle accordingly. It also activates a warning indicator
when oil pressure is too low. See Standard Display Monitor (SDM) . (Operator′s Manual.)
The engine oil pressure can also be displayed in monitor service menu. See Standard Display Monitor (SDM)—Diagnostics .
(Group 9015-16.)
ECU monitors engine oil pressure using engine oil pressure sensor (B23) and applies derate conditions when needed. If oil
pressure is below threshold pressure, ECU derates engine.
If ECU observes a value that is out of valid range, a default pressure of 500 kPa (5 bar) (72.5 psi) is utilized. Low oil pressure
engine protection is disabled. For information on engine deration, see Engine Derate and Shutdown Protection and see OEM
Engines - Derate Specifications . (CTM502.)
For information on how pressure sensors operate, see Measuring Pressure . (CTM502.)
Water-In-Fuel (WIF) Sensor (B60)
Water-in-fuel sensor measures amount of resistance of fluid in water separator bowl. Since water is a better conductor of
electricity than fuel, and, if water is present in separator bowl, ECU observes a resistance drop between pins B2 and D2 of ECU
32-pin connector (X41).
If ECU observes low resistance, indicating water in fuel, ECU derates engine 20% per minute up to 50% of full power. Engine
returns to full power (at a rate of 20% per minute) when water is no longer dectected in fuel. For information on engine
deration, see Engine Derate and Shutdown Protection and see OEM Engines - Derate Specifications . (CTM502.)
Starter Relay (K5)
When engine start switch on sealed switch module (SSM) is pressed once to turn on ignition (switched) power, SSM sends
current out pin 3 of SSM connector (X40) to pin B2 of ECU 48-pin connector (X42), causing ECU to power up. When engine start
switch is pressed a second time and held down, SSM sends a message across controller area network (CAN) to request VCU to
begin start process. If VCU determines all conditions are met for engine start, VCU forwards a message to ECU which then
applies power to starter relay (K5) from pin K4 of ECU 48-pin connector (X42). For more information on starting and charging,
see Start and Charge Circuit Theory of Operation . (Group 9015-15.)
Fuel Lift Pump Relay (K17)
When engine start switch is pressed once to turn on ignition (switched) power, sealed switch module (SSM) sends current out
SSM pin 3 of SSM connector (X40) to pin B2 of ECU 48-pin connector (X42). When this signal is detected, ECU sends current
from pin M3 of ECU 48-pin connector (X42) to coil of fuel lift pump relay, energizing the relay. The energized fuel lift pump
relay allows current to flow from fuse (F21) to fuel lift pump (M17), activating pump and providing fuel from fuel tank to high-
pressure fuel pump. ECU energizes the relay for 60 seconds to prime fuel system if ignition is on and engine is not running.
ECU keeps relay energized while engine is running.
For more information on fuel system, see Fuel System Operation . (CTM502.)
Suction Control Valve (SCV) (Y17)
Suction control valve (SCV) (Y17) regulates delivery of fuel to high-pressure common rail (HPCR). ECU sends a signal out pins
H1 and H2 of ECU 32-pin connector (X41) to SCV. When the SCV is energized, fuel is allowed to discharge from fuel outlet on
high-pressure fuel pump to HPCR. For more information, see High Pressure Fuel Pump Operation . (CTM502.)
For more information on high-pressure common rail (HCPR), see High Pressure Common Rail (HPCR) Operation . (CTM502.)
Electronic Fuel Injectors (Y41—Y44)
ECU controls injection timing and amount of fuel injected by energizing and de-energizing electronic injectors (Y41—Y44). For
more information on the electronic injectors, see Electronic Injector (EI) Operation . (CTM502.)
Engine Control Unit (ECU) Circuit Schematic—Engine 4045TT096
Engine Control Unit (ECU) Circuit Schematic (4045TT096)
LEGEND:
K5 Starter Relay
W10 Engine Harness
W14 Cab Harness
W15 Canopy Harness
Engine control unit (ECU) (A2) utilizes information received from various sensors to determine correct amount of fuel and
injection timing based on load, temperatures, and operator input. Some data calculated by ECU is transmitted across controller
area network (CAN) to other controllers. For more information on controller area network, see Controller Area Network (CAN)
ECU also detects malfunctions in sensors and sensor circuits, as well as abnormal operating conditions. When this happens,
ECU generates a diagnostic trouble code (DTC).
Crankshaft Position Sensor (B19)
ECU detects signal from crankshaft position sensor (B19) at pins D2 and B2. ECU determines when number 1 cylinder is at top
dead center. ECU also calculates engine (crankshaft) speed and sends this information across CAN to SDM where it appears as
engine RPM.
Engine Coolant Temperature Sensor (B15)
ECU senses resistance from engine coolant temperature sensor (B15) at pins B1 and D3. SDM displays this temperature on
engine coolant temperature gauge.
ECU monitors signal from engine coolant temperature sensor (B15) to apply engine derate conditions when needed. If engine
coolant temperature reaches 113°C (235°F), ECU derates fuel by 2% per minute up to 20%. If coolant temperature drops below
this derate threshold temperature, ECU increases fuel delivery by the same rate until full power is restored.
Fuel Temperature Sensor (B17)
Fuel temperature sensor (B17) is a variable-resistance temperature sensor. ECU senses resistance from a fuel temperature
sensor at pins C3 and D3. ECU transmits fuel temperature information across CAN.
ECU monitors signal from fuel temperature sensor (B17) to apply engine derate conditions when needed. If ECU senses fuel
temperature above 120°C (248°F), ECU derates fuel 2% per minute up to 20%. If fuel temperature falls below derate
temperature, ECU increases fuel delivery 2% per minute until full power is restored.
Water In Fuel (WIF) Sensor (B60)
WIF sensor measures amount of resistance of fluid in water separator bowl. Since water is a better conductor of electricity than
fuel, and, if water is present in separator bowl, ECU senses a resistance drop between pins F2 and D3 of ECU connector (X10).
If ECU senses low resistance, indicating water in fuel, ECU derates engine 20% per minute up to 50% of full power. Engine
returns to full power (at a rate of 20% per minute) when water is no longer detected in fuel.
Fuel Injection Pump Solenoid (Y16)
Fuel injection pump solenoid (Y16), located on the end of injection pump, controls movement of pump control valve. ECU
applies an electrical signal from pins A3 and K2 to the solenoid. When ECU supplies no current to solenoid, valve does not
move. Thus, injection pump delivers no fuel. When ECU supplies current to the solenoid, pump control valve closes off high
pressure injection chamber, that allows fuel in the chamber to reach injection pressure. ECU determines quantity of fuel based
on sensor inputs.
Manifold Air Temperature (MAT) Sensor (B18)
Manifold air temperature sensor (B18) is a variable-resistance temperature sensor. ECU senses resistance at pins D1 and D3.
The ECU transmits MAT sensor information across CAN system to VCU so it can be displayed in SDM service menu. See
Standard Display Monitor (SDM)—Diagnostics . (Group 9015-16.)
Engine Speed Control
Operator controls engine speed with an engine speed control pedal, an engine speed control dial, or a combination of both.
When operator is facing forward (loader position), operator primarily uses engine speed control pedal to control engine speed.
When operator is facing rear (backhoe position), operator primarily uses engine speed control dial to control engine speed.
Engine Speed Control Pedal (B20): ECU senses desired engine speed from engine speed control pedal position sensor
(B20) based on engine speed control pedal position. ECU supplies a 5-volt reference voltage and ground to engine speed
control pedal position sensor at pins E2 and D3 of ECU connector (X10). engine speed control pedal position sensor sends
an analog signal representing pedal position to pin F3 of ECU connector (X10). This signal represents desired engine
speed, that ECU compares with values recorded during self-calibration. ECU detects this signal and responds by
increasing or decreasing engine speed accordingly
Engine Speed Control Dial (B21): ECU senses desired engine speed from engine speed control dial (B21) based on engine
speed control dial position. Engine speed control dial is a potentiometer that receives 5 volts from pin E2 of ECU
connector (X10) and a ground reference from pin D3 of ECU connector (X10). Turning engine speed control dial varies the
amount of voltage sent to pin B3 of ECU connector (X10). This signal represents desired engine speed, that ECU
compares with values recorded during self-calibration. ECU detects this signal and responds by increasing or decreasing
engine speed accordingly. At engine start, regardless of current engine speed control dial position, ECU does not allow
engine speed control dial to control engine speed until it receives input from VCU. VCU sends a CAN message to ECU to
either disable engine speed control dial or enable engine speed control dial based on certain conditions. For more
information, See Vehicle Control Unit (VCU) Circuit Theory of Operation . (Group 9015-15.)
Turbocharger Cool Down

The turbocharger cool down feature allows the turbo to cool before the engine is shutdown.
When engine stop switch is pressed VCU checks turbocharger cool down timer from ECU to see if turbocharger cool down is
required. If value in ECU for turbocharger cool down timer is zero, then VCU commands SSM to turn off ignition (switched)
power relay. If value is greater than zero, VCU captures that value and sets it as turbocharger cool down timer, disables engine
speed control dial, and sets park brake. When cool down timer starts, SDM responds with a single beep, displays ENGINE
SHUTDOWN timer and decrements for a value determined by ECU no greater than 120 seconds. Once turbocharger cool down
timer has reached zero, VCU commands SSM to turn off ignition (switched) power relay.
→NOTE:
If SSM engine stop switch is pressed again or held for more than 1 second at any time, SSM turns off
ignition relay output even if turbocharger cool down is required. If engine is shutdown before
turbocharger cool down timer reaches zero a diagnostic trouble code (DTC) is set.
Vehicle Control Unit (VCU) Circuit Theory of Operation

Vehicle Control Unit (VCU) Circuit Theory of Operation—Engines 4045T054, 4045HT086
Vehicle Control Unit (VCU) Circuit Schematic—Power and Ground (4045HT054, 4045HT086)
LEGEND:
F1 Main 250 A Fuse
G1 Battery 1
G4 Alternator
K5 Starter Relay
K10 Ignition Relay
M1 Starter Motor
W4 Battery Ground
W10 Engine Harness
W14 Cab Harness
W15 Canopy Harness
Vehicle control unit (VCU) acts in conjunction with other electrical components to provide electrical function to the machine.
Major functions VCU controls include: hydraulic system, transmission control, wiper and washer circuits, and horn, lights and
beacons circuits. VCU provides power and ground to these functions and sends and receives signals based on performance.
Operator activates many of these functions using sealed switch module (SSM) (A74). SSM is a device that receives operator
input through momentary switches. SSM transmits switch selection across controller area network (CAN) to VCU. VCU sends
and receives CAN messages at pins A1 and B1 of VCU connector 1 (X11) to communicate with other controllers. For more
information on CAN, see Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.)
VCU interprets CAN signals and determines if input is valid or not. If input is not valid for machine options available or machine
state, input is ignored. If input is valid, appropriate function is activated. SSM then receives confirmation that function is
activated and causes appropriate light emitting diode (LED) on switch button to illuminate indicating function has been
activated.
VCU collects feedback from various sensors and communicates information with other controllers to display to operator.
VCU communicates much information to standard display monitor (SDM) (A3), where information is displayed. For more
information about SDM, see Standard Display Monitor (SDM) Circuit Theory of Operation . (Group 9015-15.)
VCU contains digital on/off driver outputs controlled based on inputs from sensors and other controllers on machine.
VCU driver output functions include:
Ignition and Accessory Relay Operation

Backup Alarm Operation
Park Brake
Transmission Speed and Direction Operation
Selective Flow Control Operation
Loader Coupler Operation

Window Washer Pump Operation
Front And Rear Wiper Operation
Lights Operation
Hazard Warning Signals
Differential Lock
Mechanical Front Wheel Drive (MFWD)
Return To Dig Operation
For more information on individual driver outputs:

See Wiper and Washer Circuit Theory of Operation . (Group 9015-15.)
VCU also provides diagnostics in form of diagnostic trouble codes (DTCs) for systems it controls. For more information about
vehicle control unit DTCs, see Vehicle Control Unit (VCU) Diagnostic Trouble Codes . (Group 9001-40.)
Diagnostic trouble code (DTC) conditions.
Open Circuit—An open circuit condition is detected whenever output driver does not pull down as expected when turned
on. When output is turned on, software continues to drive output so a technician can check voltage.
Short to Power—A short to power is detected whenever output is off and feedback circuit detects current.
High Current or Short to Ground—Detection of a high current condition occurs whenever output is turned on and driver
detects an overload or over temperature condition. When high current condition has been detected, output turns off and
only resets when function or engine start switch is cycled on/off.
→NOTE:
When output is turned off because of a high current condition, status LED of corresponding function on
SSM shows function is still on.
For all driver outputs:
An open circuit and a short to power look the same.

A short to ground and an overloaded circuit look the same.
When VCU detects a DTC, condition must be corrected and function cycled before DTC can be cleared. If first DTC for function
is not cleared before another DTC condition occurs, function may have two DTCs, where one DTC is not valid. (Example: Pin
Disconnect Open Circuit and Pin Disconnect High Current DTCs are displayed at the same time.)
VCU Power-Up (Power and Ground)
Unswitched power is supplied to following components:
Starter Motor (M1)

Starter Relay (K5)
Sealed Switch Module (SSM) (A74) (from SSM unswitched power 7.5 A fuse [F17])
VCU receives unswitched battery power from main 250 A fuse (F1) at pin 1 of VCU connector 4 (X14) and from SSM 7.5 A fuse
(F17) at pin L1 of VCU connector 1 (X11). VCU ground is provided at pins 3 and 4 of VCU connector 2 (X12) and at pin J1 of VCU
connector 1 (X11).
When engine start switch on SSM is pressed once, current flows from pin 3 of SSM, to coil of ignition relay (K10), energizing the
relay. With ignition relay energized, current flows to VCU at pin M1 connector 1 (X11), providing switched power to VCU.
At the same time, switched battery power becomes available at following components:
Standard Display Monitor (SDM) (A3) (from monitor switched power 5 A fuse [F30])
Forward, Neutral Reverse (FNR) Switch (S5) (from transmission control 5 A fuse [F35])
Gear Select Switch (S6) (from transmission control 5 A fuse [F35])
Alternator (G4) (from alternator excitation diode [V4])
→NOTE:
If a new vehicle control unit (VCU) is installed, VCU software for specific machine requires downloading
from software delivery system (SDS) to load correct vehicle identification. When VCU software download
is completed, switched (ignition) power must be cycled twice for ECU to acquire correct vehicle
identification.
When control units are powered up, VCU requests vehicle and model information from engine control unit (ECU). VCU then
stores vehicle identification in memory and uses saved version upon each power-up.
Auto Shutdown
This feature allows VCU to automatically turn off ignition power and stop engine if machine has been operating at slow idle for
2, 3, 4, 5, 10, 20, 30, or 45 minutes (depending on setting).
Time duration is selectable by accessing SETUP / AUTOSHUTDOWN menu in SDM service menu. See Standard Display Monitor
(SDM)—Machine Options . (Group 9015-16.)
The following conditions are required for activation of auto shutdown:
Engine speed less than 910 rpm.

Engine coolant temperature is greater than or equal to 58°C (136° F).
SSM start button is not pressed.
Transmission is in neutral.
When engine has been operating at slow idle for a set amount of time (2, 3, 4, 5, 10, 20, 30, or 45 minutes), VCU starts a
countdown on auto shutdown timer.
When 30 seconds remains on auto shutdown timer, monitor alarm beeps once and a pop-up displays ENGINE SHUTDOWN 30
PRESS START TO ABORT on SDM, indicating machine is about to shutdown.
As long as engine speed stays below 910 rpm and all other auto shutdown parameters are met, auto shutdown timer continues
to count down. When timer reaches 0, VCU broadcasts a message across CAN to communicate with SSM and ECU, turning off
switched power and stopping engine.
Temporarily increasing engine speed or activating a hydraulic function resets auto shutdown timer.
For more information on ECU, see Engine Control Unit (ECU) Circuit Theory of Operation . (Group 9015-15.)
Economy Mode
This feature is provided to reduce fuel consumption and increase machine productivity.
→NOTE:
Economy mode can only be enabled through service mode menu in monitor. For more information on
monitor service menu, see Standard Display Monitor (SDM)—Machine Options . (Group 9015-16.)
When enabled via standard display monitor (SDM), VCU sends a request across CAN to ECU for limiting maximum engine speed
while in backhoe operation mode and a different limit when in loader operation mode:
When in backhoe operation mode, maximum engine speed is limited to 2000 rpm.
When in loader operation mode and current transmission gear is N, 1 or 2, maximum engine speed is limited to 2100 rpm.
When in loader operation mode and current transmission gear is 3, 4, or 5 maximum engine speed is 2400 rpm.
VCU uses seat position and current transmission gear to determine backhoe or loader operation mode. For more information on
seat position and transmission control, see Hydraulic System Circuit Theory of Operation and Transmission Control Circuit
Theory of Operation
Vehicle Control Unit (VCU) Circuit Theory of Operation—Engine 4045TT096
Vehicle Control Unit (VCU) Circuit Schematic—Power and Ground (4045TT096)
LEGEND:
F1 Main 250 A Fuse
G1 Battery 1
G4 Alternator
K5 Starter Relay
K10 Ignition Relay
M1 Starter Motor
W10 Engine Harness
W14 Cab Harness
W15 Canopy Harness
Vehicle control unit (VCU) acts in conjunction with other electrical components to provide electrical function to the machine.
Major functions VCU controls include: hydraulic system, transmission control, wiper and washer circuits, and horn, lights and
beacons circuits. VCU provides power and ground to these functions and sends and receives signals based on performance.
Operator activates many of these functions using sealed switch module (SSM) (A74). SSM is a device that receives operator
input through momentary switches. SSM transmits switch selection across controller area network (CAN) to VCU. VCU sends
and receives CAN messages at pins A1 and B1 of VCU connector 1 (X11) to communicate with other controllers. For more
information on CAN, see Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.)
VCU interprets CAN signals and determines if input is valid or not. If input is not valid for machine options available or machine
state, input is ignored. If input is valid, appropriate function is activated. SSM then receives confirmation function is activated
and causes appropriate light emitting diode (LED) on switch to illuminate, indicating function has been activated.
VCU collects feedback from various sensors and communicates information with other controllers to display to operator.
VCU communicates much information to standard display monitor (SDM) (A3), where information is displayed. For more
information about SDM, see Standard Display Monitor (SDM) Circuit Theory of Operation . (Group 9015-15.)
VCU contains digital on/off driver outputs controlled based on inputs from sensors and other controllers on machine.
VCU driver output functions include:
Ignition and Accessory Relay Operation

Backup Alarm Operation
Park Brake
Transmission Speed and Direction Operation
Selective Flow Control Operation
Loader Coupler Operation
Window Washer Pump Operation
Front And Rear Wiper Operation

Lights Operation
Differential Lock
Return To Dig Operation
For more information on individual driver outputs:

See Wiper and Washer Circuit Theory of Operation . (Group 9015-15.)
VCU also provides diagnostics in form of diagnostic trouble codes (DTCs) for systems it controls. For more information about
vehicle control unit DTCs, see Vehicle Control Unit (VCU) Diagnostic Trouble Codes . (Group 9001-40.)
Diagnostic trouble code (DTC) conditions.
Open Circuit—An open circuit condition is detected whenever output driver does not pull down as expected when turned
on. When output is turned on, software continues to drive output so a technician can check voltage.
Short to Power—A short to power is detected whenever output is off and feedback circuit detects current.
High Current or Short to Ground—Detection of a high current condition occurs whenever output is turned on and driver
detects an overload or over temperature condition. When high current condition has been detected, output turns off and
only resets when function or engine start switch is cycled on/off.
→NOTE:
When output is turned off because of a high current condition, status LED of corresponding function on
SSM will show function is still on.
For all driver outputs:
An open circuit and a short to power look the same.

A short to ground and an overloaded circuit look the same.
When VCU detects a DTC, condition must be corrected and function cycled before DTC can be cleared. If first DTC for function
is not cleared before another DTC condition occurs, function may have two DTCs, where one DTC is not valid. (Example: Pin
Disconnect Open Circuit and Pin Disconnect High Current DTCs are displayed at the same time.)
VCU Power-Up (Power and Ground)
Unswitched power is supplied to following components:
Starter Motor (M1)

Starter Relay (K5)
Sealed Switch Module (SSM) (A74) (from SSM unswitched power 7.5 A fuse [F17])
VCU receives unswitched battery power from main 250 A fuse (F1) at pin 1 of VCU connector 4 (X14) and from SSM 7.5 A fuse
(F17) at pin L1 of VCU connector 1 (X11). VCU ground is provided at pins 3 and 4 of VCU connector 2 (X12) and at pin J1 of VCU
connector 1 (X11).
When engine start switch on SSM is pressed once, current flows from pin 3 of SSM, to coil of ignition relay (K10), energizing the
relay. With ignition relay energized, current flows to VCU at pin M1 connector 1 (X11), providing switched power to VCU.
At the same time, switched battery power becomes available at following components:
Standard Display Monitor (SDM) (A3) (from monitor switched power 5 A fuse [F30])
Forward, Neutral Reverse (FNR) Switch (S5) (from transmission control 5 A fuse [F35])
Gear Select Switch (S6) (from transmission control 5 A fuse [F35])
Alternator (G4) (from alternator excitation diode [V4])
→NOTE:
If a new vehicle control unit (VCU) is installed, VCU software for specific machine requires downloading
from software delivery system (SDS) to load correct vehicle identification. When VCU software download
is completed, switched power must be cycled twice for ECU to acquire correct vehicle identification.
When control units are powered-up, VCU requests vehicle and model information from engine control unit (ECU). VCU then
stores vehicle identification in memory and uses saved version upon each power-up.
Transmission Control Circuit Theory of Operation
Transmission Control Circuit Theory of Operation
LEGEND:
H3 Backup Alarm
W14 Cab Harness
W15 Canopy Harness
Torque Converter Oil Temperature Sensor (B6)
Torque converter oil temperature sensor (B6) provides analog voltage to vehicle control unit (VCU) (A1) at pin 43 of VCU
connector 3 (X13). VCU converts voltage to temperature and displays on standard display monitor (SDM). SDM displays torque
converter oil temperature anytime temperature exceeds 250°F (121°C) for at least 5 seconds with engine running.
Park Brake
Park brake is used to prohibit vehicle movement when applied, and allow movement when released. Park brake is a spring
applied, hydraulically released brake, requiring hydraulic pressure through park brake release solenoid (Y7) valve to release
brake.
Park brake button is on sealed switch module (SSM). The light emitting diode (LED) on park brake button indicates status of
park brake. When park brake is applied LED is ON solid, when it is released LED is OFF, and when park brake pressure switch
(B13) indicates park brake is applied but VCU is commanding release (park brake status invalid), LED flashes.
→NOTE:
When park brake status is invalid, SDM also flashes park brake indicator although these may not be
synchronized or at the same rate.
VCU controls park brake and sends a periodic controller area network (CAN) message indicating its current status. VCU applies
and releases park brake by controlling park brake release solenoid with both a high side on/off driver connected through pin G4
of VCU connector 1 (X11) and a low side driver connected through pin B4 of VCU connector 1 (X11). When park brake switch on
SSM is pressed for the first time, a park brake release message is sent via CAN to VCU. Control of park brake solenoid valve is
dependent on SSM park brake switch state, engine running state, and park brake pressure switch (B13) status.
Park brake status is broadcast over CAN based on current park brake release solenoid (Y7) state and resulting park brake
pressure switch (B13) status. Upon initial start up, VCU checks status of park brake pressure switch via pin D1 of VCU
connector 1 (X11). Status can be inactive (no pressure), active (pressure applied), or invalid (park brake pressure switch does
not reflect park break release solenoid state).
Park Brake Release: VCU releases park brake by applying current to park brake release solenoid (Y7) when all of the
following conditions exist:
Engine state is engine running.
Park brake release drivers are not shorted.
Park brake switch state changes from not pressed to pressed.

Park Brake Applied: VCU applies park brake by removing current from park brake release solenoid when any of the
following conditions exist:
Engine start switch state is OFF.
Engine state is engine OFF and park brake pressure is applied.
SSM park brake switch is pressed.
Park brake driver is shorted.
VCU removes current from park brake release solenoid if engine state is engine RUNNING and then becomes engine OFF, and
park brake pressure switch indicates park brake is applied. By removing current from park brake release solenoid, VCU ensures
that park brake is applied if engine quits and pressure switch indicates park brake is on.
VCU controls transmission using two high side/low side drivers connected to transmission direction solenoids (Y1 and Y2) and
four on/off drivers connected to transmission speed solenoids (Y3—Y6). Transmission solenoid valves control clutches in
transmission to select transmission speed and direction. Control of solenoids is dependent on:
Forward, neutral, reverse (FNR) switch (S5) position

Gear select switch (S6) position
Park brake status
Clutch disconnect status
Transmission output speed
Engine running state
Power to transmission direction solenoids is controlled by a hardware interlock and a software interlock at pins J4 and M4 from
VCU connector 1 (X11). VCU periodically checks status of inputs at pins C2, A3, and C1 of VCU connector 1 (X11) from FNR
switch and only allows solenoids to be energized if input is determined to be valid. (X) illustrates which inputs are valid for
selected FNR position.
FNR Selector Logic
Forward Switch Reverse Switch Neutral Switch Selected FNR Status
X Neutral Valid
X Reverse Valid
X X Error Invalid
X Forward Valid
X X Error Invalid
X X Error Invalid
X X X Error Invalid
→NOTE:
If seat position is not in forward (or loader position) with engine running and FNR is not in neutral,
standard display monitor (SDM) displays a RETURN TCL TO NEUTRAL pop-up.
VCU receives desired gear range command from gear select switch (S6). Inputs are applied through gear select switch to pins
8, 19, 7, and 20 of VCU connector 2 (X12), depending on gear selected. (X) illustrates which pins are activated for the selected
gear range.
Gear Select Logic
Pin 8-(X12) Pin 19-(X12) Pin 7-(X12) Pin 20-(X12) Selected Gear
X X 1st Gear
X X 2nd Gear
X X 3rd Gear
X X 4th Gear
X X 5th Gear
Any other combinations are considered invalid and VCU generates a diagnostic trouble code (DTC) and places transmission in
neutral.
VCU activates appropriate solenoids to shift transmission into its requested gear except when park brake is on, in which case
no solenoids are active and transmission stays in neutral.
(X) illustrates which solenoid is activated for the selected gear.
Transmission Solenoid Logic
Selected Gear Y1 Y2 Y3 Y4 Y5 Y6
N or Park Brake Applied
1F X X X
2F X X X
3F X X
4F X X
5F X X X
1R X X X
2R X X X
3R X X X
4R X X X
Transmission output speed is monitored by VCU through transmission output speed sensor (B14) and used to control activation
of fifth speed function of transmission. Output speed is also be used for auto shift, differential speed lockout, and some
hydraulic power controls.
When a transmission control solenoid malfunction occurs, VCU generates a diagnostic trouble code (DTC) and deactivates all
transmission solenoids (putting transmission in neutral). To get transmission out of neutral and into limp home mode FNR
switch must be moved to N (neutral) position and then to a desired direction. Any gear can be selected, but only a limited
number of gears are available (based on transmission control solenoid malfunction).
Backup Alarm (H3)
VCU controls backup alarm (H3) by applying power from pin G3 of VCU connector 1 (X11) to backup alarm when FNR switch
(S5) is placed in reverse. VCU does not power backup alarm based on actual transmission direction, but does based on
placement of FNR switch.
Maximum Gear Limit
VCU can limit maximum gear the transmission allows regardless of TCL input, dependent on operator setting in standard
display monitor (SDM). For more information on standard display monitor (SDM). see Standard Display Monitor (SDM)—Machine
Options . (Group 9015-16.)
Auto Shift
VCU has functionality to provide an automatic shift mode in addition to manual shifting. The shift mode is determined based
upon input from SSM. VCU selects current gear based upon autoshift mode, engine speed, transmission output shaft speed,
and engine speed control position.
If autoshift button on SSM is pressed, autoshift mode shall be set to auto 2-D mode and VCU sends a message across CAN
indicating left and right LEDs shall be ON solid. When autoshift is in auto 2-D mode and autoshift button on SSM is pressed and
released, autoshift mode returns to manual and VCU sends a message across CAN indicating left and right LEDs shall be OFF.
While in auto 2-D mode, VCU commands appropriate solenoids to shift when it is required starting with 2nd gear. Maximum
gear allowed by autoshift is determined by the operator selected gear on TCL or maximum gear limit set in SDM.
Differential Lock
Vehicle control unit (VCU) controls differential lock and differential lock speed limit functions based on signal from differential
lock switch (S10) at pin 31 of VCU connector 2 (X12) and output to differential lock solenoid (Y10) from pin 11 of VCU connector
3 (X13). Switch is activated by a switch on the floor of operator station.
VCU also monitors engine speed to disable differential lock when engine speed is over 1000 rpm. When DIFF LOCK SPEED LIMIT
option is enabled in standard display monitor (SDM), VCU sends a signal to SDM to generate an audible alarm in addition to
monitor displaying DIFF LOCK DISABLED DUE TO HIGH SPEED to make operator aware that differential lock is being turned OFF
because engine speed is over 1000 rpm.
If differential lock switch (S10) is held in ON (or closed) position by operator continuously for more than 10 minutes, a time-out
occurs that disengages differential lock function. After switch is maintained in open position continuously for 1 second the
switch may again be engaged.
Vehicle control unit (VCU) controls MFWD function through the status of MFWD switch (S11) and output to MFWD solenoid
(Y11).
When MFWD switch is placed in momentary or ON position, voltage is received at pin 38 of VCU connector 3 (X13) and VCU
recognizes this as change in MFWD status. VCU then applies power from pin 13 of VCU connector 3 (X13) to MFWD solenoid
(Y11). This allows high pressure oil to engage MFWD.
If VCU recognizes MFWD solenoid state and MFWD switch state as not matching, VCU generates a diagnostic trouble code
(DTC).
Mechanical Front Wheel Drive (MFWD) Braking
On machines with MFWD, VCU provides an option to engage front wheels whenever braking. MFWD is activated anytime brakes
are applied in fourth or fifth gear regardless of option state. If option is enabled via SDM, MFWD activates any time brakes are
applied. For more information on setting MFWD braking, see Standard Display Monitor (SDM)—Machine Options . (Group
9015-16.)
Clutch Disconnect
Vehicle control unit (VCU) can remove transmission load from engine in order to utilize all engine power for hydraulics. When
clutch disconnect switch is pressed on loader control lever, current is allowed to flow to pin 23 of VCU connector 3 (X13). When
VCU recieves current it removes power from direction solenoids, placing transmission in neutral. If VCU and clutch disconnect
switch state do not match, VCU generates a diagnostic trouble code (DTC).
Hydraulic System Circuit Theory of Operation
Hydraulic System Circuit Schematic
LEGEND:
B44 Loader Auxilary Flow Control Switch
W14 Cab Harness
W15 Canopy Harness
W26 Loader Coupler Solenoid Harness (if equipped)
W27 Ride Control Solenoid Harness (if equipped)
W28 Selective Flow Solenoid Harness (if equipped)
W29 Loader Auxiliary Solenoid Harness (if equipped)
W30 Pilot Enable Pattern Select Valve Harness (if equipped)
W31 Pilot Enable Switch Harness (if equipped)
Vehicle control unit (VCU) receives inputs and provides outputs that control various solenoids which, in turn control and/or
monitors hydraulic functions on the machine. For more information on VCU, see Vehicle Control Unit (VCU) Circuit Theory of
Operation . (Group 9015-15.)
Seat Position Sensor (B9)
VCU monitors inputs from a 0—240° dual channel Hall effect seat position sensor (B9). VCU uses inputs from seat position
sensor (B9) to enable/disable certain features based on seat position.
A 5 V reference is provided from pin J2 of VCU connector 1 (X11) to pins 3 and 6 of seat position sensor. The VCU provides a
return at pin H2 of VCU connector 1 (X11) from terminals 1 and 4 of seat position sensor.
Two channels are used to communicate seat position to VCU. Channel 1 sends voltage dependent on seat position from
terminal 2 of seat position sensor to pin 37 of VCU connector 2 (X12). At the same time Channel 2 sends voltage from terminal
5 of seat position sensor to pin 48 of VCU connector 2 (X12). Voltages sent from channel 1 and channel 2 should be inversely
proportional in order to provide a valid signal to VCU.
In loader position (full forward), approximately 4 V is supplied to VCU via channel 1 and decreases as seat is rotated toward full
rear facing position. At the same time approximately 1 V is supplied to VCU via channel 2 and increases as seat is rotated from
loader position to full rear facing position.
In full rear facing position, approximately 1 V is supplied to VCU via channel 1 and increases as seat is rotated toward loader
position (full forward). At the same time approximately 4 V is supplied to VCU via channel 2 and decreases as seat is rotated
toward full rear facing position.
At any time, if the sum of channel 1 and channel 2 voltages does not equal the 5 V reference, a diagnostic trouble code (DTC)
is generated by VCU. If voltage is greater than 4.5 V or less than 0.5 V on either channel a DTC is generated. When a DTC is
generated a pop-up stating SEAT SENSOR FAULT is displayed on standard display monitor (SDM).
Hydraulic Oil Filter Restriction Switch (B12)
Hydraulic oil filter restriction switch (B12) is a normally-open switch that applies ground at pin 24 of VCU connector 3 (X13)
when closed. The switch closes when hydraulic oil differential pressure at filter is greater than specification. VCU broadcasts a
message across the CAN to communicate with SDM causing hydraulic oil filter restriction indicator to illuminate.
Loader Coupler Solenoids (if equipped)
Loader coupler solenoids allow the front tool to be hydraulically disengaged from tractor by pressing a switch on sealed switch
module (SSM). When the loader coupler switch on SSM is pressed for 1 second a message is sent across CAN to VCU indicating
the switch has been pressed. VCU applies power to pin 50 of VCU connector 3 (X13) energizing loader coupler pressure
solenoid (Y30) for 5 seconds. VCU also applies power to pin 51 of VCU connector 3 (X13) energizing loader coupler unlock
solenoid (Y29) and disengaging coupler pins. The light emitting diode (LED) on the loader coupler switch illuminates and a pop-
up displays on SDM stating LOADER COUPLER DISENGAGED. An audible alarm sounds for the entire time coupler pins are
disengaged.
Pressing loader coupler switch a second time causes VCU to energize loader coupler pressure solenoid for 5 seconds and de-
energize loader coupler solenoid, engaging loader coupler pins. The LED on loader coupler switch turns OFF.
Hydraulic Pump Unload
VCU uses engine RUNNING state, engine cranking state, and seat position to control hydraulic load on the engine in order to
prevent diesel engine stall. To reduce hydraulic load on engine, VCU applies current through hydraulic pump control solenoid
(Y56) from pin K2 at VCU connector 1 (X11) to pin D4 at VCU connector 1 (X11). When hydraulic pump control solenoid is
energized auxiliary pump flow returns back to inlet through the unloading valve spool. Hydraulic pump control solenoid is
energized when any of the following conditions occur:
Engine cranking.
Engine state is RUNNING and seat position is loader.
Engine state is RUNNING and selective flow control solenoid (Y53) is energized.
For more information on hydraulic pump unload, see Hydraulic Pump Operation . (Group 9025-05.)
Auto-Idle (4045TT096 engine only)
Auto-idle is used to reduce fuel consumption by automatically reducing engine speed to 900 rpm when hydraulic functions are
not being used while in backhoe mode.
Auto-idle can be enabled or disabled in the monitor. See Standard Display Monitor (SDM)—Machine Options . (Group 9015-16.)
Also, the auto-idle threshold pressure setting (hydraulic demand) that sends machine into auto-idle is adjustable in the
monitor.
VCU receives a signal from hydraulic system pressure sensor (B26) at pin 13 of VCU connector 2 (X12) to determine hydraulic
demand. If this value is equal or less than the adjustable pressure auto-idle threshold pressure value for a continuous 5
seconds; machine is considered to be in a no hydraulic demand state.
VCU sends a signal across CAN to ECU requesting to reduce engine speed when all of the following conditions are met:
Engine state is engine running

Auto-idle is enabled in the monitor
Seat position is backhoe
Current gear is neutral
Engine coolant temperature is between 50—113° C (122—235° F) or invalid
Hand throttle status is enabled
An active filter cleaning is not active
Valid hydraulic system pressure sensor value
No hydraulic demand
Engine speed returns to hand throttle setting when hydraulic activity resumes (hydraulic system pressure is greater than auto-
idle threshold pressure), hand throttle command changes by +2%, or any of the previously listed conditions are not met.
Auto-Idle Threshold (adjustable) Pressure 800—2000 kPa
116—290 psi
Threshold (default) Pressure 1500 kPa
218 psi
Ride Control (if equipped)
When ride control switch is pressed on the SSM, the change in status of switch is communicated over CAN to VCU. The VCU
energizes ride control solenoids 1 and 2 (Y50 and Y51) through pin 42 of VCU connector 3 (X13). For more information on ride
control, see Ride Control Operation—If Equipped . (Group 9025-05.)
Selective Flow Control (if equipped)
Selective flow control is an option that allows the operator to control a hammer or other implement installed on machine either
continuously or via a momentary auxiliary hydraulic foot switch (S54). When auxiliary hydraulic foot switch is not installed,
control of selective flow is done solely by the auxiliary hydraulic switch on SSM and is shared with auxiliary loader hydraulics
function. The switch has two modes that can be selected, continuous and proportional. In continuous mode the function
operates at maximum flow while solenoid is energized. In proportional mode maximum flow can be set via standard display
monitor (SDM).
VCU receives inputs from SSM and auxiliary hydraulic foot switch to determine the state of the selecitve flow control solenoid
(Y53). If VCU recognizes the state as active it sends current out pin L3 of VCU connector 1 (X11) and provides ground at pin E4
of VCU connector 1 (X11).
Auxiliary Hydraulic Foot Switch (S54) (if equipped)
Auxiliary hydraulic foot switch (S54) is a normally-open foot-actuated switch. When auxiliary hydraulic switch on SSM is in
either continuous or proportional mode VCU uses input at pin 26 of VCU connector 3 (X13) to select status of selective flow
control function.
Pilot Enable (if equipped)
If equipped, pilot controls can be enabled or disabled by VCU based on inputs received from pilot enable switch (S52), seat
position sensor, or from other controllers.
VCU applies current through pin 28 of VCU connector 3 (X13) to pilot enable solenoid (Y52) based on inputs from pilot enable
switch (S52) at pins 34 and 47 of VCU connector 3 (X13). VCU also uses operator seat position state, engine running state, and
pattern select solenoids 1 and 2 (Y58 and Y59) state to enable or disable pilot control. For more information on pilot control,
see Pilot Control Valve Operation—If Equipped . (Group 9025-05.)
Hydraulic Pattern Select (if equipped)
If equipped with pilot controls, it is possible to change control pattern of backhoe controls via a push-button on the SSM. With
pilot control enabled there are two pattern select modes to toggle between, backhoe mode and excavator mode. While in
backhoe mode the left LED is illuminated and pattern select solenoids 1 and 2 (Y58 and Y59) are not energized. If in backhoe
mode and pattern select push-button on SSM is pressed, left LED shuts off and right LED illuminates. VCU sends current out pin
6 of VCU connector 2 (X12) and energizes pattern select solenoids 1 and 2 (Y58 and Y59). Each subsequent press toggles
between backhoe mode and excavator mode.
At shutdown VCU saves pattern select state in memory and retrieves it when powered-up.
Horn, Lights, and Beacon Circuit Theory of Operation
Lights and Beacon Circuits Theory of Operation
LEGEND:
A9 Radio
E17 Beacon Light
S26 Brake Light Switch 1
W3 Roof Ground
W14 Cab Harness
W15 Canopy Harness
W17 Roof Harness
W18 Radio Harness
Drive Lights
Drive light switch on sealed switch module (SSM) controls drive lights, marker lights, and tail lights. When switch is pressed for
less than 2 seconds VCU turns on left front marker light (E33), license plate light (E41), and both left and right tail lights (E37
and E40) through pin 8 of VCU connector 3 (X13) while illuminating left light emitting diode (LED) on switch. If pressed a
second time for less than 2 seconds, VCU turns on left and right front drive lights (E31 and E32) through pins 18 and 30 of VCU
connector 3 (X13), while illuminating middle LED on switch. Drive lights have a high and low setting controlled by drive light
high/low switch (S19). A subsequent press of drive light switch commands both marker lights and drive lights off.
→NOTE:
On cab machines power is also supplied to radio (A9) for illumination via marker lights circuit.
If front work lights switch is held for more than 2 seconds, VCU removes power from pins 8, 18, and 30 of VCU connector 3
(X13) shutting off marker lights and drive lights.
Work Lights and Docking Lights
Work lights switch on SSM has six modes:
Rear Work Lights On: When work light switch on SSM is pressed so only right LED illuminates, VCU sends current out pins
2 and 3 of VCU connector 3 (X13) to rear work lights (E1—E4), causing rear work lights to come on.
Docking Lights On: When work light switch on SSM is pressed a second time so right and middle LED illuminates, VCU
applies current to pins 17 and 53 of VCU connector 3 (X13), causing left and right docking lights (E15 and E16) to come
on.
Front Work Lights On: When work light switch on SSM is pressed a third time so only left LED illuminates, VCU shuts off
rear work lights and docking lights. VCU also sends current out pins 4 and 5 of VCU connector 3 (X13) to front work lights
(E5—E8). Causing front work lights to come on.
Front Work Lights and Docking Lights On When work light switch on SSM is pressed a fourth time so left and middle LEDs
are illuminated, VCU applies power to pins 17 and 53 of VCU connector 3 (X13), causing left and right docking lights to
come on while front work lights remain on.
All Work Lights and Docking Lights On When work light switch on SSM is pressed a fifth time so all LEDs are illuminated,
VCU sends current out pins 2 and 3 of VCU connector 3 (X13) to rear work lights (E1—E4) in addition to front work lights
and docking lights.
Lights Off Regardless of current state, if work light switch on SSM is held for 2 seconds or longer, VCU shuts off all work
lights, docking lights, and marker lights.
Anytime VCU detects a light bulb as faulted a DTC is generated, standard display monitor (SDM) displays a pop-up and an
audible alarm sounds.
Brake Lights
When a brake pedal is pressed and either service brake pressure switches 1 or 2 (S26 or S27) is closed to ground, VCU
recognizes circuit being pulled down at pin F3 of VCU connector 1 (X11) and sends current out pin 41 of VCU connector 3 (X13)
to left and right brake lights (E37 and E40).
Anytime VCU detects a brake light as faulted a DTC is generated, SDM displays a pop-up stating BRAKE LIGHT BULB MISSING
and an audible alarm sounds.
Beacon Light
Beacon light (E17) is controlled by VCU via beacon light switch (S47). When VCU is powered-up and beacon light switch is in
OFF (open) position, VCU recognizes beacon state as off at pin 45 of VCU connector 3 (X13). With beacon light switch in ON
(closed) position, ground is provided to pin 45 of VCU connector 3 (X13) and VCU recognizes beacon state as on. When beacon
state is on, current is sent through pin 1 of VCU connector 3 (X13) to beacon light (E17), causing beacon to come on.
Turn signals
Turn signals are controlled by turn signal switch (S30) and VCU.
Left Turn: When ignition (switched) power is ON and turn signal switch is moved to left-turn position, ground is supplied at
terminal 3 of turn signal switch, pulling down circuit at pin E2 of VCU connector 1 (X11).
When VCU detects system being pulled down at pin E2 of VCU connector 1 (X11), it sends pulsing current with a 50% duty
cycle from pin 30 of VCU connector 3 (X13) to left rear and left front turn signals (E39 and E36) (respectively), causing left turn
signals to flash.
Right Turn: When ignition (switched) power is ON and turn signal switch is moved to right-turn position, ground is supplied at
terminal 1 of turn signal switch, pulling down the circuit at pin D3 of VCU connector 1 (X11).
When VCU detects system being pulled down at pin D3 of VCU connector 1 (X11), it sends pulsing current with a 50% duty
cycle from pin 18 of VCU connector 3 (X13) to right rear and right front turn signals (E38 and E35) (respectively), causing right
turn signals to flash.
When ignition (switched) power is ON and hazard warning signal switch on sealed switch module (SSM) is pressed, SSM sends a
signal across CAN data line to VCU, requesting hazard warning signals.
When VCU determines that input is valid, VCU sends a signal back across CAN data line to SSM, causing LED on hazard warning
signal switch to come on.
VCU then sends pulsing current with a 50% duty cycle to turn signals (E35, E36, E38, and E39), causing all four lights to flash at
the same time.
Hazard Warning Signal and Turn Signals Activated at Same Time: If left turn signal is selected when hazard warning signals are
active, VCU sends current to turn signals as follows:
Pulsing current to left turn signals (E36 and E39).

Continuous current to right turn signals (E35 and E38).
If right turn signal is selected when hazard warning signals are active, VCU sends current to turn signals as follows:
Pulsing current to right turn signals (E35 and E38).

Continuous current to left turn signals (E36 and E39).
VCU Wakeup: Hazard warning signals can be activated when ignition (switched) power is OFF. Pressing hazard warning signal
switch on SSM when ignition is OFF causes SSM to send a “wakeup” signal to VCU. When VCU detects this signal, it sends
pulsing current to all front and rear turn signals.
Wiper and Washer Circuit Theory of Operation
Wiper and Washer Circuit Schematic

LEGEND:

W14 Cab Harness
Front Wiper Motor (M13)
When front wiper switch on sealed switch module (SSM) is pressed so one, two, or three light emitting diodes (LEDs) are
illuminated, vehicle control unit (VCU) sends current out pin 2 or 5 of VCU connector 2 (X12) depending on wiper mode.
Front wiper switch has three modes:
Intermittent
Low
High
Wiper Motor Intermittent Speed Mode: When front wiper switch on SSM is pressed once so only left LED illuminates, VCU
supplies power at pin 2 of VCU connector 2 (X12) to activate the front wiper motor (M13) in low speed. VCU provides power to
wiper motor for one complete cycle until VCU detects an open circuit at pin 21 of VCU connector 3 (X13) from a park switch,
internal to wiper motor, indicating wiper has returned to the park position.
VCU stops current flow out pin 2 of VCU connector 2 (X12) when VCU detects wiper has reached park position. VCU then waits
for 2—10 seconds, depending on delay setting, before sending current out pin 2 of VCU connector (X12) again to repeat
intermittent cycle. Wiper delay setting can be changed by accessing MAIN MENU—SETUP—WIPER DELAY submenu of SDM
menu structure. See Standard Display Monitor (SDM)—Main Menu—Setup—Wiper Delay . (Operator’s Manual.)
Wiper Motor Low Speed Mode: If front wiper switch on SSM is pressed a second time, VCU applies power to wiper motor via pin
2 of VCU connector 2 (X12) setting wiper motor on low speed. VCU also sends a message to SSM illuminating left and center
LEDs.
Wiper Motor High Speed Mode: If front wiper switch on SSM is pressed a third time, VCU removes power from pin 2 of VCU
connector 2 (X12) and applies power to pin 5 of VCU connector 3 (X13) turning wiper motor on high speed. VCU also sends a
message to SSM illuminating all three LEDs.
If front wiper switch is pressed while in high speed mode or held for two seconds at any time, VCU removes power from pin 5 of
VCU connector 2 (X12) and applies power to pin 2 until park switch is observed as open. When VCU observes park switch as
open, power is removed from both pins and SSM is commanded to shut off all LEDs.
Rear Wiper Motor (M14)
When rear wiper switch on SSM is pressed so one or two LEDs illuminate, VCU sends current out pin 1 of VCU connector 2
(X12). VCU also reads status of a rear wiper enable switch (S14) at pin 9 of VCU connector 3 (X13). With rear window closed,
rear wiper enable switch is closed to ground and wipers are enabled. With window open, switch is observed as open and rear
wipers are disabled.
Rear wiper switch has two modes:
Intermittent
Low
Wiper Motor Intermittent Speed Mode: When rear wiper switch on SSM is pressed once so only left LED is illuminated, VCU
applies power at pin 1 of VCU connector 2 (X12) to activate rear wiper motor in low speed. VCU provides power to wiper motor
for one complete cycle until VCU detects an open circuit at pin 20 of VCU connector 3 (X13) from a park switch, internal to
wiper motor, indicating wiper has returned to park position.
VCU stops current flow out pin 1 of VCU connector 2 (X12) when VCU detects wiper has reached park position. VCU then waits
for 2—10 seconds, depending on delay setting, before sending current out pin 2 of VCU connector (X12) again to repeat
intermittent cycle. Wiper delay setting can be changed by accessing MAIN MENU—SETUP—WIPER DELAY submenu of SDM
menu structure. See Standard Display Monitor (SDM)—Main Menu—Setup—Wiper Delay . (Operator’s Manual.)
Wiper Motor Low Speed Mode: If wiper switch on SSM is pressed a second time, VCU supplies power to wiper motor via pin 1 of
VCU connector 2 (X12) turning wiper motor on low speed. VCU also sends a message to SSM illuminating left and right LEDs.
Front Washer Motor (M15)
Pressing windshield washer switch on SSM supplies power to front washer motor (M15) while switch is held down and removes
power when switch is released. If front wiper motor is off, power is supplied through pin 2 of VCU connector 2 (X12) while
washer switch is held and remains for 3 complete wipe cycles after switch is released. If intermittent wiper function is active,
motor turns on in low speed for three complete cycles before returning to intermittent mode. If either low or high speed wiper
function is active, wiper motor continues to run at set speed.
Standard Display Monitor (SDM) Circuit Theory of Operation
Standard Display Monitor (SDM) Circuit Theory of Operation

LEGEND:
1 Controller Area Network (CAN) 1
Section 9015 - ELECTRICAL SYSTEM Group 16: Monitor Operation

H1 Monitor Alarm
W14 Cab Harness
W15 Canopy Harness
Standard Display Monitor (SDM) (A3)
SDM receives battery power from monitor unswitched power 5 A fuse (F15) at pin A of SDM connector 1 (X4). System ground is
available at pin P of SDM connector 1 (X4). SDM receives switched power from monitor switched power 5 A fuse (F30) at pin L
of SDM connector 1 (X4).
When powered-up, SDM performs a self-test by activating all indicators: lights, gauges, and the monitor display window.
SDM contains a menu structure designed for monitoring certain machine functions for operational and/or diagnostic purposes.
It provides a means for viewing and clearing diagnostic trouble codes (DTCs) and also provides a means for adjusting certain
machine and monitor settings. For more information on SDM menu structure, see Standard Display Monitor (SDM)—Service
Menu . (Group 9015-20.)
SDM uses controller area network (CAN) data line to communicate with various controllers on machine. For more information
on CAN system, see Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.)
Fuel Level Sensor (B8)
Fuel level sensor (B8) is a resistive (rheostat) type sensor attached to a float. Changing fuel level causes float to move up and
down relative to fuel level. The float moves a wiper in the rheostat causing resistance to change relative to movement of float.
Resistance is sensed by SDM at pin N of SDM connector 1 (X4). SDM uses this information to determine position of needle on
fuel gauge and moves needle accordingly.
Monitor Alarm (H1)
Monitor alarm (H1) is activated during monitor self test, during certain monitor selections, and when the STOP indicator is
illuminated. Power is provided to monitor alarm and to pin A of SDM connector (X4) from monitor switched power 5 A fuse
(F15). SDM provides ground at pin E of SDM connector (X4) to make alarm sound.
Group 16 - Monitor Operation

Standard Display Monitor (SDM)—Service Menu
There are two versions of the standard display monitor (SDM) menu structure: Operator Menu and Service Menu.
Operator Menu— is used to change user preferences, view operational settings, and view diagnostic trouble codes (DTCs).
For additional information, see Standard Display Monitor (SDM)—Normal Display and see Standard Display Monitor
(SDM)—Main Menu—Operation . (Operator’s Manual.)
Service Menu— provides additional menu items not available in the operator menu. This feature allows a service technician to
change operational settings and clear diagnostic trouble codes (DTCs). The service menu provides the technician a means to
monitor functions and settings for diagnostic and testing purposes.
Press and hold the MENU button for approximately 5 seconds to place SDM in SERVICE MENU mode. SDM will display SERVICE
MENU for 2 seconds before returning to previous screen.
→NOTE:
When the Service Menu is accessed, the SDM will stay in the service menu even if the SDM display is
returned to the operator display. Cycling the switched power to OFF, then back to ON resets the SDM to
the Operator Menu.
There are four buttons on the SDM used to navigate the Service Menu:
MENU—Provides initial entry into machine settings, diagnostics, and monitor functions.
BACK—Display goes back to the last active menu each time the button is pushed.
NEXT—Display goes to the next selection within a menu or mode. Press the NEXT button to cycle through all the possible
selections in a menu.
SELECT—Activates the current highlighted submenu.
Standard Display Monitor (SDM)—Clear Codes

This menu will clear all stored and active diagnostic trouble codes (DTCs).
The CLEAR CODES menu is a function of the Service Menu. See Standard Display Monitor (SDM)—Service Menu . (Group
9015-16.)
To Clear DTCs:
[1] - Press and hold the MENU button for approximately 5 seconds to place SDM in SERVICE MENU mode. SDM will display
SERVICE MENU for 2 seconds before returning to previous screen.
[2] - From MAIN MENU press NEXT button until DIAGNOSTICS is highlighted, then press the SELECT button.
[3] - Press NEXT button until CODES is highlighted, then press the SELECT button.
[4] - CODES screen is displayed, press NEXT button to display CLEAR CODES screen
→NOTE:
To exit without clearing codes, press the BACK button.
[5] - To clear codes press SELECT button. CODES CLEARED is displayed for 2 seconds before returning to CLEAR CODES
screen.
Standard Display Monitor (SDM)—Diagnostics

The main menu DIAGNOSTICS submenu is a function of the Service Menu. See Standard Display Monitor (SDM)—Service Menu .
(Group 9015-16.)
To access Diagnostics submenu:
[2] - From MAIN MENU press NEXT button until DIAGNOSTICS is highlighted, then press SELECT button.
[3] - Press NEXT button until desired submenu is highlighted.
[4] - Press SELECT to make submenu active in the display. To exit DIAGNOSTICS menu, press BACK button.
The following submenus are available from DIAGNOSTICS menu:
1. CODES
2. ENGINE
3. ELECTRICAL
4. LIGHTS
5. TRANSMISSION
6. HYDRAULICS
7. SOFTWARE VERSION
8. BUTTONS
9. SENSORS
10. SERVICE ADVISOR INFO
11. TESTS
[1] - CODES— Displays status of diagnostic trouble codes (DTCs) active and stored. Enables active and stored codes to be
cleared.
→NOTE:
Active and stored codes can be viewed in normal display mode.
CODES ACTIVE STORED—Displays status of DTCs that are currently active and stored in the SDM and the source
controller (controller reporting the problem). The codes are listed in order, starting with the most recent fault.
CLEAR CODES—Clears active and stored codes in the SDM. See Standard Display Monitor (SDM)—Clear Codes . (Group
9015-16.)
[2] - ENGINE— Displays status of sensors and switches monitored by engine control unit (ECU).
ECU ELEC POWER—Displays battery and switched voltage to ECU as BATTERY XX.X V and SWITCHED XX.X V.
THROTTLE—Displays throttle percentage as measured by engine speed control dial for hand and engine speed control
pedal for foot as HAND XXX% and FOOT XXX%.
ENGINE COOLANT TEMP—Displays engine coolant temperature as measured by engine coolant temperature sensor as
XXX F.
WATER IN FUEL—Displays signal from water-in-fuel sensor as WATER DETECTED or WATER NOT DETECTED.
FUEL TEMPERATURE—Displays fuel temperature as measured by fuel temperature sensor as XXX F.
MANIFOLD AIR TEMP—Displays manifold air temperature as measured by manifold air temperature sensor as XXX F.
FUEL RATE—Displays fuel usage in gallons per hour as XXX G/HR.
[3] - ELECTRICAL— Displays the status of switches and relays monitored by vehicle control unit (VCU).
VCU ELEC POWER—Displays battery and switched voltage to vehicle control unit (VCU) as BATTERY XX.XX V and
SWITCHED XX.XX V.
VCU VALVE POWER—Displays voltage to VCU valve power as XX.XX V.
ALTENATOR STATE—Displays alternator status as ON, OFF, or FAULTED.
ACCESSORY RELAY—Displays status of accessory relay as ON, OFF, or FAULTED and amperage drawn as XX.XX A.
FRONT WASHER (if equipped)—Displays status of front washer as ON, OFF, or FAULTED and amperage drawn as XX.XX A.
FRONT WIPER LOW (if equipped)—Displays status of front wiper low as ON, OFF, or FAULTED and amperage drawn as
XX.XX A.
FRONT WIPER HIGH (if equipped)—Displays status of front wiper high as ON, OFF, or FAULTED and amperage drawn as
XX.XX A.
REAR WIPER (if equipped)—Displays status of rear wiper as ON, OFF, or FAULTED and amperage drawn as XX.XX A.
WIPER PARK SWITCHES (if equipped)—Displays status of wiper park switches FRONT and REAR as ON or OFF.
BACKUP ALARM—Displays status of backup alarm as ON or OFF and milliamperes drawn as XXXX MA.
[4] - LIGHTS— Displays status of VCU (A1) outputs and switches to lights.
TURN SIGNAL SWITCH—Displays status of turn signal switch LEFT and RIGHT as ON or OFF.
LEFT TURN SIGNAL—Displays status of left turn signal as ON, OFF, or FAULTED and amperage drawn as XX.XX A.
RIGHT TURN SIGNAL—Displays status of right turn signal as ON, OFF, or FAULTED and amperage drawn as XX.XX A.
MARKER LIGHT (if equipped)—Displays status of marker light as ON, OFF, or FAULTED and amperage drawn as XX.XX A.
FRONT INNER WORK LT—Displays status of front inner work light as ON, OFF, or FAULTED and amperage drawn as XX.XX
A.
FRONT OUTER WORK LT—Displays status of front outer work light as ON, OFF, or FAULTED and amperage drawn as XX.XX
A.
REAR INNER WORK LT—Displays status of rear inner work light as ON, OFF, or FAULTED and amperage drawn as XX.XX A.
REAR OUTER WORK LT—Displays status of rear outer work light as ON, OFF, or FAULTED and amperage drawn as XX.XX A.
DOCKING LIGHT 1—Displays status of docking light 1 as ON, OFF, or FAULTED and amperage drawn as XX.XX A.
DOCKING LIGHT 2—Displays status of docking light 2 as ON, OFF, or FAULTED and amperage drawn as XX.XX A.
BRAKE LIGHT SWITCH—Displays status of brake light switch 1 and brake light switch 2 as ON, OFF, or FAULTED.
BRAKE LIGHT—Displays status of brake light as ON, OFF, or FAULTED and amperage drawn as XX.XX A.
DRIVE LIGHT 1 (if equipped)—Displays status of drive light 1 as ON, OFF, or FAULTED an amperage drawn as XX.XX A.
DRIVE LIGHT 2 (if equipped)—Displays status of drive light 2 as ON, OFF, or FAULTED and amperage drawn as XX.XX A.
BEACON SWITCH (if equipped)—Displays status of beacon switch as ON, OFF, or FAULTED.
BEACON LIGHT (if equipped)—Displays status of beacon light as ON, OFF, or FAULTED and amperage drawn as XX.XX A.
BACKUP LIGHT (if equipped)—Displays status of backup light as ON, OFF, or FAULTED and amperage drawn as XX.XX A.
BUCKET LEVEL LEDS—Displays status of bucket level LEDs ABOVE and BELOW as ON, OFF, or FAULTED.
[5] - TRANSMISSION— Displays status of transmission sensors and switches monitored by VCU (A1).
GEAR—Current gear of transmission.

DIRECTION & GEAR—Displays status of gear selected and engaged as 0 = error, 1, 2, 3, 4 and direction - - - = error,
F, N, R.
GEAR SWITCHES—Displays status of gear switch B1, B2, B3, and B4 as ON or OFF.
PARK BRAKE—Displays status of park brake switch and driver.
PARK BRAKE PRESS SWITCH—Displays status of park brake switch as ON, OFF, or FAULTED.
PARK BRAKE DRIVER—Displays status of park brake driver as ON, OFF, or FAULTED and amperage drawn as XX.XX
A.
TRANS SOLENOIDS—Displays status of transmission solenoids.
FORWARD — Y1 SOLENOID—Displays status of transmission solenoid Y1 as ON or OFF and amperage drawn as
XX.XX A.
REVERSE — Y2 SOLENOID—Displays status of transmission solenoid Y2 as ON or OFF and amperage drawn as XX.XX
A.
Y3 SOLENOID—Displays status of transmission solenoid Y3 as ON or OFF and amperage drawn as XX.XX A.
CLUTCH DISCONNECT—Displays status of clutch disconnect switch as SWITCH and STATUS and ON or OFF.
MFWD—Displays status of the MFWD switch and driver.
MFWD SWITCH—Displays status of the MFWD switch as ON, OFF or FAULTED.
MFWD DRIVER—Displays status of the MFWD driver as ON, OFF or FAULTED an amperage drawn as XX.XX A.
DIFF LOCK—Displays status of differential lock and differential lock switch.
DIFF LOCK SWITCH—Displays status of differential lock switch as ON or OFF.
DIFF LOCK—Displays status of differential lock as ON, OFF, or FAULTED and amperage drawn as X.XX A.
TRANS CONVERTOR TEMP—Displays transmission convertor temperature as measured by torque converter oil
temperature sensor.
OUTPUT SHAFT SPEED—Displays transmission output shaft speed in RPMs as measured by the transmission speed sensor.
[6] - HYDRAULIC— Displays status of hydraulic sensors and switches.
SWITCHES—Displays status of hydraulic switches as ON or OFF.
HYD FILTER SWITCH—Displays status of hydraulic oil filter restriction switch as ON or OFF.
LOADER AUX SWITCH (if equipped)—Displays status of loader auxiliary on/off switch CONTINUOUS and
PROPORTIONAL as ON or OFF.
FOOT SWITCH (if equipped)—Displays status of auxiliary hydraulic foot switch as ON or OFF.
PRESSURES—Displays hydraulic system pressures.
HAMMER PRESSURE—Displays backhoe flow control work port pressure by backhoe flow control work port pressure
sensor as XXXXX PSI.
VALVE DATA—Displays threshold and feedback currents of valve solenoids.
LOADER AUX (if equipped)—Displays threshold and feedback currents of loader auxiliary valve solenoid.
HAMMER (if equipped)—Displays feedback current of selective flow control valve in milliamperes (mA) as XXXX MA.
FEEDBACK CURRENT—Displays loader auxiliary function magnitude and direction in milliamperes (mA) as MAG XXXX
MA and DIR XXXX MA.
FWD THRESHOLD—Displays loader auxiliary forward function start and maximum threshold current in milliamperes
(mA) as START XXXX MA and MAX XXXX MA.
REV THRESHOLD—Displays loader auxiliary reverse function start and maximum threshold current in milliamperes
(mA) as START XXXX MA and MAX XXXX MA.
PILOT ENABLE (if equipped)—Displays status of pilot switch and solenoid.
PILOT ENABLE SWITCH—Displays the status of pilot enable switch MOMENTARY and DETENT as ON or OFF.
PILOT ENABLE SOL—Displays the status of pilot enable solenoid as ON, OFF, or FAULTED and amperage drawn as
XX.XX A.
RIDE CONTROL (if equipped)—Displays the status of ride control solenoid 1 as ON, OFF, or FAULTED and amperage drawn
as XX.XX A.
HYD PUMP CONTROL—Displays the status of hydraulic pump control amperage drawn as XX.XX A.
PATTERN SELECT—Displays pattern select on = excavator and off = backhoe as ON or OFF.
LOADER COUPLER (if equipped)—Displays the status of loader coupler solenoids.
LOADER COUPLER—Displays the status of loader coupler unlock solenoid as ON or OFF and amperage drawn as
XX.XX A.
LOADER COUPLER PRESS—Displays the status of loader coupler pressure solenoid as ON or OFF and amperage
drawn as XX.XX A .
[7] - SOFTWARE VERSION— Displays the software version numbers of installed controllers.
VCU SW VERSION—Software version number of vehicle control unit (VCU).

ECU SW VERSION—Software version number of engine control unit (ECU).
SDM SW VERSION—Software version number of standard display monitor (SDM).
SSM SW VERSION—Software version number of sealed switch module (SSM).
[8] - BUTTONS— Displays the status of switches on the sealed switch module (SSM).
SSM—Displays a grid of dashes that blank out corresponding dash when a switch on the SSM is depressed.
[9] - SENSORS— Displays the status of seat, fuel, boom, and bucket sensors.
SEAT POSITION—Displays the seat position as measured by seat position sensor as BACKHOE, MIDDLE, FORWARD, or
LOADER.
SEAT SENSOR—Displays the output voltage of the seat sensor channel 1 and seat sensor channel 2 as CH 1 X.XXX V
and CH2 X.XXX V.
FUEL GAUGE—Displays the status of fuel gauge percent full and output voltage of fuel level sensor as XX.X% and X.XXX
V.
[10] - SERVICE ADVISOR INFO— Displays the submenu SYSTEM INFO.
SYSTEM INFO—Displays the sub menus for Service ADVISOR ™ system information.
CELL STRENGHT—Displays status of cell strength.
CARRIER—Displays carrier ID number.
REGISTRATION STATE—Displays if system is registered.
LATITUDE—Displays GPS latitude.
LONGITUDE—Displays GPS longitude.
GPS ANTENNA—Displays GPS antenna status as UNKNOWN, OK, SHORT, or OPEN.
CELL ANTENNA—Displays cell antenna status.
SATELLITE MODEM—Displays satellite modem status as GOOD or NOT GOOD.
SATELLITE SIGNAL—Displays satellite signal status as REGISTERED or NOT REGISTERED.
SBD REGISTRATION—Displays SBD registration as GOOD or NOT GOOD.

TIME STAMP— Displays time stamp as year, month, day, hour (24 hour clock) and minutes as XXXX:XX:XX:XX:XX.
[11] - TESTS— Displays the sub menus VCU OUTPUTS and HVC OUTPUTS.
VCU OUTPUTS—Displays the submenu for VCU output test.

STEP XX—Steps through VCU output test will return CHECK CODES or ALL OUTPUTS PASSED KEY OFF.
Standard Display Monitor (SDM)—Main Menu Visible or Hidden

The main menu on the standard display monitor (SDM) can be made accessible or hidden from view using the VISIBLE or
HIDDEN options within MENU ACCESS submenu.
The MONITOR HIDDEN and MONITOR VISIBLE submenus are functions of the Service Menu. See Standard Display Monitor
(SDM)—Service Menu . (Group 9015-16.)
MAIN MENU HIDDEN
[1] - Press and hold MENU button for approximately 5 seconds to place SDM in SERVICE MENU mode. SDM will display SERVICE
[2] - From MAIN MENU, press NEXT button until SETUP is highlighted, then press SELECT button.
[3] - Press NEXT button until MONITOR is highlighted, then press SELECT button.
[4] - Press NEXT button until MENU ACCESS is highlighted, then press SELECT button.
→NOTE:
To exit without hiding main menu, press the BACK button.
[5] - Press NEXT button until HIDDEN is highlighted, then press SELECT button.
[6] - MENU ACCESS HIDDEN displayed for 2 seconds before returning to MONITOR submenu.
MAIN MENU VISIBLE
[1] - Push and hold MENU button for approximately 5 seconds to place SDM in SERVICE MENU mode. SDM will display SERVICE
[2] - From the MAIN MENU, press NEXT button until SETUP is highlighted , then press SELECT button.
[4] - Press NEXT button until MENU ACCESS is highlighted, then press SELECT button.
→NOTE:
To exit without enabling main menu visibility, press the BACK button.
[5] - Press NEXT button until VISIBLE is highlighted, then press SELECT button.
[6] - MENU ACCESS VISIBLE displayed for 2 seconds before returning to MONITOR submenu.
Standard Display Monitor (SDM)—Restore Monitor Defaults

The FACTORY DEFAULTS submenu is a function of the Service Menu. See Standard Display Monitor (SDM)—Service Menu .
(Group 9015-16.)
Monitor is defaulted to English units, English language, and a visible main menu.
To Restore Monitor Defaults:
[2] - From the MAIN MENU press NEXT button until SETUP is highlighted, then press SELECT button.
[4] - Press NEXT button until FACTORY DEFAULTS is highlighted, then press SELECT button.
[5] - FACTORY DEFAULTS RESTORE DEFAULTS displayed.
→NOTE:
To exit without restoring the monitor defaults, press the BACK button.
[6] - To reset factory defaults press SELECT.
[7] - FACTORY DEFAULTS—DEFAULTS RESTORED displayed for 2 seconds before returning to MONITOR submenu.
Standard Display Monitor (SDM)—Machine Options

→NOTE:
Monitor options listed are dependent on machine model and configuration. If machine is not equipped
with option, option will not show up in menu.
To access SETUP submenus:
[1] - From MAIN MENU, press NEXT button until SETUP is highlighted, then press SELECT button.
[2] - Press NEXT button until desired submenu is highlighted.
[3] - Press SELECT button to make submenu active in the display. To exit SETUP submenu, press BACK button.
The following submenus are available from the SETUP menu:

MONITOR
WIPER DELAY
MFWD BRAKING
SECURITY (if equipped)
AUTO SHUTDOWN
AUTO IDLE
CALIBRATIONS
ECONOMY MODE
SELECTIVE FLOW (if equipped)
LOADER AUX SPEED (if equipped)
BACKHOE AUX SPEED (if equipped)
GEAR LIMIT
DIFF LOCK SPD LIMIT
TIRE SIZE
BEACON LIGHT (if equipped)
MONITOR
The following submenus are accessible from the MONITOR submenu:
LANGUAGE
UNITS
CONTRAST
JOB TIMER
MENU ACCESS
FACTORY DEFAULTS
LANGUAGE
1. From MONITOR submenu, press NEXT button until LANGUAGE is highlighted, then press SELECT button.
2. Press NEXT button until desired language is highlighted, then press SELECT button.
3. Display will show LANGUAGE <RESULT> SELECTED for 2 seconds then return to MONITOR submenu.
UNITS
1. From MONITOR submenu, press NEXT button until UNITS is highlighted, then press SELECT button.
2. Press NEXT button to highlight ENGLISH or METRIC, then press SELECT.
3. Display will show UNITS <RESULT> SELECTED for 2 seconds, then return to MONITOR submenu.
CONTRAST
1. From MONITOR submenu, press NEXT button until CONTRAST is highlighted, then press SELECT button.
2. Press NEXT button to increase contrast and BACK button to decrease contrast.
3. When display is at desired contrast press SELECT button to store and SDM will return to MONITOR submenu.
JOB TIMER
1. From MONITOR submenu, press NEXT button until JOB TIMER is highlighted, then press SELECT button.
2. Press NEXT button to highlight VISIBLE or HIDDEN, press SELECT button to display or hide job timer.
3. Display will show JOB TIMER <VISIBLE/HIDDEN> for 2 seconds, then return to MONITOR submenu.
MENU ACCESS
1. Press and hold the MENU button for approximately 5 seconds to place SDM in SERVICE MENU mode. SDM will display
SERVICE MENU for 2 seconds before returning to previous screen. See Standard Display Monitor (SDM)—Service Menu .
(Group 9015-16.)
2. From MONITOR submenu, press NEXT button until MENU ACCESS is displayed, then press SELECT button.
3. Press NEXT button to highlight VISIBLE or HIDDEN, press SELECT button to display or hide menu access.
4. Display will show MENU ACCESS <VISIBLE/HIDDEN> for 2 seconds, then return to MONITOR submenu.
FACTORY DEFAULTS
To set factory defaults, see Standard Display Monitor (SDM)—Restore Monitor Defaults . (Group 9015-16.)
WIPER DELAY
1. Press NEXT button until WIPER DELAY is highlighted, then press SELECT button.
2. FRONT WIPER DELAY will be displayed. Enter delay for front wiper in 0.5 second increments with a range of 2 to 20
seconds. Press NEXT button to increment and BACK button to decrement number in the active field, then press SELECT
button.
3. Press NEXT button to highlight REAR WIPER DELAY. Enter delay for rear wiper in 0.5 second increments with a range of 2
to 20 seconds. The NEXT button increments the current digit; the BACK button decrements the current digit in the active
field, then press SELECT button.
MFWD BRAKING
1. Press NEXT button until MFWD BRAKING is highlighted, then press SELECT button.
2. Press NEXT button to highlight ON or OFF, then press SELECT button to make choice.
3. Display will show MFWD BRAKING <ON/OFF> for 2 seconds, then return to SETUP menu.
SECURITY (if equipped) To set security options, see Security System Configuration . (Group 9015-16.)
AUTO SHUTDOWN—
(Group 9015-16.)
2. Press NEXT button until AUTO SHUTDOWN is highlighted, then press SELECT button.
3. Press NEXT to highlight one of the following choices:
OFF
2 MINUTES
3 MINUTES
4 MINUTES
5 MINUTES
10 MINUTES
20 MINUTES
30 MINUTES
45 MINUTES
4. When choice is highlighted, press SELECT button.
AUTO IDLE
1. Press NEXT button until AUTO IDLE is highlighted, then press SELECT button.
2. Press NEXT button to highlight ENABLE or DISABLE, then press SELECT button to make choice.
3. Display will show SAVING SELECTION <ENABLE/DISABLE> for 2 seconds, then return to SETUP menu.
AUTO IDLE SETTINGS
1. Press NEXT button until AUTO IDLE SETTING, then press SELECT button.
2. Press NEXT button until RESET TO FACTORY is highlighted, then press SELECT button to make choice.
3. Press NEXT button until CHANGE SETTING is highlighted, then press SELECT button.
4. Use keypad on SSM to input desired setting and press SELECT button. Settings range from 800—2000 kPa (116—290 psi)
in units of 10 kPa (1.5 psi).
CALIBRATIONS
1. Press NEXT button until CALIBRATIONS is highlighted, then press SELECT button.
2. Press NEXT button until SEAT SENSOR is highlighted, then press SELECT button.
3. Follow the instructions displayed on the SDM.
4. When complete, SDM will display FAILED TO CALIBRATE CHECK CODES or SUCCESSFUL PRESS SELECT TO SAVE.
5. Press SELECT button to save.
ECONOMY MODE
1. Press NEXT button until ECONOMY MODE is highlighted, then press SELECT button.
2. Press NEXT button to highlight OFF or ON, then press SELECT button to make choice.
SELECTIVE FLOW (if equipped)

Flow rate may be adjusted manually or electronically depending on type of selective flow control valve section machine is
equipped with. This procedure is to adjust flow electronically. For manual adjustment procedure, see Auxiliary Selective Flow
Control Valve Adjustment—If Equipped . (Group 9025-20.)
→NOTE:
Flow rate unit displayed (LPM or GPM) depends on chosen monitor units setup (English or metric).
1. Press NEXT button until SELECTIVE FLOW is highlighted, then press SELECT button.
2. Press SELECT button to display the set flow rate input screen.
→NOTE: A flow rate between 19—132 LMP (5-35 GPM) may be entered. If a value below 19 LPM (5
GPM) is entered, flow rate will default to 19 LPM (5 GPM). If a value above 132 LPM (35 GPM) is
entered, flow rate will default to 132 LPM (35 GPM).
3. Enter desired flow rate using numeric keypad on SSM.

4. Press SELECT button to enable desired flow rate.
LOADER AUX SPEED (if equipped)
1. Press NEXT button until LOADER AUX SPEED is highlighted, then press SELECT button.
2. Press NEXT button to highlight one of the following choices:
SLOW
MEDIUM
FAST
BACKHOE AUX SPEED (if equipped)
1. Press NEXT button until BACKHOE AUX SPEED is highlighted, then press SELECT button.
2. Press NEXT button to highlight one of the following choices:
SLOW
MEDIUM
FAST
MAX GEAR LIMIT
(Group 9015-16.)
2. Press NEXT button until GEAR LIMIT is highlighted, then press SELECT button.
3. SET MAX GEAR will be displayed. Press NEXT button to highlight one of the following choices:
OFF
4
3
2
1
DIFF LOCK SPD LIMIT
(Group 9015-16.)
2. Press NEXT button until DIFF LOCK SPD LIMIT is highlighted, then press SELECT button.
3. Press NEXT button to highlight ON or OFF, then press SELECT button to make choice.
TIRE SIZE
(Group 9015-16.)
2. Press NEXT button until TIRE SIZE is highlighted, then press SELECT button.
3. From TIRE SIZE press NEXT button to highlight one of the following choices:
19.5L-24 FIRESTONE
19.5L-24 GOODYEAR
21L-24 FIRESTONE
21L-24 GOODYEAR
500/70R24
16.9-28 GOODYEAR
4. When choice is highlighted press SELECT button.
5. Display will show SAVING SELECTION <RESULT> for 2 seconds, then return to SETUP menu.
BEACON LIGHT (if equipped)
(Group 9015-16.)
2. Press NEXT button until BEACON LIGHT is highlighted, then press SELECT button.
3. Press NEXT button to highlight ENABLE or DISABLE, then press SELECT button to make choice.
Standard Display Monitor (SDM)—Setting Hour Meter

IMPORTANT:
Machine damage or excessive component wear can result if service intervals are extended or missed due
to incorrect hour meter readings. Existing machine hour meter values must be programmed into new
display monitor to maintain correct service intervals and warranty.
When replacing a controller, hour meter must be capable of being set to value from previous controller. This is accomplished
using one of two methods.
First method acquires hour meter value from VCU, which stores a copy of hour meter and broadcasts it to replaced standard
display monitor (SDM).
Second method is only used when first method fails, and allows an operator to enter hours into SDM manually.
If hour meter has not yet been set and if value is less than 20 hours, then hour meter shall be considered unlocked, and hour
meter Setting Process is enabled. If existing machine hour meter value is not entered during this procedure, SDM hour meter
value will reflect time accumulated since installation of new SDM. After machine has operated 20 hours it shall be considered
locked and reflect time accumulated since installation of SDM.
This procedure is used to transfer current hour meter information to new when installing new SDM.
[1] - Record existing hour meter value before removing existing SDM.
[2] - Install new SDM.
[3] - Turn switched power to ON position.
[4] - Using Service ADVISOR ™ , download and install latest SDM software on new SDM as necessary.
[5] - After software has downloaded and installed successfully, turn switched power OFF and then ON.
[6] - SDM display shows SELECT TO SET HOURS, press SELECT button.
[7] - SDM display shows ENTER HOURS.
[8] -
→NOTE:
There are two methods to enter hour setting. Both methods can be used independently or together.
Numeric Entry - use numbers on SSM
SDM - use NEXT, BACK, and SELECT buttons.
SDM Numeric Entry method
→NOTE:
When SET HOUR screen is active, SSM shall be in Numeric Entry mode. This mode prevents functions of
each button from controlling their respective function and instead operate as a numeric keypad
a. Press correct SSM keypad number to display button value on screen. Active field will shift to right of value entered.
b. After correct hour is entered, press ENTER button on SSM to submit value.
Next, Back and Select method
NEXT - increments current digit

BACK - decrements current digit
SELECT - submit entry
a. Press NEXT or BACK button to change number displayed in active field.

b. Press SELECT button to accept number displayed in active field and shift active field next digit to right.
c. After correct hour value is entered, press SELECT button to submit value.
[9] - SDM display shows VERIFY HOURS XXXXXX.0 (XXXXXX.0 is newly-entered hour meter value).
[10] -
→NOTE:
A new SDM only allows one reset to input existing machine hour meter value. Once SELECT or ENTER is
pressed hour value is locked and can not be changed.
If displayed value is correct, press SELECT or ENTER button to permanently store value.
If displayed value is not correct, press BACK button to re-enter existing hour meter value.
[11] - Once SELECT is pressed hour meter shall be locked. HOURMETER SAVED displays for 2 seconds, then display will return
to normal runtime operation.
Any button besides SELECT pressed will abort manual setting process, display will return ENTER HOURS. Then if MENU button is
pressed hour meter entry procedure will be aborted and display will return to normal runtime operation.
Security System Enable-Disable

→NOTE:
The security setup menu option is only available if machine is equipped with anti-theft security system.
Enable Security System
IMPORTANT:
Default owner PIN for security system is 1111. Operator and Transport security codes are not set and
must be set with master PIN or owner PIN. Using master PIN automatically resets owner PIN to default.
[1] - Switched power ON.
[2] - Press and hold MENU button for approximately 5 seconds to place standard display monitor (SDM) in SERVICE MENU
mode. SDM will display SERVICE MENU for 2 seconds before returning to previous screen. See Standard Display Monitor
(SDM)—Service Menu . (Group 9015-16.)
[3] - From MAIN MENU press NEXT button until SETUP is highlighted, then press SELECT button.
[4] - Press NEXT button until SECURITY is highlighted, then press SELECT button.
[5] - ENTER OWNER PIN will be displayed.
[6] - Enter correct Master or Owner security PIN:
→NOTE:
A master security PIN can be obtained from John Deere using DealerNet. Current engine hour meter
reading and machine′s serial number are needed to obtain a master security PIN.
Numeric entry - use numbers on sealed switch module (SSM)

SDM - use NEXT, BACK, and SELECT buttons
SSM Numeric Entry Method
→NOTE:
When ENTER PIN screen is active, SSM shall be in numeric entry mode. This mode prevents functions of
each button from controlling their respective function and instead operate as a numeric keypad.
1. Press correct SSM keypad number to display button value on screen. Active field will shift right of value entered.
2. After correct PIN is entered, press ENTER button on SSM to submit value.
→NOTE: Security system allows three attempts to enter a valid security PIN before requiring
switched power to be turned OFF and ON to restart process.
Next, Back and Select Method


→NOTE:
Security system allows three attempts to enter a valid security PIN before requiring switched power to be
turned OFF and ON to restart process.
[7] - If entered security PIN is correct, SECURITY menu will be displayed.
[8] - Press NEXT button until CONFIGURATION is highlighted, then press SELECT button.
[9] - There are three options to enable security, press NEXT button to choose, then press SELECT button.
LOCK AT SHUTDOWN will be displayed for 2 seconds then display will return to CONFIGURATION menu.
LOCK AT 5 MINUTES will be displayed for 2 seconds then display will return to CONFIGURATION menu.
LOCK AT 60 MINUTES will be displayed for 2 seconds then display will return to CONFIGURATION menu.
Disable Anti-Theft Security System
→NOTE:
Security system can be disabled if necessary. When disabled, no theft protection is enabled. Only
someone with owner or master security PIN can disable security system.
[1] - Perform steps 1—8 of Enable Security System in this procedure.
[2] - Press NEXT button until DISABLE is highlighted, then press SELECT button. DISABLE SELECTED will be displayed for 2
seconds then display will return to CONFIGURATION menu.
Security System Configuration

→NOTE:
→NOTE:
Default owner PIN for security system is 1111. Operator and transport security codes are not set and
must be set with master PIN or owner PIN. Using master PIN automatically resets owner PIN to default.
Once security system has been enabled, either as a factory installed option or field installation, security system needs to be
configured. Select locking method and change owner, operator and transport security PIN, as necessary.
A master security PIN can be obtained from John Deere using DealerNet. Current engine hour meter reading and machine′s
serial number are needed to obtain a master security PIN.
The locking method allows four options to set security system
Disable—Sets security system to unlock and does not require a PIN to start machine.
Lock at shutdown—Sets security system to lock when engine run goes to engine stop, require a PIN to restart machine.
Lock at 5 and 60 minutes—Set security system to lock after timer decrements 5 or 60 minutes. Operator display will
appear powered down, but will allow machine to be restarted with no PIN until timer expires, after timer expires security
system will lock requiring a PIN to start machine
Selecting Locking Method
→NOTE:
Only someone with owner or master security PIN can configure locking method.
[2] - From MAIN MENU press NEXT button until SETUP is highlighted, then press SELECT button.
[3] - Press NEXT button until SECURITY is highlighted, then press SELECT button.
[4] - ENTER OWNER PIN will be displayed.
[5] - Enter correct master or owner security PIN.
→NOTE:
Numeric entry—use numbers on SSM.
SDM—use NEXT, BACK, and SELECT buttons.
Numeric Entry Method
→NOTE:
b. After correct PIN is entered, press ENTER button on SSM to submit value.
→NOTE:
Security system allows three attempts to enter a valid security PIN before requiring switched power
to be turned OFF and ON to restart process.
NEXT, BACK and SELECT Method
NEXT—increments current digit.

BACK—decrements current digit.
SELECT—submit entry.

[6] - If entered master or owner security PIN is correct SECURITY will be displayed.
[7] - Press NEXT button until CONFIGURATION is highlighted, then press SELECT button.
[8] - From CONFIGURATION menu there are four options to enable or disable security, press NEXT to highlight choice, then
press SELECT button to activate.
DISABLE.
LOCK AT SHUTDOWN.
LOCK AT 5 MINUTES.
LOCK AT 60 MINUTES.
Changing an Operator or Owner Security PIN
→NOTE:
A security PIN can only be changed if master or owner security PIN is used during change procedure.
[1] - Perform steps 1—7 of Selecting the Locking Method in this procedure.
[2] - Press NEXT button until MANAGE PINS is highlighted, then press SELECT button.
[3] - From MANAGE PINS menu there is six options to clear and change owner and operator PIN’s.
OWNER PIN
OPERATOR 1
OPERATOR 2
OPERATOR 3
OPERATOR 4
OPERATOR 5
[4] - Press NEXT button to highlight choice, then press SELECT button.
[5] - Press NEXT button until CLEAR PIN is highlighted, then press SELECT button.
[6] - Display will show CLEARED for 2 seconds with an audible chirp before returning to CLEAR PIN submenu.
[7] - Press NEXT button until ENTER PIN is highlighted, then press SELECT button.
[8] - Display will show ENTER NEW PIN. Numeric entry method or NEXT, BACK, and SELECT method can be used independently
or together to enter a new PIN.
→NOTE:
If a PIN is entered that is already registered with another user, SDM shall display PIN ALREADY IN USE
and return to ENTER NEW PIN display to allow user to enter a new PIN.
If a PIN is entered that is not registered, SDM shall display PIN for 2 seconds and return to SECURITY
submenu.
This allows the Owner to restrict the machine use to a certain amount of time and limit some performance options, when
someone other than the Owner is transporting the machine. Engine run will cause a timer to accumulate until set time is
exceeded then security system will be locked requiring owner PIN to reset timer, each time owner PIN is used transport PIN
resets.
Changing Transport PIN
[1] - Perform steps 1—7 of Selecting the Locking Method in this procedure.
[2] - Press NEXT button until MANAGE PINS is highlighted, then press SELECT button.
[3] - Press NEXT button until TRANSPORT is highlighted, then press SELECT button.
[4] - Press NEXT button until CLEAR PIN is highlighted, then press SELECT.
[5] - Display will show TRANSPORT PIN CLEARED for 2 seconds then return to TRANSPORT submenu.
[6] - Press NEXT button until ENTER PIN is highlighted, then press SELECT button.
[7] - ENTER NEW PIN will be displayed, enter a new PIN using Numeric entry method or NEXT, BACK, and SELECT method can
be used independently or together to enter a new PIN.
→NOTE:
If a PIN is entered that is already registered with another user, SDM shall display PIN ALREADY IN USE
and return to ENTER NEW PIN submenu to allow user to enter a new PIN.
If a PIN is entered that is not registered, SDM shall display PIN for 2 seconds and return to TRANSPORT
submenu.
[8] - Press NEXT button until VALID PIN TIME is highlighted, then press SELECT button.
[9] - Enter run time in hours (1—9) using numeric entry method or NEXT, BACK, and SELECT method to enter a new hour
value.
→NOTE:
Owner shall be able to set VALID PIN TIME from 1—9 hours. SDM shall have a timer that accumulates
anytime engine state is engine Running and user is logged in with TRANSPORT PIN. When this timer
exceeds value set by owner in VALID PIN TIME submenu, TRANSPORT PIN shall be cleared and SDM shall
display PIN EXPIRED CONTACT OWNER.
[10] - VALID PIN TIME <X> HOURS SAVED is displayed for 2 seconds with an audible chirp before returning to TRANSPORT
menu.
Section 9015 - ELECTRICAL SYSTEM Group 20: References
Security System Operation

→NOTE:
Unlocking Machine (Operator and Owner)
[1] - Sit in operator′s seat to power up standard display monitor.
[3] - Standard display monitor (SDM) displays ENTER PIN.
[4] - Enter correct owner or operator security PIN.
→NOTE:
Security system allows three attempts to enter a valid security PIN before requiring switched power to be
turned OFF and ON to restart process.
→NOTE:
Numeric entry - use numbers on SSM

SDM - use NEXT, BACK, and SELECT buttons
Numeric Entry Method
→NOTE:
b. After correct PIN is entered, press ENTER button on SSM to submit value.
Next, Back and Select Method


[5] - If proper PIN is entered display will return to hour meter screen.
Group 20 - References
Electrical Component Specifications
B2—Air Conditioner Freeze Switch Opening temperature (decreasing) -1.4°C
29.5°F
Closing temperature (increasing) 2.2°C
36°F
B3—Air Conditioner Binary 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
B6—Torque Converter Oil Temperature Sensor Resistance 2.434—3.229 kilo-ohms @ 25°C (77°F)
178.8—180.5 ohms @ 100°C (212°F)
88.83—89.33 ohms @ 125°C (257°F)
B7—Engine Oil Pressure Switch Opening Pressure 37—72 kPa
0.4—0.7 bar
5.5—10.5 psi
178—184 ohms @ 100% Fill

137.3 ohms @ 3/4 Fill
B8—Fuel Level Sensor Resistance 91.8 ohms @ 1/2 Fill
46.4 ohms @ 1/4 Fill
9—11 ohms @ 0 Fill
B12—Hydraulic Oil Filter Restriction Switch Closing Pressure 344 kPa
3.45 bar
50 psi
B13—Park Brake Pressure Switch Opening Pressure 993—1213 kPa
10.2—12.4 bar
144—176 psi
Closing Pressure 806—985 kPa
8.1—9.9 bar
117—143 psi
90—108 kilo-ohms @ -40°C (-40°F)

26—31 kilo-ohms @ -20°C (-4°F)
8.7—10.2 kilo-ohms @ 0°C (32°F)
3.3—3.8 kilo-ohms @ 20°C (68°F)
B15—Coolant Temperature Sensor Resistance 1.4—1.6 kilo-ohms @ 40°C (104°F)
648—708 ohms @ 60°C (140°F)
317—350 ohms @ 80°C (176°F)
170—186 ohms @ 100°C (212°F)
97—105 ohms @ 120°C (248°F)
0.5 V @ 0 kPa (0 psi)

1 V @ 4000 kPa (580.2 psi)
1.5 V @ 7500 kPa (1087.8 psi)
2 V @ 11000 kPa (1595.4 psi)
B16—Load Sense Pressure Sensor Pressure 2.5 V @ 15000 kPa (2175.6 psi)
3 V @ 19000 kPa (2575.7 psi)
3.5 V @ 22500 kPa (3263.4 psi)
4 V @ 26000 kPa (3770.9 psi)
4.5 V @ 30000 kPa (4351.1 psi)
90—108 kilo-ohms @ -40°C (-40°F)

26—31 kilo-ohms @ -20°C (-4°F)
8.7—10.2 kilo-ohms @ 0°C (32°F)
3.3—3.8 kilo-ohms @ 20°C (68°F)
B17—Fuel Temperature Sensor Resistance 1.4—1.6 kilo-ohms @ 40°C (104°F)
648—708 ohms @ 60°C (140°F)
317—350 ohms @ 80°C (176°F)
170—186 ohms @ 100°C (212°F)
97—105 ohms @ 120°C (248°F)
90—108 kilo-ohms @ -40°C (-40°F)

26—31 kilo-ohms @ -20°C (-4°F)
8.7—10.2 kilo-ohms @ 0°C (32°F)
3.3—3.8 kilo-ohms @ 20°C (68°F)
B18—Manifold Air Temperature Sensor Resistance 1.4—1.6 kilo-ohms @ 40°C (104°F)
648—708 ohms @ 60°C (140°F)
317—350 ohms @ 80°C (176°F)
170—186 ohms @ 100°C (212°F)
97—105 ohms @ 120°C (248°F)
B19—Crank Position Sensor Resistance 2.7—3.3 kilo-ohms
B20—Foot Throttle Position Sensor Resistance 5 kilo-ohms ± 20%
B21—Engine Speed Control Dial Resistance 1 kilo-ohms ± 20%
0.5 V @ 0 kPa (0 psi)

1 V @ 4000 kPa (580.2 psi)
1.5 V @ 7500 kPa (1087.8 psi)
2 V @ 11000 kPa (1595.4 psi)
B26—Hydraulic System Pressure Sensor Pressure 2.5 V @ 15000 kPa (2175.6 psi)
3 V @ 19000 kPa (2575.7 psi)
3.5 V @ 22500 kPa (3263.4 psi)
4 V @ 26000 kPa (3770.9 psi)
4.5 V @ 30000 kPa (4351.1 psi)
B109—Engine Air Filter Restriction Switch Closes on Increased Vacuum 4.98—7.48 kPa Vacuum
20—30 in. H 2 O
S26—Brake Light Pressure Switch 1 Closing pressure 410—760 kPa
4.1—7.6 bar
60—110 psi
S27—Brake Light Pressure Switch 2 Closing pressure 410—760 kPa
4.1—7.6 bar
60—110 psi
R5—CAN Termination Resistor 1 Resistance 120 ohms
R6—CAN Termination Resistor 2 Resistance 120 ohms
R10—Blower Motor Speed Resistor Resistance Outside Resistor Terminal (2) to Terminal (4) 1.12 ohms
Outside Resistor Terminal (2) to Terminal (1) 0.42 ohms
Outside Resistor Terminal (2) to terminal (3) 0.15 ohms
R20—Temperature Control Resister Resistance Terminal (2) to Terminal (1) 5 kilo-ohms
Y1—Transmission Forward Direction Solenoid Resistance (approximate) 10.5 ohms
Length 12.12 cm
4.77 in.
Y2—Transmission Reverse Direction Solenoid Resistance 10.5 ohms
Length 13.16 cm
5.18 in.
Y3—Transmission Speed Solenoid 1 Resistance 10.5 ohms
Length 12.12 cm
4.77 in.
Y4—Transmission Speed Solenoid 2 Resistance (approximate) 10.5 ohms
Length 12.12 cm
4.77 in.
Length 13.16 cm
5.18 in.
Length 12.12 cm
4.77 in.
Y7—Park Brake Release Solenoid Resistance 10.5 ohms
Length 10.41 cm
4.10 in.
Y10—Differential Lock Solenoid Resistance 10.5 ohms
Length 10.41 cm
4.10 in.
Y11—MFWD Solenoid Resistance 10.5 ohms
Length 10.41 cm
4.10 in.
Y15—Start Aid Solenoid Resistance 1 ohm
Y20—Loader Auxiliary Extend Solenoid Resistance 5.03—5.57 ohms at 20°C (68°F)
Y21—Loader Auxiliary Retract Solenoid Resistance 5.03—5.57 ohms at 20°C (68°F)
Y29—Loader Coupler Unlock Solenoid—If Equipped Resistance 8.25 ohms
Y30—Loader Coupler Pressure Solenoid—If Equipped Resistance 8.25 ohms
Y43—Air Conditioner Compressor Clutch Solenoid Resistance 12.6—15.4 ohms
Y50—Ride Control Solenoid 1 Resistance 8.25 ohms
Y51—Ride Control Solenoid 2 Resistance 8.25 ohms
Y52—Pilot Enable Solenoid Resistance 8.56—9.08 ohms
Y53—Selective Flow Control Solenoid Circuit Amperage 1400—1500 mA
Solenoid Resistance 8.6—9.0 ohms
Y56—Hydraulic Pump Control Solenoid Resistance 8.5 ohms
Y58—Pattern Select Solenoid 1 Resistance 7.25 ohms
Y59—Pattern Select Solenoid 2 Resistance 7.25 ohms
Y67—Return-to-Dig Solenoid Resistance 13.5 ohms
Service ADVISOR™ Connection Procedure

This procedure explains how to connect Service ADVISOR ™ to the machine using an electronic data link (EDL) (2) connection.
The controller area network (CAN) used on the machine requires an EDL connection.
LEGEND:
1 USB Cable
2 Electronic Data Link (EDL)
3 Diagnostic 9-Pin Connector Cable
4 Cover
5 Warning Indicator(amber)
6 CAN Connection Indicator (red)
7 Power Indicator (green)
X1 Service ADVISOR Connector
Service ADVISOR Connection
EDL and Cables
EDL Lights
[1] - Open cover (4) to access fuse and relay block (X3) and Service ADVISOR connector (X1).
[2] - Remove cover from Service ADVISOR connector.
[3] - Connect diagnostic 9-pin connector cable (3) to Service ADVISOR diagnostic connector.
[4] - Turn machine switched power to ON position. Ensure power indicator (7) illuminates.
[5] - CAN connection indicator (6) illuminates when computer connects to the CAN data line. CAN connection indicator may
flicker, this is normal. When CAN connection indicator is illuminated, CAN data line is active and data is transmitting.
[6] - If CAN connection indicator does not illuminate and computer cannot connect to CAN data line, check all cable
connections.
[7] - Refer to Service ADVISOR system instructions to log into service computer and take data readings from machine.
JDLink™ Connection Procedure

For more information on JDLink ™ connection procedure, see Service ADVISOR™ Connection Procedure . (Group 9015-20.)
Reading Diagnostic Trouble Codes (DTCs)

Use Service ADVISOR ™ or standard display monitor (SDM) to view stored diagnostic trouble codes (DTCs). Please refer to
Section 9001—Diagnostics for DTC diagnostic procedures.
Reading DTCs with Service ADVISOR
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 computer to machine. See Service ADVISOR™ Connection Procedure . (Group 9015-20.)
[2] - Open Service ADVISOR and display appropriate model information.
[3] - Turn switched power ON.
[4] - From the Shortcut bar, click Diagnostics to open the Diagnostics shortcut bar (1).
[5] - Click the Connected Diagnostic Trouble Codes folder (2).
[6] -
Connection Options Dialog Box

Select the Connect to Model(s) radio button on the Connection Options dialog box, and click OK.
[7] -
Select Readings Adapter Dialog Box

LEGEND:
5 Available Adapters 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
→NOTE:
The controller area network (CAN) used on the machine requires an EDL connection.
[8] - Make sure correct machine to connect to displays in the Selected Models list (6). If not, click the Change Selected Models
button (7).
[9] - Click OK to connect to machine.
[10] - After Service ADVISOR ™ connects to machine, both the Readings tab (3) and Connected Diagnostic Trouble Codes tab
(4) display.
[11] - Double-click an underlined code on the Connected Diagnostic Trouble Codes tab to display a detailed description for
servicing that diagnostic trouble code.
[12] -
→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.
Reading DTCs with Standard Display Monitor (SDM)
[1] - Turn switched power ON to power up SDM.
SERVICE MENU for 2 seconds before returning to previous screen. See Standard Display Monitor (SDM)—Service Menu . (Group
9015-16.)
[3] - From the MAIN MENU press NEXT button until DIAGNOSTICS is highlighted, then press SELECT button.
[4] - Press NEXT button until CODES is highlighted, then press SELECT button.
[5] - From CODES submenu the display will show the amount of stored and active codes.
[6] - View DTC info:
Press the NEXT button to scroll through list of codes.

Press the SELECT button to view DTC details.
Press the BACK button to move up one menu level.
[7] - To clear codes, see Standard Display Monitor (SDM)—Clear Codes . (Group 9015-16.)
Diagnostic Trouble Code (DTC) Monitor Messages

Standard display monitor (SDM) automatically displays a message for certain diagnostic trouble codes (DTCs) and machine
conditions. When DTC is initially active, a message displays on SDM until either condition is resolved or operator presses any
button on SDM.
DTCs and machine conditions that automatically generate a SDM message include:
DTC List
Control
Monitor Text DTC Code Description
Unit
AUXILIARY FLOW XX GPM VCU ———— Displays first time hammer is turned on per power cycle.
BACKHOE ACTIVE VCU ———— Pilot enable switch is activated while operator′s seat is not in backhoe position.
CALIBRATE SEAT SENSOR VCU 520713.13 Operator′s seat position calibration values are invalid, calibrate seat.
CONVERTER TEMP FAULT TCU 000177.04 Error (low input voltage) in torque converter temperature sensor circuit.
CONVERTER OIL TEMP HIGH TCU 000177.00 Transmission oil temperature is too high, above 121°C (250° F).
DIFF LOCK DISABLED DUE TO HIGH Differential Lock engagement was attempted above 1000 rpm engine speed threshold. (only
TCU 000746.31
SPEED displays if differential lock speed limit setting is enabled)
Display shall persist until it is acknowledged by operator and shall not be displayed more than
DOCK LIGHT BULB MISSING VCU 002366.18
once per power cycle.
ECU CONFIGURATION MISMATCH ECU 002000.13 ECU security error. Monitor and ECU do not agree on power level of engine.
Restriction in engine air filter, filter system, or in-range sensor error. Data valid but above normal
ENGINE AIR FILTER RESTRICTED ECU 000107.00
operational range (most severe level).
Restricted air filter, other restrictions in air inlet system, in-range sensor malfunction. Data valid
ENGINE AIR FILTER RESTRICTED ECU 000107.16
but above normal operating range (moderately severe level).
One of speed derate conditions exists on engine. Data valid but above normal operational range
ENGINE DERATED ECU 000189.00
(most severe level).
000189.31
ENGINE DERATED ECU One of speed derate conditions exists on engine.
001569.31
ENGINE SHUTDOWN XX PRESS START When ENGINE SHUTDOWN timer reaches 30 seconds, VCU shall set delayed shutdown timer value
VCU ————
TO ABORT set in SDM or press start to abort.
Cooling system performance has degraded. Coolant temperature is at or above 116°C (241° F).
ENGINE TEMP HIGH ECU 000110.00
Data valid but above normal operational range (most severe level).
Cooling system performance has degraded. Coolant temperature is at or above 114°C (237° F).
ENGINE TEMP HIGH ECU 000110.16
Data valid but above normal operating range (moderately severe level).
ENGINE TEMP SENSOR FAULT ECU 000110.03 Open circuit in harness, either signal or ground. Coolant temperature sensor malfunction.
ENGINE TEMP SENSOR FAULT ECU 000110.04 Coolant temperature sensor signal shorted to ground. Coolant temperature sensor malfunction.
EXHAUST FILTER PRESS SELECT TO

VCU ———— Exhaust diesel particulate filter (DPF) is ready to initiate a parked cleaning.
ENTER CLEANING CYCLE
EXHAUST FILTER AUTO CLEANING

VCU ———— Idle is elevated for exhaust aftertreatment auto cleaning mode.
IDLE ELEVATED
Exhaust diesel particulate filter (DPF) has reached a high restriction level (soot level 3), filter
EXHAUST FILTER RESTRICTING VCU ————
cleaning is needed.
EXHAUST FILTER CLEANING REQD Exhaust diesel particulate (DPF) has reached a very high restriction level (soot level 4), engine
VCU ————
ENGINE PWR LMTD power is derated 50%, perform a PARKED CLEANING.
Exhaust diesel particulate filter (DPF) has reached a severe restriction level (soot level 5, most
EXHAUST FILTER SERVICE REQD
ECU 003719.00 severe) engine power is derated 50% until filter is cleaned. See your authorized dealer to perform
ENGINE PWR LMTD
a SERVICE CLEANING.
Engine fan speed low, check fan drive system. Data valid but below normal operational range
FAN SPEED FAULT ECU 001639.01
(most severe level).
FASTEN SEATBELT VCU ———— Displays when engine state transitions to engine running.
FRONT LIGHT BULB MISSING VCU 002354.18
FRONT LIGHT BULB MISSING VCU 002356.18
FUEL GAUGE FAULT SDM 000096.03 Voltage above normal or shorted to high source.
FUEL GAUGE FAULT SDM 000096.04 Voltage below normal or shorted to low source.
Voltage above normal or shorted to high source. Rail pressure solenoid is forced closed due to a
FUEL PUMP CONTROL FAULT ECU 001347.03
short to a high source. Detected only during harness diagnostics.
Current below normal or open circuit. A wiring connection to pump solenoid #1 is open. Wiring to
pump solenoid #1 is shorted to ground. Pump solenoid #1 has malfunctioned.
Current above normal grounded circuit or ECU malfunction. Fuel injection pump fuel control valve
current fall time too long.
High loads with poor EGR cooling, occurs at > 299°C (570° F). Data valid but above normal
HIGH EGR TEMPERATURE ECU 000412.00
High loads with poor EGR cooling, occurs at > 290°C (544° F). Data valid but above normal
HIGH EGR TEMPERATURE ECU 000412.16
operating range (moderately severe level).
Cooling system performance has degraded. Fuel at or above 100°C (212° F), data valid but above
HIGH FUEL TEMPERATURE ECU 000174.00
normal operational range (most severe level).
HIGH SYSTEM VOLTAGE SDM 000168.03 Voltage above normal or shorted to high source.
HYDRAULIC OIL FILTER RESTRICTED VCU 001713.00 Hydraulic filter is restricted.
Voltage below normal shorted to low source or hydraulic oil temperature sensor is shorted to
HYDRAULIC OIL SENSOR FAULT VCU 001638.04
ground.
HYDRAULIC OIL TEMP XXXF VCU 001638.00 Data valid but above normal operational range (most severe level).
HYDRAULIC OIL TEMP XXXF VCU 001638.16 Data valid but above normal operating range (moderately severe level).
INCORRECT VIN ECU 000237.02 PIN does not match or other controllers in networks are not committed in required time.
INCORRECT VIN ECU 000237.31 VIN messages are missing or other controllers in network are not committed in required time.
Voltage above normal or shorted to high source. Injector drive circuit has detected a short to
INJECTOR FAILURE ECU 000611.03
battery on injector wires.
Voltage below normal or shorted to low source. Injector drive circuit has detected a short to
INJECTOR FAILURE ECU 000611.04
ground on injector wires.
Out of calibration VIN option bytes are 0, still have not learned options from other controllers on
LEARNING OPTIONS SDM 000237.13
bus.
If left joystick is not neutral (both X & Y axis) when trying to enable backhoe hydraulics in rear
LEFT JOYSTICK NOT CENTERED HVC ————
facing position.
If outer stabilizer roller is not neutral (both X & Y axis) when trying to enable hydraulics in rear
LEFT STAB NOT CENTERED HVC ————
facing position.
When engine state is engine running and loader coupler button has been pressed, loader coupler
LOADER COUPLER DISENGAGED VCU ————
shall transition to disengaged state.
Coolant level below loss switch while coolant temp > 95°C (203° F). Data valid but above normal
LOW COOLANT LEVEL ECU 000111.01
Coolant level below loss switch while coolant temp is > 60°C (140° F) and < 95°C (203° F). Data
LOW COOLANT LEVEL ECU 000111.18
valid but above normal operating range (moderately severe level).
Oil pressure low due to low or no oil present. Data valid but below normal operational range (most
LOW ENGINE OIL PRESSURE ECU 000100.01
severe level).
Oil pressure low due to low or no oil present. Data valid but below normal operating range
LOW ENGINE OIL PRESSURE ECU 000100.18
(moderately severe level).
LOW FUEL VCU ———— Repeats every 5 minutes as long as condition exists.
LOW SYSTEM VOLTAGE SDM 000168.04 Voltage below normal or shorted to low source.
MANIFOLD AIR TEMP HIGH ECU 000105.00 Cooling system performance has degraded. Manifold air temperature is above 91°C (196° F).
MANIFOLD AIR TEMP HIGH ECU 000105.16 Cooling system performance has degraded. Manifold air temperature is above 89.5°C (193° F).
If mini joystick is not neutral (both X & Y axis) when trying to enable override mode with SSM
MINI JOYSTICK NOT CENTERED HVC ————
button, in loader seat position.
Voltage above normal or shorted to high source. Clutch disconnect switch is either shorted or
NO CLUTCH DISCONNECT TCU 524172.03
stuck.
Mechanical system not responding or out of adjustment. Clutch disconnect normally open and
clutch disconnect normally closed switches do not agree.
Abnormal update rate, an internal-use DTC indicating a communication error has occurred, which
has caused clutch disconnect feature to be disabled.
If option is not installed and option button is pressed on SSM, message is displayed on PDU each
OPTION NOT INSTALLED VCU ————
time button is pressed.
If SSM communication is lost preventing operator from engaging park brake and machine is in
PARK BRAKE APPLY XX TCU ———— motion above 0.5 km/h (0.3 mph) or ground speed is invalid. TCU shall delay park brake apply for
15 seconds and decrements 15 second timer before engaging.
If machine speed is invalid or greater than 0.5 km/h (0.3 mph) and current gear is not neutral and
PARK BRAKE APPLY XX PRESS START
TCU ———— stop button has been pressed. TCU shall delay park brake apply for 15 seconds and decrements
TO ABORT
15 second timer before engaging or press start to abort.
Timer exceeded value set by owner in VALID PIN TIME menu, TRANSPORT PIN shall be cleared and
PIN EXPIRED CONTACT OWNER VCU ————
SDM displays PIN EXPIRED CONTACT OWNER.
Voltage above normal, or shorted to high source. An open in ground circuit of rail pressure sensor.
RAIL PRESSURE SENSOR FAULT ECU 000157.03
Short in harness to high voltage. Rail pressure sensor malfunction.
Voltage below normal or shorted to low source. An open in ground circuit of rail pressure sensor.
RAIL PRESSURE SENSOR FAULT ECU 000157.04
Short in harness to high voltage. Rail pressure sensor malfunction.
REAR LIGHT BULB MISSING VCU 002360.18
REAR LIGHT BULB MISSING VCU 002362.18
RELEASE PARK BRAKE VCU ———— Park brake switch indicating park brake on.
RETURN TLC TO NEUTRAL VCU ———— For pass through neutral request. Display acknowledgeable but audible and stop indicator remain.
RIGHT DOOR OPEN VCU ———— Right door switch indicating open.
If right joystick is not neutral (both X & Y axis) when trying to enable backhoe hydraulics in rear
RIGHT JOYSTICK NOT CENTERED HVC ————
facing position.
If inner stabilizer roller is not neutral (both X & Y axis) when trying to enable hydraulics in rear
RIGHT STAB NOT CENTERED HVC ————
facing position.
Voltage above normal or shorted to high source. Voltage on seat sensor channel 1 or channel 2 is
SEAT SENSOR FAULT VCU 520713.03
above 4.5 V.
Voltage below normal or shorted to low source. Voltage on seat sensor channel 1 or channel 2 is
below 0.5 V.
Malfunctioning intelligent device or component. Channel 1 and channel 2 do not match, cross
check of two channels exceeds 250 mV.
When machine is cycled from OFF to ON or OFF to START, and security system is locked,
SECURITY ENABLED VCU ————
SECURITY ENABLED displayed.
Brake charge pressure below 6200 kPa (899 psi). Has 10 second initial delay after engine running.
SERVICE BRAKE PRESSURE LOW TCU 520654.01
Data valid but below normal operational range (most severe level).
Seat position is in between backhoe and loader seat positions when trying to enable loader
TURN SEAT TO ENABLE HVC ————
hydraulics.
ECU has exceeded 60 seconds of continuous cranking. Ignition off and wait 60 seconds before
WAIT TO START ECU 001321.16
attempting to start again.
WAIT TO START XX ECU ———— XX displays count down before attempting to start again.
WATER IN FUEL ECU 000097.16 Water has been detected in separator bowl.
Intermittent Diagnostic Trouble Code (DTC) Diagnostics

An intermittent diagnostic trouble code (DTC) is a DTC that periodically “goes away.” A loose terminal that intermittently does
not make contact with its mating terminal is a likely cause of an intermittent DTC. Other intermittent DTCs may only be set
under certain operating conditions such as heavy load or extended idle.
Possible Causes of Intermittent DTCs

Contact between terminals in connector. Check for loose, dirty, or partially disconnected connectors.
Connection between sensor or actuator and harness. Inspect wiring routing, looking for possible intermittent shorts to
ground caused by contact with external parts (for example, rubbing against sharp sheet metal edges).
Terminal-to-wire connection. Check for broken wires, damaged splices, and wire-to-wire shorts.
Electromagnetic interference (EMI) from an improperly installed 2-way radio, etc., can cause erroneous signals to be sent
to controller.
→NOTE:
A controller is the component least likely to malfunction. Replace a controller only if diagnostic procedure
indicates that a controller replacement is necessary.
Diagnosing Intermittent DTCs

If diagnostic procedure indicates problem is intermittent, try to reproduce operating conditions present when DTC was
active. Service ADVISOR ™ can be used to help locate intermittent problems using a function called Recording. Recording
function permits recording of data parameter values during a diagnostic session. If a DTC is active during a certain
diagnostic session, parameters can be played back and observed to see what each applicable parameter′s value was
when DTC occurred.
If a connection or wire is suspected cause of intermittent problem, clear DTCs, then check connection or wire by wiggling
it while watching Service ADVISOR and observe if DTC resets.
Voltage measured at controller input for most sensors can be monitored in Service ADVISOR as a data point. Minimum
and maximum value of voltage (measured since data point was selected) is displayed along with current value of voltage.
Check minimum and maximum voltage columns in data points screen after each section of harness is wiggled to help
isolate problem location.
After all causes for intermittent DTCs are repaired, clear codes, cycle ignition power, and check for active DTCs. See Reading
Diagnostic Trouble Codes (DTCs) . (Group 9015-20.)
If DTC reappears, see specific diagnostic procedure in Section 9001.
Controller Area Network (CAN) Circuit Test
Controller Area Network (CAN) Circuit
LEGEND:
W10 Engine Harness
W14 Cab Harness
W15 Canopy Harness
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)
IMPORTANT:
Avoid connector and connector terminal damage. Inserting test leads into harness connectors can
damage the terminal and connector. When testing wire harnesses, always use spare mating terminals to
connect test leads to connector terminals. See Wire Harness Test . (Group 9015-20.)
This machine uses one CAN network. For more information, see Controller Area Network (CAN) Circuit Theory of Operation .
(Group 9015-15.)
Controller Area Network (CAN) Diagnostics

( 1 ) System Check
Action:
Switched power ON.

Locate Service ADVISOR ™ connector and establish machine connection. See Service ADVISOR™ Connection Procedure .
(Group 9015-20.)
Does Service ADVISOR establish a connection?
Result:

NO:Go to Service ADVISOR Fuse Test.
Action:
Do all controllers show up under connected controllers?
Result:
YES: Go to CAN Termination Resistor Check .

NO:Go to next step in this check.
Action:
Is Service ADVISOR able to connect to any machine controllers?
Result:
YES: Go to Controller Fuse Check .

NO: Go to CAN Circuit Short to Ground Check .
( 2 ) Service ADVISOR Fuse Test
Action:
Remove fuse for Service ADVISOR and check for continuity. For fuse location, see Fuse and Relay Location and Specifications .
(Group 9015-10.)
Result:
YES:Go to CAN Termination Resistor Check.

NO:Replace Service ADVISOR fuse.
( 3 ) CAN Termination Resistor Check
Action:
Disconnect modular telematics gateway (MTG) control unit 48-pin connector (X6014). See Modular Telematics Gateway (MTG)
See Controller Area Network (CAN) Resistor Test . (Group 9015-20.)
Result:
YES:Go to CAN High Wire Voltage Check.

NO:Replace termination resistor.
( 4 ) CAN High Wire Voltage Check
Action:
IMPORTANT:
damage the terminal and connector. When testing wire harnesses, always use spare mating terminals to
connect test leads to connector terminals. See Wire Harness Test . (Group 9015-20.)
Switched power ON.

Using a multimeter, measure voltage from pin C (CAN high) to pin A (ground) of Service ADVISOR connector (X1).
Is voltage between 2 and 3 volts?
Result:
YES:Go to CAN Low Wire Voltage Check.

Action:
Is system voltage present between pin C (CAN high) and pin A (ground) of Service ADVISOR connector?
Result:
YES:A short circuit on CAN high wire. Check CAN high voltage one controller at a time to locate short circuit.
Action:
Is zero voltage present between pin C (CAN high) and pin A (ground) of Service ADVISOR connector?
Result:
YES: Go to CAN High Wire Circuit Check .

NO:Remove one controller at a time and check voltage. When voltage is in range, check harness of disconnected controller for
short circuits. Repair or replace harness as necessary.
( 5 ) CAN Low Wire Voltage Check
Action:
Using a multimeter, measure voltage from pin D (CAN low) to pin A (ground) of Service ADVISOR connector.
Is voltage between 2 and 3 volts?
Result:
YES:Go to CAN High Wire Circuit Check.

Action:
Is system voltage present between pin D (CAN low) and pin A (ground) of Service ADVISOR connector?
Result:
YES:A short circuit exists on CAN low wire. Check CAN low voltage one controller at a time to locate short circuit. Repair or
replace harness as necessary.
Action:
Is zero voltage present between pins D (CAN low) and pin A (ground) of Service ADVISOR connector?
Result:
YES: Go to CAN Low Wire Circuit Check .

NO:Remove one controller at a time and check voltage. When voltage is in range, check harness of disconnected controller for
short circuits. Repair or replace harness as necessary.
( 6 ) CAN High Wire Circuit Check
Action:
Using a multimeter, measure continuity between pin C (CAN high) of Service ADVISOR connector and machine ground.
Result:
YES:A short to ground exists on CAN high wire. Check CAN high voltage one controller at a time to locate harness where short
is located. Repair or replace harness as necessary.
( 7 ) CAN Low Wire Circuit Check
Action:
Using a multimeter, measure continuity between pin D (CAN low) of Service ADVISOR connector and machine ground.
Result:
YES:A short to ground exists on CAN low wire. Check CAN low voltage one controller at a time to locate harness where short is
located. Repair or replace harness as necessary.
( 8 ) CAN Circuit Short to Ground Check
Action:
Switched power OFF.

Using a multimeter, measure continuity between pin D (CAN low) and pin A (ground) of Service ADVISOR connector.
Using a multimeter, measure continuity between pin C (CAN high) and pin A (ground) of Service ADVISOR connector.
Result:
YES:A short to ground exists in CAN circuit. Disconnect each harness and check for continuity to ground at pin A of Service
ADVISOR connector. Repair or replace harness that has short to ground condition.
Action:
Switched power OFF.

Using a multimeter, measure continuity between pin D (CAN low) and machine ground.
Using a multimeter, measure continuity between pin C (CAN high) and machine ground.
Result:
YES:A short to machine ground exists in CAN circuit. Disconnect each harness and check for continuity to machine ground.
Repair or replace harness that has short to ground condition.
NO:Go to CAN High/CAN Low Short Check.
( 9 ) CAN High/CAN Low Short Check
Action:
Switched power OFF.

Using a multimeter, check for continuity between CAN high and CAN low circuits.
Result:
YES:Short circuit between CAN high and CAN low wires. Check continuity between CAN high and CAN low circuits one
controller at a time to locate harness where short is located. Repair or replace harness as necessary.
NO: Go to Service ADVISOR Fuse Test .
( 10 ) Controller Fuse Check
Action:
Remove fuse for missing controller(s). Check fuse(s) for continuity.

Is continuity indicated in all fuses?
Result:
YES:Go to Controller Check.

NO:Replace fuse(s) that did not indicate continuity.
( 11 ) Controller Check
Action:
Switched power OFF.

Disconnect modular telematics gateway (MTG) control unit 48-pin connector (X6014). See Modular Telematics Gateway (MTG)
Harness (W6002) Component Location . (Group 9015-10.) Locate suspected controller(s). Using system functional schematic,
wiring diagram and component location master legend, locate CAN wires and disconnect appropriate connector. Using a
multimeter, measure resistance between CAN high and CAN low wires.
Is resistance between 55 and 65 ohms?
Result:

NO:An open or short circuit exists in one of CAN wires. Work from controller back to main harness, checking CAN high and low
wires for an open or short circuit.
Action:
Switched power ON.

Using system functional schematic, wiring diagram and component location master legend, check for power and ground at
suspect controller(s).
Is power and ground present?
Result:

NO:An open or short circuit exists in circuit with no power or ground. Work from controller back to main harness, checking
power and ground circuits for an open or short circuit. Repair or replace harness as necessary.
Controller Area Network (CAN) Resistor Test

Specifications
SPECIFICATIONS
Service ADVISOR ™ Connector (pins C and D) Resistance 54—66 ohms
CAN Termination Resistor 1 (R5) and CAN Termination Resistor 2 (R6) Resistance 108—132 ohms
The purpose of controller area network (CAN) resistor test is to check the two CAN termination resistors. The following
resistance check can be made to ensure that both CAN resistors are in place and working properly. For more information on
CAN networks, see Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.)
[1] - If equipped with JDLink ™ , complete the following:
a. Remove tool box to access modular telematics gateway (MTG) control unit 48-pin connector (X6014).
b. Disconnect MTG control unit 48-pin connector (X6014). See Modular Telematics Gateway (MTG) Harness (W6002)
[2] -
LEGEND:
C Pin C
D Pin D
X1 Service ADVISOR™ Connector
Service ADVISOR™ Connector

Remove console cover to access fuse and relay block and Service ADVISOR ™ connector (X1).
[3] - Using a multimeter, check resistance between pins (C and D) in Service ADVISOR™ connector.
Service ADVISOR™ Connector (pins C and D) Resistance 54—66 ohms
[4] -
→NOTE:
If equipped with JDLink™, CAN termination resistor 1 (R5) is internal to MTG harness (W6002).
If resistance is not to specification, check the resistance at pins A and B of the following:
If equipped with JDLink™: modular telematics gateway (MTG) CAN 1 connector (X102).
If not equipped with JDLink™: CAN termination resistor 1 (R5).
CAN termination resistor 2 (R6).
CAN Termination Resistor 1 (R5) and CAN Termination Resistor 2 (R6) Resistance 108—132 ohms
For CAN termination resistor 1 (R5) or MTG CAN 1 connector (X102) location and pin information:
If equipped with JDLink™, see Modular Telematics Gateway (MTG) Harness (W6002) Component Location and see Modular
Telematics Gateway (MTG) Harness (W6002) Wiring Diagram . (Group 9015-10.)
If not equipped with JDLink™, see Engine Harness (W10) Component Location and see Engine Harness (W10) Wiring Diagram .
(Group 9015-10.)
For CAN termination resistor 2 (R6) location and pin information:
See Canopy Harness (W15) Component Location or see Canopy Harness (W15) Wiring Diagram . (Group 9015-10.)
See Cab Harness (W14) Component Location or see Cab Harness (W14) Wiring Diagram . (Group 9015-10.)
Alternator Test
Common Alternator Circuit

LEGEND:
1 Battery
2 Alternator
3 Key Switch
4 To Accessories
5 ACC
6 Alternator Excitation Diode
7 Excitation Terminal (marked D+)
8 B+
9 Exciter Diodes
10 Positive Diodes
11 Negative Diodes
12 Stator
13 Excitation Winding (field)
14 Regulator
15 AC Terminal (marked W)
16 To Display Module (indicator lamp)
[1] - 12 V System — 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
.
[3] - If voltage from previous steps is below 13.5 VDC
, 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 does not produce specified voltage after testing, check for worn out brushes in the regulator/brush assembly.
Replace brush/regulator assembly if necessary. Test and repair if possible. If alternator still malfunctions, replace it. If
alternator tests OK, check indicator light circuit.
[1] - 24 V System — With engine running at slow idle, check DC voltage between terminal D+ and ground. Voltage should be
27.5 VDC or greater
.
[2] - With engine running at slow idle, check DC voltage between terminal B+ and ground. Voltage should be 27.5 VDC or
greater
.
[3] - If voltage from previous steps is below 27.5 VDC
, 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 does not produce specified voltage after testing, check for worn out brushes in the regulator/brush assembly.
Replace brush/regulator assembly if necessary. Make specific test and repair procedures. If alternator still malfunctions,
replace it. If alternator tests OK, check indicator light circuit.
Wire Harness Test

IMPORTANT:
damage the terminal and connector. When testing wire harnesses, always use spare mating terminals (2)
to connect test leads (1) to connector terminals.
LEGEND:
1 Test Lead
2 Spare Mating Terminal
Test Lead Connection
This technique is used to prevent a connector terminal from malfunctioning.
Sensor Circuit Test

→NOTE:
The following procedure will determine if there is a malfunction in the wiring harness or controller. This
procedure does not test the sensor.
LEGEND:
1 Jumper Wire
2 Jumper Wire (short to power)
3 Jumper Wire (short to ground)
Two-Wire Sensor Connector
Three-Wire Sensor Connector
[1] - Record and clear diagnostic trouble codes. See Reading Diagnostic Trouble Codes (DTCs) . (Group 9015-20.)
[2] - With switched power OFF, disconnect suspected sensor wiring harness connector.
Two-Wire Sensor—Connect jumper wire (1) between the terminals in the harness connector.
Three-Wire Sensor—If the original diagnostic trouble code was “Short-to-Power,” connect jumper wire (2) between the
sensing terminal and the ground terminal in the wiring harness connector. If the original diagnostic trouble code was
“Short-to-Ground,” connect jumper wire (3) between the sensing terminal and the power terminal in the wiring harness
connector.
[3] - Start engine and run for several seconds. Stop engine.
[5] - Record all diagnostic trouble codes as in step 1 above.
[6] - If a new diagnostic trouble code ( Short-to-Ground or Short-to-Power ) appears, a sensor malfunction is indicated.
If a new diagnostic trouble code does not appear, a harness or controller malfunction is indicated.
Crank Position Sensor Test
Standard Display Monitor (SDM) RPM Display
[2] - The standard display monitor (SDM) operator display mode shows engine rpm in top right of LCD display.
[3] - Start engine.

If engine does not start and rpm is not displayed, check the following:
Check start and charge circuits, see Start and Charge Circuit Theory of Operation . (Group 9015-15.)
Check ECU unswitched power 40 A fuse (F4). See Fuse and Relay Location and Specifications . (Group 9015-10.)
Check crank position sensor (B19) and wiring. See Engine Control Unit (ECU) Circuit Theory of Operation . (Group
9015-15.)
Transmission Control Circuit Test

Specifications
SPECIFICATIONS
Essential Tools
ESSENTIAL TOOLS
JDG10508 Diagnostic Connector
This procedure uses Service ADVISOR ™ to check transmission control circuit, including transmission control lever (TCL), wiring
harness, and transmission solenoids.
→NOTE:
Second part of procedure requires machine to be operated in gear with service brakes applied to test
transmission solenoids.
[1] - Connect to machine using Service ADVISOR and display model information for appropriate machine. See Service
ADVISOR™ Connection Procedure . (Group 9015-20.)
[2] - Open K-Backhoe Transmission Interactive Test.
[3] - Follow on-screen prompts within Service ADVISOR to check TCL and wiring harness.
[4] - Use JDG10508 Diagnostic Connector, as needed, to troubleshoot TCL and wiring harness.
LEGEND:
1 Steering Column
a.
Transmission Control Lever (TCL) Connector
JDG10508 Diagnostic Connector

Remove steering column covers as needed to access TCL connector (X48) on steering column (1).
b. Disconnect TCL switch connector and connect JDG10508 Diagnostic Connector to TCL connector.
Diagnostic Connector
JDG10508
Used to check transmission control lever (TCL) and wiring harness.
[5] - Troubleshoot wiring harness or TCL as directed by Service ADVISOR test results. Otherwise, proceed to next step.
See Transmission Control Lever (TCL) Test . (Group 9015-20.) See System Functional Schematic and Section Legend . (Group
9015-10.)
[6] - Start engine when directed by interactive test. Operate engine at specification.
[7] - Place TCL in neutral.
[8] - Follow on-screen prompts within Service ADVISOR to check transmission solenoids.
[9] - Troubleshoot transmission solenoids as directed by Service ADVISOR test results.

See Transmission Solenoid Check . (Group 9015-20.) See Transmission Harness (W13) Component Location . (Group 9015-10.)
[10] - View diagnostic trouble codes (DTCs) for machine, as DTCs may be generated during interactive test. Clear DTCs if
necessary. See Reading Diagnostic Trouble Codes (DTCs) . (Group 9015-20.)
Transmission Solenoid Circuit Test

This procedure tests transmission control solenoids using vehicle control unit (VCU) and standard display monitor (SDM),
without having to operate machine. Test cycles through all transmission control solenoids to ensure no malfunctions exist
between VCU and solenoids. This test is performed with engine off. A systematic activation of each control solenoid will check
for short to ground or open circuits. If a malfunction is detected, SDM displays a CHECK CODES message. Stored diagnostic
trouble codes (DTCs) should be checked for specific malfunction information.
This test should be run whenever a transmission electrical problem is suspected, or after a transmission harness replacement
as a way to verify all connections have been made correctly.
[1] - Park machine on a flat level surface.
[2] - Lower all equipment to ground, and turn engine off.
[3] - Switched power to ON position.
[4] - Press and hold MENU button for approximately 5 seconds to place SDM in SERVICE MENU mode. SDM will display SERVICE
MENU for 2 seconds before returning to previous screen. See Standard Display Monitor (SDM)—Service Menu . (Group
9015-16.)
[5] - From MAIN MENU press NEXT button until DIAGNOSTIC is highlighted, then press SELECT button. See Standard Display
Monitor (SDM)—Diagnostics . (Group 9015-16.)
[6] - Press NEXT button until TESTS is highlighted, then press SELECT button.
[7] - Press NEXT button until VCU OUTPUTS is highlighted, then press SELECT button.
→NOTE:
One transmission control solenoid is tested in each step. Each step is approximately 5 seconds in
duration.
[8] - If a malfunction is detected, CHECK CODES appears on display and audible alarm beeps twice. Check stored diagnostic
trouble codes (DTCs) to correct problem. See Reading Diagnostic Trouble Codes (DTCs) . (Group 9015-20.)
[9] - When test is complete with no malfunctions present, ALL OUTPUTS PASSED KEY OFF appears on display and audible alarm
beeps twice.
[10] - Switched power OFF.
Transmission Control Lever (TCL) Test

Procedure checks continuity through the transmission control lever (TCL) forward, neutral, reverse (FNR) switch (S5) and gear
select switch (S6) based on direction and gear selection.
[1] - Switched power OFF.
[2] -
LEGEND:
1 Steering Column
TCL/Range Switch Connector

Remove steering column covers as needed to access transmission control lever (TCL) connector (X48) on steering column (1).
[3] - Remove tie bands securing wire harness to steering column.
[4] - Disconnect TCL connector.
[5] -
IMPORTANT:
Continuity Check with Spare Mating Terminals

LEGEND:
2 Spare Mating Terminal (as required)
Avoid damage to connector from inserting test leads directly into connector. Use mating terminals or
JDG10466 Flex Probe Kit to perform test.
Cycle TCL through forward, neutral, and reverse positions. Using a multimeter, compare continuity measured between TCL
connector pins to the following table. Check continuity at TCL side of connector.
Direction Enable Circuit Continuity
Direction Enable Circuit Continuity
TCL Connector Pin
Selected Direction 1 2 3 4 5 6 7 8 9 10 11 12
Forward X X
Neutral X X
Reverse X X
[6] - Rotate gear select on TCL to cycle TCL range switch through gear positions. Using a multimeter, compare continuity
measured between TCL connector pins to the following table. Check continuity at TCL side of connector.
Range Enable Circuit Continuity
Range Enable Circuit Continuity
TCL Connector Pin
Selected Gear 1 2 3 4 5 6 7 8 9 10 11 12
First X X X
Second X X X
Third X X X
Fourth X X X
[7] - If continuity measured does not match tables, replace TCL assembly.
[8] - Connect TCL connector.
[9] - Install new tie bands to secure wire harness to steering column.
[10] - Install steering column covers, as required.
Transmission Solenoid Check

Disconnect the machine harness to the suspect transmission solenoid. Using a multimeter, measure the solenoid resistance. If
the resistance is not approximately 10.5 ohms, replace the solenoid valve. If resistance is within specification, check wiring.
Throttle Position Sensor Test

This procedure checks the engine speed control pedal (B20) and engine speed control dial (B21) using the service menu within
the standard display monitor (SDM). See Standard Display Monitor (SDM)—Diagnostics . (Group 9015-16.)
Engine Speed Control Pedal (B20) Test
[1] - Turn switched power ON to power up standard display monitor (SDM).
9015-16.)
[3] - From the MAIN MENU press NEXT button until DIAGNOSTICS is highlighted, then press the SELECT button.
[4] - Press NEXT button until ENGINE is highlighted, then press SELECT button.
[5] - Press NEXT button until THROTTLE is highlighted, then press SELECT button.
[6] - Press NEXT button until FOOT is highlighted, then press SELECT button.
[7] - Depress the engine speed control pedal and observe the change in the percent value displayed on the SDM.
[8] - If the engine speed control pedal percentage does not change from approximately 0% to 100% during full travel of pedal,
replace engine speed control pedal assembly.
Engine Speed Control Dial (B21) Test
[1] - Turn switched power ON to power up standard display monitor (SDM).
9015-16.)
[3] - From the MAIN MENU press NEXT button until DIAGNOSTICS is highlighted, then press the SELECT button.
[4] - Press NEXT button until ENGINE is highlighted, then press SELECT button.
[5] - Press NEXT button until THROTTLE is highlighted, then press SELECT button.
[6] - Press NEXT button until HAND is highlighted, then press SELECT button.
[7] - Turn the engine speed control dial and observe the change in the percent value displayed on the SDM.
[8] - If the engine speed control dial percentage does not change from approximately 0% to 100% during full travel of dial,
replace engine speed control dial assembly.
Engine Speed Control Pedal Test

The purpose of this test is to test signal output of engine speed control pedal (B20). Engine speed control pedal provides a
signal to engine control unit (ECU), based on pedal position, to control engine speed. For more information, see Engine Control
Unit (ECU) Circuit Theory of Operation . (Section 9015-15.)
Engine Speed Control Pedal Test Diagnostic Procedure

( 1 ) Engine Speed Control Pedal Signal Test
Action:
Check for engine speed control pedal signal change with primary display unit (PDU). See Throttle Position Sensor Test . (Group
9015-20.)
Does signal change approximately from 10% to 90% ± 5%?
Result:
YES:Check complete.
NO:Go to Engine Speed Control Pedal Sensor Check.
( 2 ) Engine Speed Control Pedal Sensor Check
Action:
Turn switched power to OFF position.

Disconnect the engine speed control pedal connector. See Canopy Harness (W15) Component Location or see Cab Harness
LEGEND:
1 Engine Speed Control Sensor Harness Connector
Engine Speed Control Pedal Test
Use JDG10466 Flex Probe Kit to connect power from pin C on engine speed control sensor harness connector to pin C on engine
speed control pedal (B20).
Use JDG10466 Flex Probe Kit to connect ground from pin B on engine speed control sensor harness connector to pin B on
engine speed control pedal (B20).
Set multimeter to measure voltage and connect multimeter positive test lead to pin A and multimeter negative test lead to
ground.
Turn switched power to ON position.
Move pedal through full range of motion and record voltage output. Compare to specification.
Engine Speed Control Pedal (B20) Voltage 4.75 V pedal fully pushed
0.5 V pedal released
→NOTE:
Voltage output should increase as pedal is being pushed through full range of motion, but must remain
within specification.
Does voltage change approximately from 0.5 V to 4.75 V ?
Result:
YES:Go to Wiring Harness Check.

NO:Replace engine speed control pedal (B20).
( 3 ) Wiring Harness Check
Action:
Turn switched power to OFF position.

Using system functional schematic, wiring diagram, and component location master legend, check for shorts and opens in the
circuit. Work from engine control unit back to engine speed control pedal, checking for shorts and opens in the circuit.
Is a short or open detected?
Result:
YES:Repair or replace harness as necessary.

NO:Checks complete.
Vehicle Control Unit (VCU) Output Test

This procedure tests outputs of the vehicle control unit (VCU) using the standard display monitor (SDM), without need to
operate machine. The test cycles through most VCU outputs (including transmission solenoid outputs) to ensure there are no
malfunctions between VCU and component controlled by the VCU output. The test is performed with engine off, and
systematically activates outputs to check for short to ground and open circuits. If a malfunction is detected, the SDM displays a
CHECK CODES message. Stored diagnostic trouble codes (DTCs) should be checked for specific malfunction information.
[1] - Park machine on a flat, level surface.
[2] - Lower all equipment to ground, and turn engine off.
9015-16.)
[5] - From MAIN MENU press NEXT button until DIAGNOSTICS is highlighted, then press SELECT button.
[6] - Press NEXT button until TESTS is highlighted, then press SELECT button.
[7] - VCU OUTPUTS is highlighted, press SELECT button.
[8] - One output is tested in each step. Each step is approximately 5 seconds in duration.
[9] - If a malfunction is detected, CHECK CODES appears on the display and audible alarm beeps twice. Check the stored
diagnostic trouble codes (DTCs) to correct the problem. See Reading Diagnostic Trouble Codes (DTCs) . (Group 9015-20.)
[10] - When test is complete with no malfunctions present, ALL OUTPUTS PASSED KEY OFF is displayed and alarm beeps twice.
[11] - Turn switched power to OFF position.
Seat Position Sensor Remove and Install

Use this procedure to remove and install the seat position sensor (B9). For more seat information, see Mechanical Suspension
Seat Disassemble and Assemble or see Air Suspension Seat Disassemble and Assemble—If Equipped . (Group 1821.)
[1] - Place operator′s seat in the forward (loader) position, and slide seat all the way to the rear.
[2] - Rotate seat counterclockwise 45 degrees and remove front seat bracket nuts (1).
LEGEND:
1 Front Seat Bracket Nut (2 used)
2 Back Seat Bracket Nut (2 used)
Seat Bracket
[3] - Return seat clockwise 45 degrees and slide seat all the way forward.
[4] - Remove rear seat bracket nuts (2).
[5] - To access seat position sensor, tilt complete seat assembly forward. Rest seat against steering wheel and secure.
[6] - Remove wire connector from seat position sensor.
[7] - Mark position of seat sensor.
[8] - Remove seat position sensor cap screws (3).

LEGEND:
3 Cap Screw (2 used)
Seat Position Sensor
[9] -
→NOTE:
Position sensor and position sensor lever are keyed.
Remove seat position sensor (B9).
[10] - Install new seat position sensor, lining up key on seat position sensor lever and seat position sensor.
[11] -
IMPORTANT:
Avoid damage to wiring. Route and secure wiring in original positions during assembly.
Place seat position sensor in marked position and install cap screws to sensor plate.
POWER TRAIN (g) by Belgreen v2.0
[12] - Connect wire connector to seat position sensor.
[13] - Carefully set seat on operator′s station platform without damaging wiring.
[14] - Install rear seat bracket nuts.
[15] - Slide seat all the way to the rear and rotate seat counterclockwise 45 degrees.
[16] - Install front seat bracket nuts.
Controller Remove and Install

When a machine controller is replaced, the new controller must be programmed according to machine′s serial number. This will
ensure correct software and options are installed to controller for that particular machine. Machine may run and operate
without programming new controller, but some features and options may not be available.
Section 9020 - POWER TRAIN

Table of contents
Power Train Overview ........................................................................................................................... 1
Transmission Pump Operation .............................................................................................................. 4
Torque Converter Operation ................................................................................................................. 5
Transmission Filter Operation ............................................................................................................... 7
Clutch Modulation Operation ................................................................................................................ 8
Clutch Pack Operation ........................................................................................................................ 10
Transmission Gear Flow ...................................................................................................................... 11
Transmission Clutch Engagement and Solenoid Activation ................................................................ 14
Differential Operation ......................................................................................................................... 15
Differential Lock Operation ................................................................................................................. 16
Mechanical Front Wheel Drive (MFWD) Operation—If Equipped ......................................................... 18
Mechanical Front Wheel Drive (MFWD) Differential Operation—If Equipped ...................................... 20
Park Brake Operation ......................................................................................................................... 22
Service Brake Operation ..................................................................................................................... 24
Power Boost Service Brake Valve Operation ...................................................................................... 25
Group 15 - Diagnostic Information ...................................................................................................... 29
Hydraulic Circuit—Symbols ................................................................................................................. 29
Power Train Component Location ....................................................................................................... 30
Power Train Schematic—Neutral ........................................................................................................ 32
Power Train Schematic—First Forward ............................................................................................... 34
Diagnose Transmission Malfunctions .................................................................................................. 36
Transmission Slippage Diagnostic Procedure ..................................................................................... 37
Machine Lacks Power or Moves Slow Diagnostic Procedure ............................................................... 38
Transmission Overheats Diagnostic Procedure .................................................................................. 42
Excessive Power Train Noise Diagnostic Procedure ............................................................................ 45
No Power to Mechanical Front Wheel Drive (MFWD) Diagnostic Procedure ........................................ 47
No Power to One Wheel of Mechanical Front Wheel Drive (MFWD) Diagnostic Procedure ................. 49
No Differential Lock Operation Diagnostic Procedure ......................................................................... 50
Differential Lock Slips or Chatters When Engaged Diagnostic Procedure ........................................... 50
Differential Lock Will Not Release Diagnostic Procedure .................................................................... 52
Rear Axle Overfilled With Oil Diagnostic Procedure ............................................................................ 53
Poor Service Brakes Diagnostic Procedure ......................................................................................... 53
Service Brakes Will Not Release Diagnostic Procedure ...................................................................... 54
Service Brakes Chatter or Noisy Diagnostic Procedure ...................................................................... 55
Park Brake Will Not Hold Diagnostic Procedure .................................................................................. 56
Park Brake Will Not Release Diagnostic Procedure ............................................................................. 57
Group 20 - Adjustments ........................................................................................................................ 58
Mechanical Park Brake Release—Towing ........................................................................................... 58
Service Brake Pedal Adjustment ......................................................................................................... 61
Service Brake Bleed Procedure .......................................................................................................... 63
Tracking Angle Check and Adjust ....................................................................................................... 67
Toe-In Check and Adjust ..................................................................................................................... 69
Steering Angle Check and Adjust ....................................................................................................... 72
Group 25 - Tests ..................................................................................................................................... 74
Transmission Oil Warm-Up Procedure ................................................................................................ 74
Transmission Oil Sampling Procedure—If Equipped ........................................................................... 75
Transmission Overall Test Connections, Ports, and Locations ............................................................ 76
Torque Converter Stall Speed Test ..................................................................................................... 78
Torque Converter-In Relief Valve Test ................................................................................................ 81

Power Boost Service Brake Valve Leakage Test ................................................................................. 84

Park Brake Release Pressure Test ...................................................................................................... 87
Transmission System Pressure Test ................................................................................................... 89
Clutch Pressure Test ........................................................................................................................... 92
Differential Lock Pressure Test ........................................................................................................... 95
Mechanical Front Wheel Drive (MFWD) Pressure Test ........................................................................ 97
Cooler In and Cooler Out Pressure Test .............................................................................................. 99
Solenoid Circuit Leakage Test .......................................................................................................... 103
Transmission Pump Flow Test .......................................................................................................... 104

Section 9020 - POWER TRAIN Group 05: Theory of Operation

Power Train Overview
Power Train Overview

LEGEND:
1 Pump Drive Shaft
2 Mechanical Front Wheel Drive (MFWD) Output Shaft (if equipped)
31 Transmission Pump
36 Torque Converter
45 First Speed Clutch (K1)
46 Second Speed Clutch (K2)
47 Third Speed Clutch (K3)
59 Low Range Forward Clutch (KV)
60 High Range Forward Clutch (K4)
61 Reverse Clutch (KR)
64 Mechanical Front Wheel Drive (MFWD) Clutch
70 Transmission
→NOTE:
For locations of components, see Power Train Component Location . (Group 9020-15.)
The power train consists of the following components:
Front Axle (non-powered)

Mechanical Front Wheel Drive (MFWD) Axle (if equipped)
Front Drive Shaft (MFWD, if equipped)
Torque Converter
Transmission Pump
Transmission
Rear Drive Shaft
Rear Axle
Differential Lock
Park Brake
A single stage dual phase torque converter (36) drives a hydraulically engaged five speeds forward and three speeds reverse
countershaft type power shift transmission (70).
Six clutch packs provide five forward and three reverse speeds. Two clutch packs have to be engaged for movement. One
directional clutch pack, either low-range forward or high-range forward, and one speed range clutch pack either first or second.
For reverse, the reverse directional clutch pack will be engaged, and one speed range clutch pack, either first or second.
The transmission pump (31) is a gear type pump. The transmission pump is driven at engine speed through the impeller drive
from the torque converter. For information on how the transmission pump operates, see Transmission Pump Operation . (Group
9020-05.)
The optional MFWD front axle consists of either an open or self applied limited slip differential with outboard planetary final
drives. For more information on MFWD operation, see Mechanical Front Wheel Drive (MFWD) Operation—If Equipped . (Group
9020-05.)
The rear axle is an outboard four planetary design with internal wet multi-disk service brakes that are self adjusting. Pressure
oil for the service brakes is supplied by a foot operated brake valve. For information on how the differential operates, see
Differential Operation . (Group 9020-05.)
The park brake is a wet multi-disk design which is spring applied and hydraulically released. For information on how the park
brake operates, see Park Brake Operation . (Group 9020-05.)
The differential lock is a sliding sleeve design, which is hydraulically engaged and spring released. For information on how the
differential lock operates, see Differential Lock Operation . (Group 9020-05.)
Transmission Pump Operation
Transmission Pump
LEGEND:
2 Seal
3 O-Ring
The transmission uses a high capacity fixed displacement gear-type pump to provide constant flow for the transmission
hydraulic system. Pump flow is proportional to engine speed.
The input shaft to the pump is driven by the engine. The pump gears rotate inside of the pump housing. As the gears rotate, oil
is trapped between the gear teeth and the pump housing which forces oil to move from the pump inlet around the gears to the
pump outlet.
Torque Converter Operation
Torque Converter Operation

LEGEND:
1 Pump Drive Shaft
2 Stator
3 Turbine
4 Impeller
5 Stator Shaft
6 Shaft Seal
7 Freewheel Clutch
8 Transmission Clutch Drive Shaft
The transmission utilizes a hydrodynamic torque converter. Supply oil from transmission pump flows through a system
pressure regulating valve then to the converter. The converter inlet also incorporates a relief valve that protects converter
from high internal pressures. The converter must always be completely filled with oil to avoid cavitation.
Pump drive shaft (1) is driven directly by the engine at engine speed. The pump drive shaft provides input to the hydraulic
system pump, which also has a direct mechanical connection to the flywheel through the outer skin of the converter.
The impeller (4) is connected to the pump drive shaft. This forces the turbine to rotate in same direction as impeller. As it
rotates, centrifugal force throws oil out of impeller against the blades of turbine (3). The turbine (3) is connected to the
transmission clutch drive shaft (8) which provides input to the transmission gear train.
Oil leaving turbine enters stator (2) in the opposite direction of turbine and impeller oil flow. The stator is curved to change oil
flow direction back to match direction of impeller rotation. Oil leaving the stator is now moving in the same direction as the
impeller. This adds to the force of the oil entering impeller. The turbine will be rotating at a slower speed than the impeller, but
it will produce a higher torque. It is this increased force developed by the stator that makes a converter able to multiply torque.
Under light load turbine speed will increase until it equals impeller speed. When the two speeds are equal, free wheel clutch (7)
unlocks, allowing stator to freewheel or rotate with turbine and impeller as a unit. Input speed and torque are equal to output
speed and torque when stator is free wheeling.
The transmission pump is constantly pumping oil through the converter. The converter multiplies torque and at the same time,
heat created in the converter is eliminated through the oil circulation from converter to cooler and back to sump.
Transmission Filter Operation
Transmission Filter Operation

LEGEND:
1 Spring
2 To Transmission Circuit
3 From Transmission Circuit
32 Transmission Oil Filter
33 Oil Filter Bypass Valve
→NOTE:
Filter housing removed to show element and bypass valve.
The transmission oil filter (32) is a spin on replaceable element. If the transmission oil filter becomes obstructed, an oil filter
bypass valve (33) opens to maintain flow to the transmission control system.
Oil from the transmission pump enters from outside of transmission oil filter element. The transmission oil filter element traps
contaminants as the oil passes through it. Filtered oil flows up through the middle of the element to the transmission control
system.
If the transmission oil is extremely cold or the transmission filter element is obstructed, the pressure difference across the
transmission oil filter element increases causing the filter bypass valve to shift against the bypass spring and unseat. This
unseated valve allows unfiltered oil to pass through the filter housing. Bypass operation for extended periods of time is not
recommended.
Clutch Modulation Operation
Modulation in Clutch Pack

LEGEND:
1 Piston
2 Orifice
3 From Transmission Pump
4 Modulation Spring
5 Inner Disk Carrier
6 End Plate
7 Clutch Fill
8 Pre-Modulation
9 Modulation
10 Engagement
11 Orifice (modulation spool)
600 High Pressure Oil
601 Medium Pressure Oil
602 Low Pressure Oil
603 Lubrication Oil

Rate of shift is controlled by movement of modulation spring (4) and piston during a shift. By regulating amount of oil flow sent
to engage the clutch pack, modulation time is controlled to assure a smooth shift.
A controlled leak in piston (1) through orifice (2) is used to soften clutch engagement. Clutch fill (7) begins when a shift is
electronically commanded. The activation of solenoids allows oil to flow from transmission pump (3) to the clutch piston.
Pressure is reduced to low pressure through orifice (11) during fill.
Pre-modulation (8) begins when oil has filled the passages between transmission pump and clutch piston. During pre-
modulation, the lower load spring of the modulation spring (4) is compressed applying a small amount of load to the clutch.
Modulation (9) begins when the lower load spring of the modulation spring is fully compressed. During modulation, the higher
load spring of the modulation spring is compressed applying additional load to the clutch.
During pre-modulation and modulation, compression of the modulation spring progressively restricts oil flow through the piston
orifice.
Engagement (10) occurs when the piston orifice is blocked by the compressed modulation spring.
Clutch Pack Operation
Clutch Pack
LEGEND:
1 Clutch Piston
2 Clutch Drum
3 Coil Spring
4 Inner Disc Carrier
5 End Plate
6 Clutch Plate
7 Clutch Disk
8 Modulation Spring
603 Lubrication Oil
→NOTE:
All power shift transmission clutches are covered in this operation. Function of all clutch packs is the
same, but quantity of disks and separator plates are different.
When transmission control lever (TCL) is placed in forward or reverse, high pressure oil (600) from transmission pump forces
clutch piston (1) to compress plates (6) and disks (7). The plates are splined to clutch drum (2) and the disks are splined to
inner disc carrier (4), locking them together. All gears are constantly meshed and supported by antifriction bearings. The
bearings and clutches are lubricated with cooled lubrication oil (603). When clutch pack is disengaged, coil spring (3) pushes
the clutch piston away from plates and disks, releasing the multi disk clutch.
Transmission Gear Flow
Transmission Gear Flow—Foward
Transmission Gear Flow—Reverse

LEGEND:
1 Neutral
2 First Forward
3 Second Forward
4 Third Forward
5 Fourth Forward
6 Fifth Forward
7 First Reverse
8 Second Reverse
9 Third Reverse
10 Input/Output Gear
11 Middle Gear
12 Direction Clutch
13 Input/Output Gear (engaged)
14 Middle Gear (engaged)
15 Direction Clutch (engaged)
47 Third Speed Clutch
64 Mechanical Front Wheel Drive (MFWD) Clutch
The torque converter sends power down the reverse clutch (61) shaft which consists of two input gears. When a forward gear is
selected the smaller reverse shaft input gear sends power to the low range forward clutch (59) output gear. Power continues to
flow through the high range forward clutch (60) and speed gears to the second speed clutch (46) output shaft. When a reverse
gear is selected power is sent to the high range forward clutch (60) shaft and continues to flow through the speed gears to
second speed clutch output shaft.
Example: Fifth forward (6)
The torque converters supplies torque down the reverse clutch (61) shaft. Power from the reverse clutch shaft flows to the low
range forward clutch (59) middle gear. Since the low range forward clutch does not engage for fifth gear, power stays on same
side of low range forward clutch shaft and is output through the large low range clutch gear down to the high range forward
clutch (60) small gear. See Transmission Clutch Engagement and Solenoid Activation . (Group 9020-05.) The high range
forward clutch is engaged causing the entire shaft to spin at the same speed. Power travels down the high range forward shaft
to the large gear. Power is output from the high range forward clutch large gear and flows through freewheeling first and
second forward clutch (2, 3) large gears down to third forward clutch (4) small gear. With third forward clutch engaged, power
flows down third forward clutch shaft to the large gear. Third forward clutch large gear outputs power back up to second
forward clutch small gear sending torque out the final output shaft.
Transmission Clutch Engagement and Solenoid Activation

Transmission Clutch to Gear Relationship
1F 2F 3F 4F 5F 1R 2R 3R N
Low Range Forward (KV) X X
Reverse Clutch (KR) X X X
1st Speed Clutch (K1) X X X
2nd Speed Clutch (K2) X X X
3rd Speed Clutch (K3) X X
High Range Forward (K4) X X X
Solenoid to Gear Relationship
1F 2F 3F 4F 5F 1R 2R 3R N
Y1 X X X X X
Y2 X X X
Y3 X X X X
Y4 X X X X X
Y5 X X X
Y6 X X
Solenoid to Clutch Pack Relationship
Low Range Forward (KV) Reverse Clutch (KR) High Range Forward (K4) 1st Speed Clutch (K1) 2nd Speed Clutch (K2) 3rd Speed Clutch (K3)
Y1 X X
Y2 X
Y3 X
Y4 X X
Y5 X
Y6 X
Differential Operation
Differential Operation
LEGEND:
1 Differential Housing
2 Ring Gear (differential)
3 Bevel Pinion
4 Bevel Pinion Shaft
5 Side Gear
6 Sun Pinion Shaft
The differential allows independent rotation of the axles when the machine is steered. The final drive planetaries are attached
to the axles. Their purpose is to reduce speed and increase torque through gear reduction. The input pinion shaft to differential
ring gear also provides a reduction in speed and an increase to torque.
Input torque from the drive shaft rotates the input bevel pinion shaft which meshes with the ring gear (differential) (2), causing
it to turn. The ring gear is fastened to the differential housing (1) which drives the bevel pinion shafts (4) and bevel pinions (3).
The bevel pinions located on the bevel pinion shaft are in mesh with the side gears (5) which spline to the sun pinion shaft (6).
As the machine is steered, the inside wheel slows down in relation to the outside wheel. This causes the side gear, attached to
the inside wheel’s axle, to slow down. The rotating differential housing and bevel pinion shafts allow the differential bevel
pinions to rotate around the slow moving side gear; this allows the opposite side gear to rotate at a faster speed. This rotation
causes the outside wheel’s axle to rotate faster than the inside axle which prevents tire scuffing.
Differential Lock Operation
Differential Lock Operation

LEGEND:
1 Ring Gear
2 Bevel Pinion
3 Bevel Pinion Shaft
4 Side Gear
5 Piston
6 Sliding Gear
7 Spring
8 Bearing
603 Lubrication Oil
When differential lock foot control switch is in the ON position, the differential lock solenoid (Y10) on the transmission is
energized. High pressure oil (600) flows to the inlet and through cross-drilled passages to the piston (5). Pressure oil forces
piston against sliding gear (6) locking sliding gear with side gear (4) of the differential, causing both axles to rotate at the same
speed.
When the differential lock foot control switch in the OFF position, spring force (7) moves sliding gear (6) and piston (5) back
releasing the differential lock. Return oil flows through the same port as when switch is in the ON position.
Mechanical Front Wheel Drive (MFWD) Operation—If Equipped
Mechanical Front Wheel Drive (MFWD) Operation

LEGEND:
1 MFWD Disengaged
2 MFWD Engaged
3 Front Output Shaft
4 Clutch Drum
5 Bevel Spring
6 Drive Gear
8 Piston
9 Disk
10 Plate
11 Inner Disk Carrier
603 Lubrication Oil
604 Return Oil

Mechanical front wheel drive (MFWD) is hydraulically applied and spring released. When MFWD switch is in the ON position,
MFWD solenoid (Y11) is energized sending high pressure oil from transmission pump forces clutch piston (8) to compress disks
(9) and plates (10). Plates are splined to the clutch drum and disks are splined to the inner disk carrier, locking them together.
When MFWD switch is in the OFF position, the MFWD clutch oil passage is open to return. Bevel spring (5) forces the piston
back, disengaging the multi-disk clutch and front output shaft.
This gear is supported by antifriction bearings. The bearings and clutch are lubricated with cooled lubrication oil (603).
Mechanical Front Wheel Drive (MFWD) Differential Operation—If

Equipped
Open Differential
Open Differential
LEGEND:
1 Pinion Gears
2 Bevel Drive Gear (2 used)
3 Drive Shaft
6 Power Flow
7 Rotation Direction
79 Drive Shaft (MFWD) (if equipped)
Equal Traction
With mechanical front wheel drive (MFWD) engaged and equal traction, each wheel receives the same amount of power on the
same axle, and no differential action occurs.
Power flows into axle housing through drive shaft (MFWD) (79) turning ring gear (differential) (5) and attached differential
housing (4). When both wheels have equal traction, pinion gears (1) remain stationary within rotating housing.
Unequal Traction
With MFWD engaged and unequal traction, the most torque will go to the wheel on each axle which requires less torque to
move. If a wheel slips, torque will go to that wheel and it will continue to spin.
Power flows into axle housing through drive shaft (MFWD) turning ring gear (differential) and attached housing. When a wheel
spins, the pinion gears will rotate causing the wheel with least amount of traction to receive the most torque. The wheel with
the most traction will stay stationary.
Limited Slip Differential
Limited Slip Differential

LEGEND:
1 Pinion Gears
2 Bevel Drive Gear (2 used)
3 Drive Shaft (2 used)
6 Clutch Disks
7 Clutch Plates
8 Power Flow
9 Rotation Direction
79 Drive Shaft (MFWD) (if equipped)
Equal Traction
Mechanical front wheel drive (MFWD) axle has a self-applied limited slip differential. The differential utilizes a wet multi-disk
clutch to distribute torque. When confronted with slippery field conditions, this system automatically applies correct amount of
torque to match traction available to each tire.
With MFWD engaged, when tractor is moving in a straight line and each wheel has equal traction, equal power is supplied to
left and right drive shafts (3). No differential action occurs.
Power flows into axle housing through drive shaft (MFWD) (79), turning ring gear (differential) (5) and attached differential
housing (4). When both wheels have equal traction, pinion gears (1) remain stationary within rotating housing. Pinions turn
bevel drive gears (2) and drive shaft (3) splined to drive gears.
Unequal Traction
When one wheel starts slipping more than the other, the pinion gears (1) will start "walking" around the bevel drive gear (2)
with most traction. At the same time the angle of gear teeth forces the meshed gears (pinion and bevel) apart. The bevel drive
gear with most traction is forced out and away from gear mesh assembly, compressing a clutch pack with disks (6) splined to
axle and plates (7) splined to housing. The more torque required to turn wheel, the more clutch pack is compressed, therefore
the more coupled wheels become.
Because wheel with less traction is exerting less force trying to keep its axle from turning, the pinion gears do not force the
bevel drive gear outward, effectively not engaging it’s clutch pack. Less drive force is being transmitted to this drive shaft. As
long as the difference in traction between tires remains the same, the clutch pack on the side with less traction will continue to
slip more than pack for other side.
Park Brake Operation
Park Brake Operation

LEGEND:
1 Spring
2 Piston
4 Plate
5 Disk
603 Lubrication Oil
The park brake is spring applied and hydraulically released. When the park brake switch is in the ON position or machine is
shutoff, spring force applies the park brake. Spring (1) forces piston (2) against disks (5) and plates (4) on the axle input shaft.
When park brake switch is cycled to the OFF position, the switch energizes the park brake release solenoid (Y7) on the
transmission. The solenoid routes high pressure oil (600) to the piston. The piston moves against the spring and releases the
disks and plates. Two manual operated cap screws (3) release the park brake for emergency towing.
Service Brake Operation
Service Brakes
LEGEND:
1 Piston
2 Disk
3 Plate
4 Spring
591 Pinion Shaft
The rear axle assembly uses wet multi-disk brakes which are self-adjusting to compensate for wear. The disks are splined to
the sun gear shaft and the plates are splined to the rear axle housing.
When the service brakes are applied, the pressure oil from the brake valve, forces the brake piston (1) against the brake plates
(3) and disks (2) which stops rotation of the pinion shaft (5). When the brakes are released the return oil flows back out the
same port to the brake valve.
Power Boost Service Brake Valve Operation

Service Brakes Released
Service Brakes Released, Engine On

LEGEND:
1 Transmission Reservoir Port
2 Push Rod (brake pedal) (2 used)
3 Check Ball (2 used)
4 Land (2 used)
5 Inlet Port (2 used)
6 Spring (2 used)
7 Spring (2 used)
8 Seal (2 used)
9 Piston (2 used)
10 Tip Valve Assembly (2 used)
11 Master Hydraulic Reservoir Port (2 used)
12 Spring (2 used)
13 Brake Port (2 used)
14 Equalization Spool
604 Pressure Free Oil
Low pressure oil (602) from the transmission enters inlet ports (5) separately. This oil flows through land (4) areas, through the
center of pistons (9) and on to the transmission reservoir port (1). This oil provides boost pressure to assist piston movement.
The two halves of the master cylinder reservoir are open to one another. Hydraulic oil from the main hydraulic reservoir or
steering valve on later models enters the master cylinder reservoir at ports (11). A small flow of oil at these hydraulic ports
keeps the master cylinder reservoir full.
In the neutral position, pistons (9) are fully retracted and tip valve assemblies (10) are open. The brake system is at reservoir
pressure through brake ports (13).
The pedals are held in the neutral position by springs (6 and 7).
Service Brakes Engaged—Engine On
Service Brakes Engaged, Engine On

LEGEND:
4 Land (2 used)
6 Spring (2 used)
7 Spring (2 used)
8 Seal (2 used)
9 Piston (2 used)
12 Spring (2 used)
Medium pressure oil (601) from the transmission enters inlet ports (5) separately and flows through land (4) area to
transmission reservoir port (1). Both pedals are depressed forcing springs (6) to compress. Oil flowing through land areas
becomes restricted. Oil flow moves to close check balls (3). Restricted oil flow and lands causes pressure to act against the
large diameter of pistons (9). Pistons move to compress springs (7). As more push rod displacement occurs, tip valve
assemblies (10) close, stopping brake system oil from moving to reservoir or atmosphere pressure. Additional movement of the
push rods and pistons forces brake system oil to the brakes causing brakes to fill through ports (13).
Equalization spool (14) moves against either spring (12) to perform an equalization function by compensating for differences
between right and left brake pack fill volumes.
After the brakes are filled, higher brake pressure is developed by the inlet oil pressure being modulated at lands causing piston
to generate a higher pressure at the brake ports. Brake pedal modulated feel is determined by the hydraulic areas of push rods
and modulated pressure at lands.
Maximum boosted brake pressure is limited by the inlet oil pressure at inlet ports (5). Additional pedal effort can cause higher
brake pressure and is dependent only by the amount of pedal force applied.
Service Brakes Engaged—One Pedal
Service Brakes Engaged—One Pedal, Engine On

LEGEND:
4 Land (2 used)
6 Spring (2 used)
7 Spring (2 used)
8 Seal (2 used)
9 Piston (2 used)
12 Spring (2 used)
When only one pedal is applied, the opposite side brake remains at reservoir pressure. Tip valve assembly (10) closes the
passage to reservoir on the right side and opens the work port cavity on left side to allow oil to return to brake reservoir.
Equalization spool (14) moves against spring (12) towards side of valve with brake not applied. The effort required on one
pedal is one half that of the effort when you apply both pedals to obtain the same brake pressure.
Service Brakes Engaged—Engine Off
Section 9020 - POWER TRAIN Group 15: Diagnostic Information
Service Brakes Engaged—Engine Off

LEGEND:
4 Land (2 used)
6 Spring (2 used)
7 Spring (2 used)
8 Seal (2 used)
9 Piston (2 used)
12 Spring (2 used)
When the engine is not running, one or both brakes can be actuated manually. When push rods (2) are displaced by the pedals,
springs (6) compress until lands (4) are mechanically closed. Additional push rod displacement forces pistons (9) to move. Tip
valve assemblies (10) close, stopping oil from going to the hydraulic reservoir. More push rod travel fills the brakes and
pressure is developed to provide pedal force. The amount of pressure to the brakes depends on how hard the pedals are
pushed. When the pedals return to the neutral position, tip valve assemblies (10) open and return brakes to reservoir pressure.

Hydraulic Circuit—Symbols
Hydraulic Circuit Symbols
Power Train Component Location
Power Train Component Location
LEGEND:
36 Torque Converter
70 Transmission
71 Drive Shaft (rear)
72 Park Brake Housing
73 Rear Axle
74 Front Axle (non-powered)
75 Park Brake Valve-to-Park Brake Line
76 Service Brake Valve
77 Service Brake Valve-to-Service Brake Line (2 used)
78 Differential Lock Valve-to-Differential Lock Line
79 Drive Shaft (MFWD)(if equipped)
80 Mechanical Front Wheel Drive (MFWD) Axle (if equipped)
81 Transmission Dipstick
Power Train Schematic—Neutral
Power Train Schematic—Neutral
LEGEND:
34 Pressure Regulating Valve
35 Torque Converter Relief Valve
36 Torque Converter
40 To Lube
63 Differential Lock Clutch
64 Mechanical Front Wheel Drive (MFWD) Clutch (if equipped)
65 Park Brake Clutch
66 Screen (3 used)
86 Torque Converter Pressure Port
90 Differential Lock Pressure Port
91 Park Brake Pressure Port
97 System Pressure Test Port
99 Mechanical Front Wheel Drive (MFWD) Pressure Test Port
103 Low Range Forward Clutch Pressure Test Port (KV)
104 Third Speed Clutch Pressure Test Port (K3)
105 Second Speed Clutch Pressure Test Port (K2)
106 First Speed Clutch Pressure Test Port (K1)
107 High Range Forward Clutch Pressure Test Port (K4)
108 Reverse Clutch Pressure Test Port (KR)
603 Lubrication Oil
604 Return Oil
Y11 Mechanical Front Wheel Drive (MFWD) Solenoid (if equipped)
Power Train Schematic—First Forward
Power Train Schematic—First Forward Mechanical Front Wheel Drive (MFWD) Engaged
LEGEND:
34 Pressure Regulating Valve
35 Torque Converter Relief Valve
36 Torque Converter
40 To Lube
63 Differential Lock Clutch
64 Mechanical Front Wheel Drive (MFWD) Clutch (if equipped)
65 Park Brake Clutch
66 Screen (3 used)
603 Lubrication Oil
604 Return Oil
Y11 Mechanical Front Wheel Drive (MFWD) Solenoid (if equipped)
Diagnose Transmission Malfunctions

Diagnose Transmission Malfunctions
Symptom Resulting Transmission State Suspect Component(s)
N 1F 2F 3F 4F 5F 1R 2R 3R
-Transmission control lever (TCL) switch malfunction

-Vehicle Control Unit (VCU) circuit
No forward or reverse N N N N N N N N N -Internal VCU logic error
-Transmission forward direction solenoid (Y1) short to power
-Transmission reverse direction solenoid (Y2) short to power
-Transmission forward direction solenoid (Y1) open or short to ground

No forward gears N N N N N N 1R 2R 3R
-TCL switch malfunction
-TCL switch malfunction

No reverse gears N 1F 2F 3F 4F 5F N N N -Transmission reverse direction solenoid (Y2) open or short to ground
-Reverse clutch (KR) problem
Incorrect 1F, 2F and slight resistance

N 3F 4F 3F 4F 5F 1R 2R 3R Transmission speed solenoid 1 (Y3) open or short to ground
in 1R, 2R gears
Incorrect 3F, 4F, 5F gears N 1F 2F 1F 2F 4.5F 1R 2R 3R Transmission speed solenoid 1 (Y3) solenoid short to power
-Transmission speed solenoid 2 (Y4) open or short to ground

No 2F, 4F, 5F, 2R, 3R gears N 1F N 3F N N 1R N N
-Transmission speed solenoid 3 (Y5) short to power
-Transmission speed solenoid 2 (Y4) short to power

No 1F, 3F, 1R gears N N 2F N 4F 5F N 2R 3R
-Transmission speed solenoid 3 (Y5) open or short to ground
Incorrect 5F, 3R gears N 1F 2F 3F 4F 4F 1R 2R 2R Transmission speed solenoid 4 (Y6) open or short to ground
Incorrect 2F, 4F, 2R gears N 1F 2.5F 3F 5F 5F 1R 3R 3R Transmission speed solenoid 4 (Y6) short to power
No 1F, 2F gears N N N 3F 4F 5F 1R 2R 3R Low range forward clutch (KV) problem
No 1F, 3F, 1R gears N N 2F N 4F 5F N 2R 3R First speed clutch (K1) problem
No 2F, 4F, 2R gears N 1F N 3F N 5F 1R N 3R Second speed clutch (K2) problem
No 5F, 3R gears N 1F 2F 3F 4F N 1R 2R N Third speed clutch (K3) problem
No 3F, 4F, 5F gears N 1F 2F N N N 1R 2R 3R High range forward clutch (K4) problem
Transmission Slippage
79
Transmission Slippage Diagnostic Procedure

( 1 ) Low Oil Level
Action:
Check transmission oil level. See Check Transmission Oil Level . (Operator′s Manual.)
Is oil level low?
Result:
YES:Add oil as necessary. See Transmission, Axles, and Mechanical Front Wheel Drive (MFWD) Oil . (Operator′s Manual.)
NO:Go to Wrong Oil Grade.
( 2 ) Incorrect Oil Grade
Action:
Check grade of oil. See Transmission, Axles, and Mechanical Front Wheel Drive (MFWD) Oil . (Operator′s Manual.)
Is the grade of oil incorrect?
Result:
YES:Change oil. See Transmission, Axles, and Mechanical Front Wheel Drive (MFWD) Oil . (Operator′s Manual.)
NO:Go to Low Torque Converter Oil Pressure.
( 3 ) Low Torque Converter Oil Pressure
Action:
Check torque converter oil pressure. See Torque Converter-In Relief Valve Test . (Group 9020-25.)
Is torque converter oil pressure low?
Result:
YES:Check transmission pump flow. See Transmission Pump Flow Test . (Group 9020-25).
NO:Go to Worn or Slipping Clutch Disks.
( 4 ) Worn or Slipping Clutch Disks
Action:
Check clutch disks to see if they are worn or slipping. See Clutch Pressure Test . (Group 9020-25.)
Are clutch disks worn or slipping?
Result:
YES:Repair clutch disks.For 210K-410K models, see Clutch Packs Remove . (Group 0350.) For 710K models, see First Speed,
Second Speed, and High Range Forward Clutch Packs Repair or see Low Range Forward, Reverse, and Third Speed Clutch Packs
Repair . (Group 0350.)
NO:Checks complete.
Machine Lacks Power or Moves Slow

81
Machine Lacks Power or Moves Slow Diagnostic Procedure

( 1 ) Check DTCs
Action:
Check machine for DTCs. See Reading Diagnostic Trouble Codes (DTCs) . (Group 9015-20.)
Are DTCs present?
Result:
YES:Follow appropriate DTC for diagnostic procedure.

NO:Go to Machine Lacks Power or Moves Slow in All Gears.
( 2 ) Machine Lacks Power or Moves Slow in All Gears
Action:
Operate machine in all gears.

Does machine lack power or move slow in all gears?
Result:
YES:Go to Oil Level Low.

NO: Go to Clutch Pack Slipping
( 3 ) Oil Level Low
Action:
Is oil level low?
Result:
YES:Add oil. See Transmission, Axles, and Mechanical Front Wheel Drive (MFWD) Oil . (Operator′s Manual.)
NO:Go to Wrong Oil, Aerated Oil.
( 4 ) Incorrect Oil, Aerated Oil
Action:
Verify oil type used is correct and that oil is not aerated. See Transmission, Axles, and Mechanical Front Wheel Drive (MFWD)
Oil . (Operator′s Manual.)
Is incorrect oil used or aerated?
Result:
YES:Change oil. See Transmission, Axles, and Mechanical Front Wheel Drive (MFWD) Oil . (Operator′s Manual.)
NO:Go to Transmission Cooler Lines Damaged.
( 5 ) Transmission Cooler Lines Damaged
Action:
Inspect transmission cooler lines.

Are transmission cooler lines damaged?
Result:
YES:Repair cooler lines.

NO:Go to Stall Speeds Not Within Specification Limits.
( 6 ) Stall Speeds Not Within Specification Limits
Action:
Check stall speeds and combined stall speeds. Perform Torque Converter Stall Speed Test . (Group 9020-25.)
Are stall speeds and combined stall speeds within specifications?
Result:
YES:Go to Low Pressure in Transmission Cooler.

NO:Diagnose cause of incorrect stall speeds. See Torque Converter Stall Speed Test . (Group 9020-25.)
( 7 ) Low Pressure in Transmission Cooler
Action:

Are cooler in and cooler out pressures within specifications?
Result:
YES:Go to Transmission Pump Flow Not Within Specification.

NO:Diagnose cause of low transmission cooler pressures. See Cooler In and Cooler Out Pressure Test . (Group 9020-25.)
( 8 ) Transmission Pump Flow Not Within Specification
Action:
Perform Transmission Pump Flow Test . (Group 9020-25.)

Is transmission pump flow within specification?
Result:
YES:Go to Service Brake Dragging.

NO:Diagnose cause of low transmission pump flow. See Transmission Pump Flow Test . (Group 9020-25.)
( 9 ) Service Brake Dragging
Action:
Check for excessive heat in brake area of axle housing after operating machine.
Is service brake dragging?
Result:
YES:Adjust brakes. See Service Brake Pedal Adjustment . (Group 9020-20.)

NO:Go to Park Brake Dragging, Piston Stuck.
( 10 ) Park Brake Dragging, Piston Stuck
Action:
Check park brake operation. See Park Brake Release Pressure Test . (Group 9020-25.)
Is park brake dragging or piston stuck?
Result:
YES:Repair park brake. See Park Brake Disassemble and Assemble . (Group 0250.)
NO:Go to Low Pressure in Transmission System.
( 11 ) Low Pressure in Transmission System
Action:
Check transmission system pressure. Perform Transmission System Pressure Test . (Group 9020-25.)
Is transmission system pressure low?
Result:
YES:Check pressure regulating valve, repair or shim adjust. See Transmission System Pressure Test . (Group 9020-25.)
NO:Go to Clutch Pack Slipping.
( 12 ) Clutch Pack Slipping
Action:
Operate machine in all gears.

Are clutch packs slipping?
Perform Clutch Pressure Test . (Group 9020-25.)
Are any clutch pressures below specification?
Result:
YES:Inspect and repair clutches. See Clutch Packs Remove . (Group 0350.)
NO:Go to Clutch Pack Dragging, Disks Warped.
( 13 ) Clutch Pack Dragging, Disks Warped
Action:
Are clutch packs dragging or disks warped?
Result:
YES:Inspect and repair clutch packs. See Clutch Packs Remove . (Group 0350.)
NO:Go to Low Torque Converter Oil Pressure.
( 14 ) Low Torque Converter Oil Pressure
Action:
Check torque converter oil pressure. See Torque Converter-In Relief Valve Test . (Group 9020-25.)
Is torque converter oil pressure low?
Result:
YES:Check transmission pump flow. See Transmission Pump Flow Test . (Group 9020-25).
NO:Go to Low Engine Power.
( 15 ) Low Engine Power
Action:
Check for low engine power.

Does engine have low power?
Result:
YES:Repair engine. See John Deere Engine Operation . (Group 9010-05.)

NO:Go to Mechanical Malfunction in Transmission or Axle.
( 16 ) Mechanical Malfunction in Transmission or Axle
Action:
Has transmission or axle malfunctioned?
Result:
YES:Inspect and repair transmission or axle. See Transmission Outer Components Removal . (Group 0350.) See Rear Axle
Remove and Install . (Group 0250.)
NO:Checks complete.
Transmission Overheats
79
Transmission Overheats Diagnostic Procedure

( 1 ) Oil Level Too High or Too Low
Action:
Is oil level too high or too low?
Result:
YES:Add or drain oil. See Backhoe Loader Drain and Refill Capacities . (Operator′s Manual.)
NO:Go to Incorrect Type of Oil.
( 2 ) Incorrect Type of Oil
Action:
Check transmission oil. See Transmission, Axles, and Mechanical Front Wheel Drive (MFWD) Oil . (Operator′s Manual.)
Is the correct type of oil being used in the transmission?
Result:
YES:Go to Operating in Too High of Gear.

NO:Drain and replace oil. See Backhoe Loader Drain and Refill Capacities . (Operator′s Manual.)
( 3 ) Operating in Too High of Gear
Action:
Is machine operating in too high of gear?
Result:
YES:Operate machine in correct gear for work situation. See Driving the Machine . (Operator′s Manual.)
NO:Go to Torque Converter Stalled Excessively.
( 4 ) Torque Converter Stalled Excessively
Action:
Is torque converter stalled excessively?
Result:
YES:Use clutch disconnect switch in machine operations to reduce stall.

NO:Go to Oil Cooler Package Air Flow Restricted.
( 5 ) Hydraulic/Transmission Radiator Air Flow Restricted
Action:
Check hydraulic/transmission radiator for excessive debris.

Is hydraulic/transmission radiator air flow restricted? See Engine Cooling System Component Location . (Group 9010-15.)
Result:
YES:Remove debris from hydraulic/transmission radiator.

NO:Go to Missing Baffles, Damaged Fan Shrouds or Loose Fan Belt.
( 6 ) Missing Baffles, Damaged Fan Shrouds or Loose Fan Belt
Action:
Inspect and check baffles, fan shrouds, and fan belt.

Is baffles missing? Are fan shrouds missing or is there a loose fan belt?
Result:
YES:Repair as necessary. See Fan Remove and Install . (Group 0510.).

NO:Go to Oil Cooler Restricted Internally.
( 7 ) Oil Cooler Restricted Internally
Action:

Is oil cooler restricted internally?
Result:
YES:Remove and flush transmission oil cooler. See Hydraulic and Transmission Oil Coolers Remove and Install . (Group 2160.)
NO:Go to Torque Converter Malfunction.
( 8 ) Torque Converter Malfunction
Action:
Perform Torque Converter Stall Speed Test . (Group 9020-25.)

Is torque converter malfunctioning?
Result:
YES:Repair or replace torque converter. See Torque Converter Remove and Install . (Group 0651.)
NO:Go to Torque Converter-In Relief Valve Malfunction.
( 9 ) Torque Converter-In Relief Valve Malfunction
Action:
Perform Torque Converter-In Relief Valve Test . (Group 9020-25.)

Is torque converter-In relief valve malfunctioning?
Result:
YES:Replace torque converter-in relief valve.

NO:Go to Low Transmission Pump Flow.
( 10 ) Low Transmission Pump Flow
Action:
Perform Transmission Pump Flow Test . (Group 9020-25.)

Is transmission charge pump flow low?
Result:
YES:Repair transmission charge pump. See Transmission Charge Pump Remove and Install . (Group 0350.)
NO:Go to Transmission Mechanical Malfunction.
( 11 ) Transmission Mechanical Malfunction
Action:
Inspect transmission.
Is there a mechanical malfunction in the transmission?
Result:
YES:Repair transmission as necessary. See Transmission Outer Components Removal . (Group 0350.)
NO:Checks complete.
Excessive Power Train Noise

81
Excessive Power Train Noise Diagnostic Procedure

( 1 ) Oil Level Low
Action:
Check oil level in power train systems. Check oil levels. See Check Transmission Oil Level , see Check Rear Axle Oil Level , see
Check MFWD Planetary Housing Oil Level—If Equipped , and see Check MFWD Axle Oil Level—If Equipped . (Operator′s Manual.)
Are power train oil levels low?
Result:
YES:Add oil to systems that are low. See Backhoe Loader Drain and Refill Capacities . (Operator′s Manual.)
NO:Go to Hydraulic Lines in Contact With Power Train Components.
( 2 ) Hydraulic Lines in Contact With Power Train Components
Action:
Inspect hydraulic lines.

Are hydraulic lines in contact with power train components?
Result:
YES:Repair as needed.
NO:Go to Misalignment of Power Train Components.
( 3 ) Misalignment of Power Train Components
Action:
Check position of power train components. Verify that components are mounted correctly and mounts are in good condition.
Are power train components misaligned?
Result:
YES:Align components and repair or replace mounts as necessary.

NO:Go to Worn Universal Joints on Drive Shaft.
( 4 ) Worn Universal Joints on Drive Shaft
Action:
Inspect universal joints or drive shaft.

Are universal joints on drive shaft worn?
Result:
YES: See Universal Joint and Drive Shaft Remove and Install . (Group 0225.)
NO:Go to Transmission Assembly Adjustments or Setting Made Incorrectly.
( 5 ) Worn or Damaged Parts in Transmission or Axle
Action:
Check transmission filter for metal particles.

Are metal particles in transmission filter?
Result:
YES:Inspect transmission and axle for possible internal damage.

NO:Checks complete.
No Power to Mechanical Front Wheel Drive (MFWD)

81
No Power to Mechanical Front Wheel Drive (MFWD) Diagnostic

Procedure
( 1 ) Solenoid Not Actuated
Action:

Is mechanical front wheel drive (MFWD) solenoid actuated?
Result:
YES:Go to Drive Shaft Malfunctioning.

NO:Check electrical connection. Check mechanical front wheel drive (MFWD) solenoid and repair. See Transmission Control
( 2 ) Drive Shaft Malfunction
Action:
Inspect drive shaft.

Has drive shaft malfunctioned?
Result:
YES:Repair drive shaft. Universal Joint and Drive Shaft Remove and Install . (Group 0225.)
NO:Go to Malfunctioning Mechanical Front Wheel Drive (MFWD) Output Shaft Spline.
( 3 ) Malfunctioning Mechanical Front Wheel Drive (MFWD) Output Shaft Spline
Action:
Inspect output shaft spline.

Has the mechanical front wheel drive (MFWD) output shaft spline malfunctioned?
Result:
YES:Inspect and repair.For 210K-410K machines, see Mechanical Front Wheel Drive (MFWD) Axle Disassemble . (Group 0240.)
For 710K machines, See Mechanical Front Wheel Drive (MFWD) Axle Repair . (Group 0240.)
NO:Go to Malfunctioning Axle Shaft in Mechanical Front Wheel Drive (MFWD).
( 4 ) Malfunctioning Axle Shaft in Mechanical Front Wheel Drive (MFWD)
Action:
Inspect axle shaft.

Has the axle shaft in mechanical front wheel drive (MFWD) malfunctioned?
Result:
YES:Repair axle shaft.For 210K-410K machines, see Mechanical Front Wheel Drive (MFWD) Axle Disassemble . (Group 0240.)
For 710K machines, See Mechanical Front Wheel Drive (MFWD) Axle Repair . (Group 0240.)
NO:Go to Malfunctioning Ring Gear or Pinion in Front Axle.
( 5 ) Malfunctioning Ring Gear or Pinion in Front Axle
Action:
Inspect ring gear or pinion in front axle.

Has ring gear or pinion in front axle malfunctioned?
Result:
YES:Inspect and repair as necessary.For 210K-410K machines, see Mechanical Front Wheel Drive (MFWD) Axle Disassemble .
(Group 0240.) For 710K machines, See Mechanical Front Wheel Drive (MFWD) Axle Repair . (Group 0240.)
NO:Go to Malfunctioning Mechanical Front Wheel Drive (MFWD) Gear Train Components in Transmission.
( 6 ) Malfunctioning Mechanical Front Wheel Drive (MFWD) Gear Train Components in Transmission
Action:
Has mechanical front wheel drive (MFWD) gear train components in transmission malfunctioned?
Result:
YES:Inspect and repair transmission. See Transmission Outer Components Removal . (Group 0350.)
NO:Checks Complete.
No Power to One Wheel of Mechanical Front Wheel Drive (MFWD)

81
No Power to One Wheel of Mechanical Front Wheel Drive (MFWD)

Diagnostic Procedure
( 1 ) Malfunctioning Wheel U-Joint
Action:
Inspect U-joint.
Has wheel U-joint malfunctioned?
Result:
YES:Repair U-joint. See Universal Joint and Drive Shaft Remove and Install . (Group 0225.)
NO:Go to Malfunctioning Outboard Planetary.
( 2 ) Malfunctioning Outboard Planetary
Action:
Disassemble mechanical front wheel drive (MFWD) axle and inspect outboard planetary. For 210K—410K machines, see
Mechanical Front Wheel Drive (MFWD) Axle Disassemble . (Group 0240.) For 710K machines, see Mechanical Front Wheel Drive
(MFWD) Axle Repair . (Group 0240.)
Has outboard planetary malfunctioned?
Result:
YES:Repair outboard planetary.For 210K—410K machines, see Mechanical Front Wheel Drive (MFWD) Axle Disassemble .
(Group 0240.) For 710K machines, see Mechanical Front Wheel Drive (MFWD) Axle Repair . (Group 0240.)
NO:Go to Malfunctioning Axle Shaft in Mechanical Front Wheel Drive (MFWD).
( 3 ) Malfunctioning Axle Shaft in Mechanical Front Wheel Drive (MFWD)
Action:
Disassemble mechanical front wheel drive (MFWD) axle and inspect axle shaft. For 210K—410K machines, see Mechanical
Front Wheel Drive (MFWD) Axle Disassemble . (Group 0240.) For 710K machines, see Mechanical Front Wheel Drive (MFWD)
Axle Repair . (Group 0240.)
Has axle shaft in mechanical front wheel drive (MFWD) malfunctioned?
Result:
YES:Repair axle shaft.For 210K—410K machines, see Mechanical Front Wheel Drive (MFWD) Axle Disassemble . (Group 0240.)
For 710K machines, see Mechanical Front Wheel Drive (MFWD) Axle Repair . (Group 0240.)
NO:Go to Malfunctioning Limited-Slip in Mechanical Front Wheel Drive (MFWD).
( 4 ) Malfunctioning Limited-Slip in Mechanical Front Wheel Drive (MFWD)
Action:
Inspect ring gear and differential in mechanical front wheel drive (MFWD) axle. For 210K—410K machines, see Mechanical
Front Wheel Drive (MFWD) Axle Disassemble . (Group 0240.) For 710K machines, see Mechanical Front Wheel Drive (MFWD)
Axle Repair . (Group 0240.)
Has the limited-slip malfunctioned in mechanical front wheel drive (MFWD)?
Result:
YES:Inspect and repair as necessary.For 210K—410K machines, see Mechanical Front Wheel Drive (MFWD) Axle Disassemble .
(Group 0240.) For 710K machines, see Mechanical Front Wheel Drive (MFWD) Axle Repair . (Group 0240.)
NO:Checks Complete.
No Differential Lock Operation

81
No Differential Lock Operation Diagnostic Procedure

( 1 ) Malfunction in Electrical Circuit to Solenoid
Action:
With engine stopped and key switch turned to accessory, activate differential lock and listen for a click from solenoid valve.
Is there a malfunction in the electrical circuit?
Result:
YES: See Transmission Control Circuit Theory of Operation . (Group 9015-15.)

NO:Go to Stuck Differential Lock Solenoid Valve.
( 2 ) Stuck Differential Lock Solenoid Valve
Action:
Perform Differential Lock Pressure Test . (Group 9020-25.) Perform Transmission Solenoid Check . (Group 9015-20.)
Is differential lock solenoid valve stuck?
Result:
YES:Repair solenoid.
NO:Go to Excessive Wear on Differential Lock Engaging Gears.
( 3 ) Excessive Wear on Differential Lock Engaging Gears
Action:
Inspect differential lock system. See Rear Axle Disassemble . (Group 0250.) See Differential Lock Operation . (Group 9020-05.)
Is there excessive wear on differential lock engaging gears?
Result:
YES:Inspect and repair as necessary. See Gear Tooth Contact Pattern Check . (Group 0250.) See Rear Axle Assemble . (Group
0250.)
NO:Checks complete.
Differential Lock Slips or Chatters When Engaged
81
Differential Lock Slips or Chatters When Engaged Diagnostic Procedure

( 1 ) Excessive Leakage Differential Lock Piston Seals
Action:
Perform Differential Lock Pressure Test . (Group 9020-25.)

Is there leakage in differential lock piston seals?
Result:
YES:Repair piston seals.

Action:
Verify differential lock piston is operating correctly and not stuck. See Differential Lock Pressure Test . (Group 9020-25.)
Is differential lock piston stuck?
Result:
YES:Repair or replace parts as necessary.

NO:Go to Excessive Wear on Differential Lock Engaging Gears.
( 2 ) Excessive Wear on Differential Lock Engaging Gears
Action:
Inspect differential lock engaging gears. See Rear Axle Disassemble . (Group 0350.)
Is there excessive wear on differential lock engaging gears?
Result:
YES:Inspect and repair as necessary. See Rear Axle Disassemble . (Group 0250.)
NO:Checks complete.
Differential Lock Will Not Release

81
Differential Lock Will Not Release Diagnostic Procedure

( 1 ) Oil Level Low in Transmission
Action:
Check transmission oil level.

Is oil level low in transmission?
Result:
YES:Add oil to correct level. See Backhoe Loader Drain and Refill Capacities . (Operator′s Manual.)
NO:Go to Stuck Differential Lock Switch.
( 2 ) Stuck Differential Lock Switch
Action:
Check differential lock switch.

Is differential lock switch stuck?
Result:
YES:Repair foot switch. See Transmission Control Circuit Theory of Operation . (Group 9015-15.)
NO:Go to Malfunction in Electrical Circuit.
( 3 ) Malfunction in Electrical Circuit
Action:
With engine stopped and switched power ON, activate differential lock and listen for a click from solenoid valve.
Did solenoid valve click?
Result:
YES:Go to Stuck Differential Lock Solenoid Valve.

NO:Repair solenoid. See Transmission Outer Components Removal (Group 0350) or see System Functional Schematic, Wiring
Diagram, and Component Location Legend and see System Functional Schematic and Section Legend . (Group 9015-10.)
( 4 ) Stuck Differential Lock Piston
Action:
Verify differential lock piston is operating correctly and not stuck. See Differential Lock Pressure Test . (Group 9020-25.)
Is differential lock piston stuck?
Result:
YES:Repair or replace parts as necessary.

NO:Go to Stuck Differential Lock Engaging Gears or Clutch.
( 5 ) Stuck Differential Lock Engaging Gears or Clutch
Action:
Disassemble rear axle and inspect differential lock engaging gears. See Rear Axle Disassemble . (Group 0250.)
Is differential lock engaging gears or clutch stuck?
Result:
YES:Inspect and repair as necessary. See Rear Axle Disassemble . (Group 0250.)
NO:Checks Complete.
Rear Axle Overfilled With Oil
81
Rear Axle Overfilled With Oil Diagnostic Procedure

→NOTE:
The following checks assume that axle oil has been checked and once at correct level has then been
checked again after machine operation and found axle is now overfilled with oil.
( 1 ) Differential Lock Piston Seals Leaking
Action:
Perform Differential Lock Pressure Test . (Group 9020-25.)

Are differential lock piston seals leaking?
Result:
YES:Drain rear axle oil to specified level. See Transmission, Axles, and Mechanical Front Wheel Drive (MFWD) Oil . (Operator′s
Manual.) Repair differential lock piston seals as necessary.
NO:Go to Service Brake Piston Seals Leaking.
( 2 ) Service Brake Piston Seals Leaking
Action:
Perform Power Boost Service Brake Valve Leakage Test . (Group 9020-25.)
Are service brake piston seals leaking?
Result:
YES:Repair service brake piston seals as necessary.

NO:Go to Park Brake Piston Seals Leaking.
( 3 ) Park Brake Piston Seals Leaking
Action:

Are park brake piston seals leaking?
Result:
YES:Repair park brake piston seals as necessary.

NO:Checks Complete.
Poor Service Brakes
81
Poor Service Brakes Diagnostic Procedure

( 1 ) Air in Brake Valve or Lines Or Piston
Action:
Is there air in the brake valve, lines, or piston?
Result:
YES:Bleed brake system. See Service Brake Bleed Procedure . (Group 9020-20.)
NO:Go to Restriction in Brake Disks Worn Excessively.
( 2 ) Brake Disks Worn Excessively
Action:
See Service Brakes Inspection . (Group 0250.)

Are brake disks worn excessively?
Result:
YES:Inspect brake disks and repair as necessary.

NO:Checks complete.
Service Brakes Will Not Release
81
Service Brakes Will Not Release Diagnostic Procedure

( 1 ) Brake Pedal Not Returning to Full UP Position or Not Adjusted Properly
Action:
Depress brake pedal. Examine brake pedal as it is released.

Is brake pedal returning to full UP position or adjusted properly?
Result:
YES:Go to No Free Travel on Brake Adjusters.

NO:Inspect brake pedal linkage and adjust. Perform Service Brake Pedal Adjustment . (Group 1060.)
( 2 ) No Free Travel on Brake Adjusters
Action:
Adjust brake pedals. See Service Brake Pedal Adjustment . (Group 9020-20.)
Is there no free travel on brake adjusters?
Result:
YES:Inspect and repair as necessary.

NO:Go to Warped Brake Disks.
( 3 ) Warped Brake Disks
Action:
Remove, disassemble and inspect brake disks. See Service Brakes Inspection . (Group 0250.)
Are brake disks warped?
Result:
YES:Repair brake disks. See Brake Disk and Pressure Plate Remove and Install . (Group 0250.)
NO:Go to Stuck Brake Piston.
( 4 ) Stuck Brake Piston
Action:
Remove and inspect piston. See Rear Axle Disassemble . (Group 0250.)
Is brake piston stuck?
Result:
YES:Inspect and repair as necessary. See Rear Axle Assemble . (Group 0250.)
NO:Checks Complete.
Service Brakes Chatter or Noisy
81
Service Brakes Chatter or Noisy Diagnostic Procedure

( 1 ) Incorrect Oil in Rear Axle
Action:
See Check Rear Axle Oil Level . (Operator′s Manual.)

Is there incorrect oil in rear axle?
Result:
YES: See Backhoe Loader Drain and Refill Capacities . (Operator′s Manual.)
NO:Go to Air in Brake System.
( 2 ) Air in Brake System
Action:
Bleed brake system and check for noise. See Service Brake Bleed Procedure . (Group 9020-20.)
Do service brakes still chatter or are they noisy?
Result:
YES:Go to Disks Worn Excessively.

NO:Checks complete.
( 3 ) Disks Worn Excessively
Action:
Perform Service Brakes Inspection . (Group 0250.)

Are brake disks worn excessively?
Result:
YES:Inspect and repair as necessary. See Brake Disk and Pressure Plate Remove and Install . (Group 0250.
NO:Checks complete.
Park Brake Will Not Hold

81
Park Brake Will Not Hold Diagnostic Procedure

( 1 ) Check Tow Release Cap Screws
Action:
Check park brake adjustment cap screws. Mechanical Park Brake Release—Towing . (Group 9020-20.)
Are park brake adjustment cap screws within normal operation specification?
Result:
YES:Go to Check DTCs.

NO:Adjust park brake adjustment cap screws to specification. Mechanical Park Brake Release—Towing . (Group 9020-20.)
( 2 ) Check DTCs
Action:
Check machine for DTCs for park brake system. See Reading Diagnostic Trouble Codes (DTCs) . (Group 9015-20.)
Are park brake related DTCs present?
Result:

NO:Go to Park Brake Pressure Check.
( 3 ) Park Brake Pressure Check
Action:
Check park brake pressure. See Park Brake Release Pressure Test . (Group 9020-25.)
Does park brake release pressure drop to zero when park brake is applied?
Result:
YES:Go to Park Brake Piston Stuck.

NO:Remove and inspect park brake solenoid valve. Verify solenoid valve is not stuck or held open allowing pressure to release
park brake.
( 4 ) Park Brake Piston Stuck or Worn Internal Parts
Action:
Disassemble park brake and check for stuck park brake piston or worn internal parts. See Park Brake Disassemble and
Assemble . (Group 0250.)
Are parts worn on park brake?
Result:
YES:Repair or replace as necessary. See Park Brake Remove and Install . (Group 1111.)
NO:Checks complete.
Section 9020 - POWER TRAIN Group 20: Adjustments
Park Brake Will Not Release

81
Park Brake Will Not Release Diagnostic Procedure

( 1 ) Check DTCs
Action:
Check machine for DTCs. See Reading Diagnostic Trouble Codes (DTCs) . (Group 9015-20.)
Are DTCs present?
Result:

NO:Go to Park Brake Hose Leaking.
( 2 ) Park Brake Hose Leaking
Action:
Inspect park brake hose.

Is park brake hose leaking?
Result:
YES:Inspect and repair as necessary.

NO:Go to Park Brake Release Check.
( 3 ) Park Brake Release Check
Action:
Inspect for malfunction in park brake release circuit. See Park Brake Release Pressure Test . (Group 9020-25.)
Is park brake pressure within specification?
Result:
YES:Go to Park Brake Stuck.

NO:Diagnose cause of low park brake release pressure.Check transmission system pressure. See Transmission System
Pressure Test . (Group 9020-25.) Verify operation of park brake solenoid valve. See Transmission Solenoid Check . (Group
9015-20.) Visually inspect condition of solenoid valve seals. Replace as necessary. Check rear axle oil level. If oil level is high,
this could indicate park brake piston seals are leaking.
( 4 ) Park Brake Stuck
Action:
Manually release park brake using park brake cap screws. See Mechanical Park Brake Release—Towing . (Group 9020-20.)
Did park brake release manually?
Result:
YES:Return park brake cap screws to operating position and check operation of park brake. If park brake continues to remain
applied after operation, remove and inspect for malfunctioning park brake. See Park Brake Disassemble and Assemble . (Group
0250.)
NO:Inspect for malfunctioning park brake. See Park Brake Disassemble and Assemble . (Group 0250.)
Mechanical Park Brake Release—Towing
Access Plate Removed
Specifications
SPECIFICATIONS
27—28 mm
Cap Screw Position From Housing
1.06—1.10 in.
IMPORTANT:
Prevent damage to transmission from insufficient oil supply. Do not attempt to start engine by towing.
DO NOT tow machine faster than 10 km/h (6.21 mph) or a distance longer than 10 km (6.21 miles).
Towing IS NOT recommended. If you MUST tow machine, use the following procedure:
[1] - Turn engine off.
[2] -
CAUTION:
Prevent possible injury or death from unexpected machine movement. Block wheels to prevent machine
movement before disengaging park brake.
Block tires.
[3] -
CAUTION:
Prevent possible injury or death from unexpected machine movement. Only release the park brake
through the access hole in floor of operator’s station.
Remove access plate in floor of operator’s station.
[4] -
IMPORTANT:
Prevent park brake damage from heat build-up. Manually disengage brake.
Park Brake Screws
Park Brake Screws

LEGEND:
2 Hex Nut (2 used)
3 Cap Screw Position From Housing
Loosen hex nuts (2) to adjust park brake cap screws (1).
[5] - Release park brake for tow by turning cap screws (1) completely in.
[6] - Remove blocks from tires.
[7] - When towing is completed, enable park brake to hold machine by turning both cap screws out to specification (3) as
illustrated.
Cap Screw Position From Housing 27—28 mm
1.06—1.10 in.
[8] - Lock cap screws with hex nuts (2).
[9] - Install operator′s station floor access plate when complete.
Service Brake Pedal Adjustment

[1] -
LEGEND:
1 Location (pedal stop screw to bracket clearance)
2 Jam Nut
3 Pedal Stop Cap Screw
4 Brake Valve Piston
5 Pedal Lock Bar
Service Brake Pedal Adjustment

Park machine on level ground with loader and attachments lowered to ground.
[2] - Stop engine.
[3] - Unlock brake pedals by moving pedal lock bar (5) to the disengaged position.
[4] - Loosen jam nut (2).
[5] -
→NOTE:
Make sure that the brake pedal DOES NOT apply force against brake valve piston (4) when checking and
adjusting pedal stop screw-to-bracket clearance. Brake pedal must only rest against the brake valve
piston.
While allowing the pedal to rest on brake valve piston (4), adjust pedal stop cap screw (3) to specification at location (1).
Pedal Stop Screw to Bracket Clearance 0.13— 0.38 mm
0.005—0.015 in.
[6] - Hold stop cap screw and tighten jam nut.
[7] - Repeat procedure to adjust other pedal.
[8] -
Brake Pedal Travel

LEGEND:
6 Brake Pedal Travel
Check brake pedal travel (6).
Brake Pedal Travel

Dual Brake Pedal Travel (lock bar engaged) Distance (maximum) 95 mm
3.75 in.
Single Brake Pedal Travel (lock bar disengage) Distance 114 mm
4.5 in.
Service Brake Bleed Procedure
Brake Bleeding Procedure Using Bleed Screw Method

LEGEND:
1 Bleed Screw (right side)
2 Clear Plastic Hose
3 Container
4 Bleed Screw (left side)
CAUTION:
Avoid personal injury. Do not operate machine if pedal travel exceeds 133 mm (5.25 in.) while applying
267 N (60 lb-force). Operating machine with excessive brake travel could cause brakes not to stop
machine on first application.
→NOTE:
Air will "gravity bleed" from brake system through brake valve without use of bleed screws but the
procedure may take much longer so bleed screw method is the recommended procedure. Brake lines
must be inclined toward brake valve for procedures other than bleed method.
Low ambient temperature or aeration of oil will slow bleed process.
The rear axle is equipped with two brake bleed screws, one for each wheel. Brake bleeding must be done
whenever the brake system has been opened to repair or after replacing the brake valve, brake lines,
fittings, O-rings or axle internal brake parts.
Depressing each brake pedal separately will help utilize a more efficient bleed.
All fittings must be inspected for leaks and tightened if leaks occur.
The preferred method for the brake bleeding procedure is to use the bleed screw method. The vacuum and manual methods
are much slower methods but may be used as alternates.
Bleed Screw Method
→NOTE:
Two people are required to bleed brake system oil, one to operate brake valve and other to open and
close bleed screws.
[1] -
CAUTION:
Hot oil can cause serious burn injury. Secure drain hose on bleed screw and in container to prevent it
from blowing off when bleed screw is opened while brakes are applied.
Secure a clear plastic hose (2) on bleed screw (4) with hose clamp and secure other end in a small container (3).
[2] - Start engine and run at slow idle with park brake on.
[3] - Steer from right to left stop to stop three times to fill the brake valve reservoir.
[4] - Shut off engine.
[5] -
→NOTE:
Only two pedal bleeding applications can be done without refilling the brake valve reservoir.
Bleed screw must be closed before the fully depressed pedal reaches the floor.
Depress and hold the brake pedal, and open one (side) service brake bleed screw to allow air and oil mixture into a container.
Close bleed screw before pedal reaches maximum travel or floor.
If the bleeding procedure (applying brake pedal full distance or travel) is done more than twice, fill the brake valve reservoir
again by starting the machine and steering from stop-to-stop three times.
Repeat the process until oil from bleed screw runs clear and without air.
[6] - Repeat process for opposite side.
[7] - After bleeding process is completed, pump each pedal to check if pedal is firm.
[8] -
Brake Pedal Travel

LEGEND:
5 Brake Pedal
6 Travel Distance
Check brake pedal (5) travel distance (6) by measuring from floor to brake pedal as shown.
Dual Brake Pedal Travel Max. Distance 95 mm
3.75 in.
Single Brake Pedal Travel Max. Distance 114 mm
4.5 in.
[9] - Recycle old oil.
Vacuum Method
[1] - Engage park brake. Connect a vacuum to breather port on hydraulic reservoir. After 10 minutes, disconnect air pressure.
[2] - Leave hose from breather port to vacuum device connected until brake circuit is filled with oil. Both pedals should become
solid.
[3] - Check brake pedal (5) travel distance (6) by measuring from floor to brake pedal as shown.
Manual Method
[1] - Engage park brake. Run engine at slow idle.
[2] - Steer from stop to stop three times to fill the brake valve reservoir.
[3] - Pump left brake pedal five times, allowing 2 seconds between each pump for air to escape.
[4] - Repeat steps 2 and 3 until the left pedal is solid.

[5] - Pump right pedal until pedal is solid, then pump both pedals together until pedals are solid.
[6] - Check brake pedal (5) travel distance (6) to specification by measuring from floor to brake pedal as shown.
Tracking Angle Check and Adjust

→NOTE:
The purpose of this procedure is to align the planetary drive housings perpendicular to the axle. Wheels
should point straight forward, with no toe-in or toe-out.
[1] -
Tracking Angle Adjustment

LEGEND:
1 Steering Cylinder Rod Dimension
2 Tie Rod Dimension
3 Jam Nut
4 Tie Rod End Ball Joint
5 Tire (2 used)
6 Wheel-to-Wheel Distance (rear of tire)
7 Wheel-to-Wheel Distance (front of tire)
Center steering cylinder rod so dimension (1) is equal on both sides.
[2] - Loosen tie rod jam nut (4).
[3] - Adjust tie rod length so tie rod dimension (2) between end of steering cylinder rod and center of tie rod ball joint (4) are
equal on both sides of axle.
[4] - Measure wheel-to-wheel distance (6 and 7) for front of wheel and for rear of wheel. Distance should also be equal for both
front and rear measurements.
[5] - Adjust toe-in. See Toe-In Check and Adjust . (Group 9020-20.)
Toe-In Check and Adjust

Specifications
SPECIFICATIONS
3—6 mm (less than rear wheel-to-wheel measurement)

Front Wheel-to-Wheel Measurement Distance
0.13—0.25 in. (less than rear wheel-to-wheel measurement)
120 N•m
Tie Rod Jam Nut Torque
89 lb.-ft.
→NOTE:
Check and adjust tracking angle before checking and adjusting axle toe-in. See Tracking Angle Check and
Adjust . (Group 9020-20.)
Toe-In Measurement Check
[1] -
LEGEND:
8 Ground to Center of Hub (2 used)
Center of Hub
Measure distance from ground to center of hubs (8) on both sides of machine. If distance from ground to center of both hubs is
not equal, check and adjust tire pressure. See Tire Pressures . (Operator’s Manual.)
[2] -
Tracking Angle Adjustment

LEGEND:
1 Tire (2 used)
2 Wheel-to-Wheel Distance (rear of tire)
3 Wheel-to-Wheel Distance (front of tire)
Measure wheel-to-wheel distance (2 and 3) for front of wheels and for rear of wheels.
[3] - Front wheel-to-wheel distance (3) must be smaller than rear wheel-to-wheel distance (2) within specification.
Front Wheel-to-Wheel Measurement Distance 3—6 mm (less than rear wheel-to-wheel measurement)
Toe-In Adjustment
[1] -
LEGEND:
4 Threaded Rod (2 used)
5 Jam Nut (2 used)
Jam Nut
Loosen jam nuts (5).
[2] -
→NOTE:
Adjust toe-in equally on both tie rods.
Turn threaded rod (4) to adjust toe-in to meet specification.

Front Wheel-to-Wheel Measurement Distance 3—6 mm (less than rear wheel-to-wheel measurement)
[3] -
→NOTE:
If tracking angle and toe-in adjustment procedures are performed on mechanical front wheel drive
(MFWD) axle, maximum steering angle stop screws must be adjusted. See Steering Angle Check and
Adjust . (Group 9020-20.)
Tighten jam nut to specification.

Tie Rod Jam Nut Torque 120 N•m
89 lb.-ft.
Steering Angle Check and Adjust

Specifications
SPECIFICATIONS
32—34 mm
Maximum Steering Angle Stop Screw Distance
1.26—1.34 in.
150 N·m
Maximum Steering Angle Stop Screw Jam Nut Torque
111 lb.-ft.
This procedure is only used on mechanical front wheel drive (MFWD) axle. Non-powered front axle not adjustable. Check and
adjust tracking angle before checking and adjusting steering angle. See Tracking Angle Check and Adjust . (Group 9020-20.)
[1] -
Maximum Steering Angle Stop Screw (left side shown)
Maximum Steering Angle Stop Screw

LEGEND:
2 Jam Nut (4 used)
Check if steering angle stop cap screw (1) distance is within specification.
Maximum Steering Angle Stop Cap Screw Distance 32—34 mm
Section 9020 - POWER TRAIN Group 25: Tests
1.26—1.34 in.
[2] - If not within specification, loosen jam nut (2) and adjust stop cap screw to specification.
[3] - Tighten jam nut to specification.

Maximum Steering Angle Stop Screw Jam Nut Torque 150 N·m
111 lb.-ft.
Group 25 - Tests
Transmission Oil Warm-Up Procedure
Specifications
SPECIFICATIONS
7 835 kg
310SK Weight (approximate)
17 258 lb.
9 014 kg
310SK TMC Weight (approximate)
19 855 lb.
8 644 kg
315K, 325K, 325SK, 410K Weight (approximate)
19 043 lb.
9 304 kg
410K TMC Weight (approximate)
20 494 lb.
Slow Idle
Engine Speed
Fast Idle
75—85°C
Transmission Oil Temperature
167—185°F
IMPORTANT:
Never operate machine equipped with mechanical front wheel drive (MFWD) with front wheels (axle) on
the ground, rear wheels (axle) off the ground, and transmission in fourth gear forward. Damage to the
mechanical front wheel drive (MFWD) will occur.
→NOTE:
Have test equipment installed before warm-up. Cooling system is highly efficient and may require
blocking air flow around the transmission cooling system to control temperature.
[1] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
Raise machine off ground using loader and stabilizers until all tires are off the ground and block with hardwood timbers or
appropriate floor stands.
310SK Weight (approximate) 7 835 kg
17 258 lb.
310SK TMC Weight (approximate) 9 014 kg
19 588 lb.
315K, 325K, 325SK, 410K Weight (approximate) 8 644 kg
19 043 lb.
410K TMC Weight (approximate) 9 304 kg
20 494 lb.
[2] - View transmission oil temperature on standard display monitor (SDM). See Standard Display Monitor (SDM)—Diagnostics .
(Group 9015-16.)
[3] - With park brake OFF, put transmission control lever (TCL) in third gear forward.
[4] -
IMPORTANT:
Do not stall converter for longer than 20 seconds or serious converter damage could result.
Cycle engine at fast idle for 10 seconds with service brakes engaged and then at slow idle for 5 seconds with service brakes
disengaged until desired temperature is reached.
Fast Idle
Transmission Oil Temperature 75—85°C
167—185°F
Transmission Oil Sampling Procedure—If Equipped

For transmission oil sampling procedure, see Fluid Sampling Procedure—If Equipped . (Group 9010-25.)
Transmission Overall Test Connections, Ports, and Locations
Power Shift Transmission

LEGEND:
1 Output Yoke
2 Hydraulic Pump Mounting Flange
3 Mechanical Front Wheel Drive (MFWD) Output Shaft
84 Brake Boost Return Pressure Port

85 Brake Boost Pressure Port
86 Torque Converter Inlet Pressure Test Port (2 used)
87 Second Speed Clutch Orifice (K2)
88 Third Speed Clutch Orifice (K3)
89 Directional Clutch (KV, KR, K4)
92 Oil Sampling Port
93 First Speed Clutch Orifice (K1)
94 Temperature Sensor Port
95 Transmission-to-Cooler Port
96 Cooler-to-Transmission Port
100 Oil Drain Port
Torque Converter Stall Speed Test

Specifications
SPECIFICATIONS
75—85°C
167—185°F
Transmission Gear Third Forward
Slow Idle
Engine Speed
Fast Idle
Torque Converter Stall Speed (engine 4045TT096) 2090—2170 rpm
Torque Converter Stall Speed (engines 4045HT054, 4045HT086) 2100—2280 rpm
Combined Torque Converter and Hydraulic Stall Speed (engine 4045TT096) 1400—1730 rpm
Combined Torque Converter and Hydraulic Stall Speed (engines 4045HT054, 4045HT086) 1460—1780 rpm
→NOTE:
Air conditioner must be turned off during testing. Stall speeds will be too low giving false readings with
air conditioner running.
Torque Converter Stall
(Group 9015-16.)
[2] - Warm oil to specification. See Transmission Oil Warm-Up Procedure . (Group 9020-25.)
167—185°F
[3] -
IMPORTANT:
Prevent damage to torque converter. Converter MUST NOT be stalled longer than 20 seconds. Return
transmission control lever (TCL) to neutral position for 10 seconds before doing next stall test.
Raise machine off ground.
[4] - Apply service brakes and release park brake.
[5] -
→NOTE:
Number two (No. 2) fuel produces more power than number one (No. 1) fuel and will impact engine
performance. Minimum engine speed listed is for an engine that is broken in and using No. 2 fuel.
With service brakes engaged and transmission in third gear forward, cycle engine from slow idle to fast idle while reading rpm
on monitor. Highest stabilized speed measured is torque converter stall speed.
Fast Idle
Torque Converter (engine 4045TT096) Stall Speed 2090—2170 rpm
Torque Converter (engines 4045HT054, 4045HT086) Stall Speed 2100—2280 rpm
[6] - If torque converter stall speed is low, check for:
Low oil level. See Check Transmission Oil Level . (Operator′s Manual.)
Incorrect oil in machine. See Transmission, Axles, and Mechanical Front Wheel Drive (MFWD) Oil . (Operator′s Manual.)
Freewheel clutch malfunction in torque converter. See Torque Converter Remove and Install . (Group 0651.)
Low engine output.
If torque converter stall speed is high, check for:
Check specifications for oil temperature.Low system (pump) pressure in transmission. See Transmission System Pressure
Test . (Group 9025-25.)
Restricted suction screen. See Clutch Packs Remove . (Group 0350.)
Torque converter malfunction. See Torque Converter Remove and Install . (Group 0651.)
Transmission clutch pack malfunction. See Clutch Packs Remove . (Group 0350.)
Combined Torque Converter Stall
(Group 9015-16.)
[2] - Warm oil to specification. See Transmission Oil Warm-Up Procedure . (Group 9020-25.)
167—185°F
[3] -
IMPORTANT:
Prevent damage to torque converter. Converter MUST NOT be stalled longer than 20 seconds. Return
transmission control lever (TCL) to neutral position for 10 seconds before doing next stall test.
Raise rear of machine off ground.
[4] - Apply service brakes and release park brake.
[5] -
→NOTE:
Number two (No. 2) fuel produces more power than number one (No. 1) fuel and will impact engine
performance. Minimum engine speed listed is for an engine that is broken in and using No. 2 fuel.
With service brakes engaged and transmission in third gear forward, cycle engine from slow idle to fast idle while reading rpm
on monitor. Highest stabilized speed measured is torque converter stall speed.
Fast Idle
Torque Converter (engine 4045TT096) Stall Speed 2090—2170 rpm
Torque Converter (engines 4045HT054, 4045HT086) Stall Speed 2100—2280 rpm
[6] - With service brakes engaged, transmission in third gear forward, and engine speed at fast idle, hold loader bucket dump
over relief while raising loader boom.
[7] - Observe engine speed while boom is rising.

Combined Torque Converter and Hydraulic (engine 4045TT096) Stall Speed 1400—1730 rpm
Combined Torque Converter and Hydraulic (engines 4045HT054, 4045HT086) Stall Speed 1460—1780 rpm
[8] - If torque converter stall speed is low, check for:
Low oil level. See Check Transmission Oil Level . (Operator′s Manual.)
Incorrect oil in machine. See Transmission, Axles, and Mechanical Front Wheel Drive (MFWD) Oil . (Operator′s Manual.)
Low engine output. See Intake Manifold Pressure—Turbocharger Boost . (Group 9010-25.)
Failed power limiting valve solenoid.
Failed freewheel clutch in torque converter. See Torque Converter Remove and Install . (Group 0651.)
If torque converter stall speed is high, check for:

Specifications for oil temperature.Low system (pump) pressure in transmission. See Transmission System Pressure Test .
(Group 9025-25.)
Restricted suction screen. See Clutch Packs Remove . (Group 0350.)
Torque converter failed. See Torque Converter Remove and Install . (Group 0651.)
Failed transmission clutch pack. See Clutch Packs Remove . (Group 0350.)
Torque Converter-In Relief Valve Test

Specifications
SPECIFICATIONS
75—85°C
167—185°F
Engine Speed 2250—2300 rpm
450—650 kPa
Torque Converter-In Relief Valve Pressure 4.5—6.5 bar
65—94 psi
SERVICE EQUIPMENT AND TOOLS
Quick Coupler (9/16-18 ORB)
JT02158 Digital Pressure and Temperature Analyzer
JT02161 Transducer 3450 kPa (34.5 bar) (500 psi)
[1] - Park machine on level surface.
[2] - Turn park brake ON.
[3] -
Torque Converter Pressure Port

LEGEND:
Install quick coupler to torque converter pressure port (86).
Quick Coupler (9/16-18 ORB)
Used to connect digital pressure / temperature analyzer.
[4] - Install JT02161 Transducer and JT02158 Digital Pressure and Temperature Analyzer to quick coupler. See JT02156A Digital
Pressure and Temperature Analyzer Kit Installation . (Group 9025-25.)
Digital Pressure and Temperature Analyzer
JT02158
Used to measure pressure and transmission oil temperature.
Transducer
JT02161
Used to measure pressure.
[5] - Place transmission control lever (TCL) in neutral and engine throttle at slow idle.
[6] - Slowly increase engine speed to 2000 rpm and record pressure with cold oil.
(Group 9015-16.)
[8] - Warm transmission oil to specification. See Transmission Oil Warm-Up Procedure . (Group 9025-25.)
167—185°F
[9] - Put transmission control lever (TCL) in neutral and engine throttle at slow idle.
[10] - Record pressure at slow idle with warm oil.
[11] - Slowly increase engine speed to 2000 rpm and record pressure with warm oil.
[12] - Slowly increase engine speed to fast idle and record pressure with warm oil.
[13] - Slowly increase engine speed until maximum pressure is reached on gauge.
[14] - Recorded pressures with warm oil at 2000 rpm should be lower than recorded pressures at 2000 rpm with cold oil.
Similarly, recorded pressures at slow idle with warm oil should be lower than recorded pressures at 2000 rpm with warm oil.
If either condition is not true, check for blockage in cooling circuit, either in lines to and from cooler or in cooler. Back flush
using an oil filter caddy. Replace cooler if necessary.
[15] - If pressure at 2000 rpm is higher than specification or pressure under any warm oil condition exceeds 13.0 bar (1300
kPa) (189 psi), remove transmission and relief valve. Disassemble, clean and inspect relief valve.
Engine Speed 2000 rpm
Torque Converter-In Relief Valve Pressure 400—750 kPa
4.0—7.5 bar
58—109 psi
[16] - If pressure at 2000 rpm is lower than specification, check transmission pump flow. See Transmission Pump Flow Test .
(Group 9020-25).
[17] - If transmission pump flow is okay, check pressure drop across the cooler. See Cooler In and Cooler Out Pressure Test .
(Group 9020-25). If pressure drop across the cooler is low, remove transmission and relief valve. Check for weak or broken
spring and scored or sticking valve.
[18] - If relief valve looks okay, look for internal leak downstream of transmission filter outlet. If no internal leak is identified, a
problem with internal cooler restriction is indicated and the cooler should be replaced.
[19] - Install relief valve and transmission. Check relief valve after repair.
Power Boost Service Brake Valve Leakage Test

Specifications
SPECIFICATIONS
689 kPa
Brake Valve Pressure Drop (in 30 seconds time with brake applied) 7 bar
100 psi
Swivel Run Tee (-6 M x -6 M x -6 F ORFS)
Quick Coupler (-6 F)
JT02158 Digital Pressure/Temperature Analyzer
Nut (-6 ORFS) (2 used)
Plug (-6 ORFS) (2 used)
[1] - Warm hydraulic oil. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)
[2] - Stop engine.
[3] - Push left and right brake pedals individually. If either pedal settles, leakage is indicated in final drive brake piston or brake
valve reservoir.
[4] -
Service Brake Line

LEGEND:
73 Rear Axle
77 Service Brake Valve-to-Service Brake Line
Disconnect service brake valve-to-service brake line (77) from brake pressure port in rear axle (73).
[5] -
LEGEND:
1 Quick Coupler
2 Swivel Run Tee Fitting
3 JT02161 Transducer
77 Service Brake Valve-to-Service Brake Line
Pressure Test Port (rear axle, left side)

Install swivel run tee fitting (2) and quick coupler (1) to open pressure port as shown.
Swivel Run Tee (—6 M x —6 M x —6 F ORFS)
Used to connect park brake line and quick coupler.
[6] - Connect service brake valve-to-service brake line to tee fitting.

Quick Coupler (—6 F)
Used to connect digital pressure and temperature analyzer.
[7] - Install JT02161 Transducer (3) and JT02156A Digital Pressure and Temperature Analyzer to quick coupler. See JT02156A
Digital Pressure and Temperature Analyzer Kit Installation . (Group 9025-25.)
Digital Pressure / Temperature Analyzer
JT02156A
Transducer
JT02161
[8] - Remove air in brake line after all test connections are completed. See Service Brake Bleed Procedure . (Group 9020-20.)
[9] - Push brake pedal down and block in place when gauge reads 500 psi.
[10] - Monitor gauge. If pressure drops more than specified pressure in 30 seconds time, excessive leakage is indicated.
Brake Valve Pressure Drop (in 30 seconds time with brake applied) 689 kPa
7 bar
100 psi
→NOTE:
When pedals are released, pressure should be zero.
[11] - To isolate leakage, cap brake pressure hose.

—6 Nut (2 Used)
To cap disconnected line.
—6 Plug (2 Used)
To cap disconnected line.
[12] - If leakage continues in either side but with one side applied only, check the following:
Tip valve is leaking and allowing a slow leak back to brake reservoir. Check for free operation. Replace valve if necessary.
Equalization spool O-ring is allowing leakage to either right or left side return circuit. Replace O-ring if necessary.
Brake piston spool seal is allowing leakage back to transmission circuit. Replace seal if necessary.
See Power Boost Service Brake Valve Operation . (Group 9020-05.)
[13] - No pressure drop indicates leakage at piston seals in axle housing. See Service Brake Operation . (Group 9020-05.)
Park Brake Release Pressure Test

Specifications
SPECIFICATIONS
75—85°C
167—185°F
1700—2000 kPa
Park Brake Release Pressure 17—20 bar
246—290 psi
0 kPa
Park Brake Applied Pressure 0 bar
0 psi
AT202955 Quick Coupler -10 x 1 ORB (or equivalent)
LEGEND:
72 Park Brake Housing
73 Rear Axle
Park Brake Release Pressure Port
[1] - Remove park brake pressure switch (B13) from park brake housing (72). See Transmission Harness (W13) Component
[2] - Install AT202955 Quick Coupler (or equivalent) to park brake pressure port.
AT202955 Quick Coupler -10 x 1 ORB (or equivalent)
Pressure And Temperature Analyzer Kit Installation . (Group 9025-25.)
JT02158
Transducer
JT02161
(Group 9015-16.)
167—185°F
[6] - Run engine at specification. Record pressure with machine in the following state:
Park brake off
Transmission control lever (TCL) in neutral
Mechanical four wheel drive (MFWD) engaged
Differential lock disengaged.
Park Brake Release Pressure 1700—2000 kPa
17—20 bar
246—290 psi
[7] - Record pressure with park brake switch ON. Pressure should be zero.
Park Brake Applied Pressure 0 kPa
0 bar
0 psi
[8] - If park brake pressure is not to specification, check transmission system pressure. See Transmission System Pressure Test
. (Group 9020-25.)
If system pressure is OK, but park brake pressure is low, leakage in park brake circuit is indicated. Check axle oil level. See
Check Rear Axle Oil Level . (Operator′s Manual.)
If oil level is high, park brake piston seals may be leaking.
If axle oil level is OK, but park brake pressure is low, leakage is indicated in park brake solenoid or gasket.
Transmission System Pressure Test

Specifications
SPECIFICATIONS
75—85°C
167—185°F
2000—2100 kPa
Transmission System Pressure 20—21 bar
290—305 psi
Adapter (3/4 M x 3/4 M ORB)
Quick Coupler (3/4 F ORFS)
[1] - Remove floor panel in cab or ROPS.
[2] -
Transmission System Pressure Port

LEGEND:
Install adapter and quick coupler to transmission system pressure port (97).
Adapter (3/4 M x 3/4 M ORB)
Used to connect quick coupler.
Quick Coupler (3/4 F ORFS)
JT02158
Transducer
JT02161
(Group 9015-16.)
167—185°F
.
[6] - With transmission control lever (TCL) in neutral, run engine at specification and record pressure.
Transmission System Pressure 2000—2100 kPa
20—21 bar
290—305 psi
[7] - If not within specification, check transmission pump flow. See Transmission Pump Flow Test . (Group 9020-25.)
Clutch Pressure Test

Specifications
SPECIFICATIONS
75—85°C
167—185°F
1700—2000 kPa
Direction and Speed Clutch Pressure 17—20 bar
232—276 psi
0 kPa
Clutch Disconnect Activated Pressure 0 bar
0 psi
Quick Coupler (M10 x 1)
[1] - Remove floor panel in cab or ROPS.
[2] -
Clutch Pressure Test Ports

LEGEND:
93 First Speed Clutch Orifice/Pressure Test Port (alternate)
109 Low Range Forward Pressure Test Port (alternate) (KV)
Install quick coupler to appropriate port (93, 103-109).
Quick Coupler (M10 x 1)
Used to connect digital pressure and temperature analyzer.
JT0158

Transducer
JT02161
(Group 9015-16.)
167—185°F
[6] -
→NOTE:
All clutch pressures may not be the same due to internal leakage. All clutch pressures should be in the
specified range.
Raise machine off the ground. With engine speed at specification, park brake OFF, and transmission control lever in forward or
reverse, record pressure in all speed ranges.
Direction and Speed Clutches Pressure 1700—2000 kPa
17—20 bar
232—276 psi
Low pressure in 1F and 2F indicates a leakage in low range forward (KV) clutch circuit.
Low pressure in 3F, 4F, and 5F indicates a leakage in high range forward (K4) clutch circuit.
Low pressure in 1R, 2R, and 3R indicates a leakage in reverse (KR) clutch circuit.
Low pressure in 1F, 3F, and 1R indicates a leakage in first speed (K1) clutch circuit.
Low pressure in 2F, 4F, 5F, and 2R indicates a leakage in second speed (K2) clutch circuit.
Low pressure in 5F and 3R indicates a leakage in third speed (K3) clutch circuit.
Low pressure in any other combination indicates low system pressure or between circuit leakage. See Transmission
System Pressure Test . (Group 9020-25.)
[7] - When clutch disconnect is activated, pressure should be zero.

Clutch Disconnect Activated Pressure 0 kPa
0 bar
0 psi
Differential Lock Pressure Test

Specifications
SPECIFICATIONS
75—85°C
167—185°F
1650—2050 kPa
Differential Lock Pressure 16.5—20.5 bar
239—297 psi
Swivel Run Tee (-6 M x -6 M x -6 F)
Quick Coupler (-6 F)
[1] - Prepare machine for service. See Park and Prepare for Service Safely . (Group 9000-01.)
[2] - Remove floor panel or ROPS.
[3] -
Differential Lock Pressure Test

LEGEND:
Connect swivel run tee and quick coupler to differential lock pressure port (90).
Swivel Run Tee (—6 M x —6 M x —6 F)
Used to connect the gauge.
Quick Coupler (—6 F)
Used to connect the gauge.
Digital Pressure/Temperature Analyzer
JT0156A
Transducer
JT02161
(Group 9015-16.)
167—185°F
[7] - Engage mechanical front wheel drive (MFWD) and park brake.
[8] -
→NOTE:
The DIFF LOCK SPEED LIMIT option must be disabled OFF to allow for differential lock function to operate
above 1000 rpm. See Standard Display Monitor (SDM)—Main Menu . (Operator’s Manual.)
Increase engine speed to specification.

→NOTE:
When differential lock pedal switch is released, pressure should be zero.
[9] - Record pressure reading with differential lock pedal switch pressed down.
Differential Lock Pressure 1650—2050 kPa
16.5—20.5 bar
239—297 psi
[10] - If differential pressure is low:
Verify differential lock speed option in monitor is turned off. See Standard Display Monitor (SDM)—Main Menu .
(Operator’s Manual.)
Check axle oil level. See Check Rear Axle Oil Level . (Operator’s Manual.) If oil level is too high seals may be leaking. If
axle oil level is OK, but differential lock pressure is low, leakage is indicated in transmission control valve, differential lock
solenoid, or gasket.
Check transmission system pressure. See Transmission System Pressure Test . (Group 9020-25.) If pressure is OK, but
differential lock pressure is low, it indicates a leak in the circuit. See Rear Axle Remove and Install . (Group 0250.)
Mechanical Front Wheel Drive (MFWD) Pressure Test

Specifications
SPECIFICATIONS
75—85°C
167—185°F
1650—2050 kPa
Mechanical Front Wheel Drive (MFWD) Pressure 16.5—20.5 bar
239—297 psi
Quick Coupler (M10 x 1.0)
[2] -
Mechanical Front Wheel Drive (MFWD) Pressure Test

LEGEND:
Install quick coupler to mechanical front wheel drive (MFWD) pressure test port (99).
Quick Coupler (M10 x 1.0)
Used to connect the Digital Pressure/Temperature Analyzer.
JT02158
Transducer
JT02161
(Group 9015-16.)
167—185°F
[6] - Increase engine speed to specification and record pressure reading with machine in the following state:
MFWD engaged
Park brake engaged
Differential lock disengaged
Mechanical Front Wheel Drive (MFWD) Pressure 1650—2050 kPa
16.5—20.5 bar
239—297 psi
[7] - If pressure is low, check transmission system pressure. See Transmission System Pressure Test . (Group 9020-25.)
If system pressure is correct, leakage in MFWD circuit is indicated. Possible locations include the delivery tube (inside case),
the MFWD piston seal, or the MFWD solenoid.
Cooler In and Cooler Out Pressure Test

Specifications
SPECIFICATIONS
25.4 mm
Hose Diameter
1 in.
75—85°C
167—185°F
124—165 kPa
Transmission Cooler In Pressure 1.24—1.65 bar
18—24 psi
55—83 kPa
Transmission Cooler Pressure Differential (drop) 0.55—0.83 bar
8—12 psi
Tee (-12 F x -12 F x -12 F)
Adapter (-12 M x -6 F ORFS)
Quick Coupler (-6 M)
Nipple (-12 M)
Test Hose 1 in. (cut to length as required) (2 used)
[2] - Remove floor panel in cab.
[3] -
Transmission Cooler
LEGEND:
1 Transmission Cooler-to-Transmission Line
2 Transmission-to-Transmission Cooler Line
Disconnect transmission cooler lines (1 and 2) from transmission oil cooler (39).
[4] -
LEGEND:
1 Quick Coupler
2 Fitting
3 Tee
Transmission Cooler Test Connection

Connect tees and quick couplers to transmission cooler lines.
Tee (—12 F x —12 F x —12 F)
Used to connect JT02156A digital pressure and temperature analyzer.
Adapter (—12 M x —6 F ORFS)
Quick Coupler (—6 M)
Nipple (—12 M)
[5] - Connect test hoses to tees and transmission oil cooler.

Test Hose
Used to make test connections.
[6] - Install JT02161 Transducer and JT02158 Digital Pressure and Temperature Analyzer to quick couplers. See JT02156A
Digital Pressure and Temperature Analyzer Kit Installation . (Group 9025-25.)
JT02158
Used to measure pressure and temperature.
Transducer
JT02161
(Group 9015-16.)
167—185°F
[9] -
→NOTE:
Pressure specifications should be the same in all gears.
With transmission control lever (TCL) in neutral, operate machine to specifications and record pressure.
Transmission Cooler In Pressure 124—165 kPa
1.24—1.65 bar
18—24 psi
[10] - Check transmission cooler out pressure and record.

Transmission Cooler Pressure Differential (drop) 55—83 kPa
0.55—0.83 bar
8—12 psi
[11] - If cooler pressure differential is above specification, inspect cooler hoses and cooler for damage. If no damage is found,
clean cooler using oil filter caddy. See General Oil Cleanup Procedure . (Group 2160.)
[12] - If cooler pressures are low, possible locations include:
Transmission control solenoid. Check solenoids. See Solenoid Circuit Leakage Test . (Group 9020-25.)
Pump problems. Check transmission pump flow. See Transmission Pump Flow Test . (Group 9020-25.)
Pump stop sleeve may be blocking flow to torque converter, or torque converter may be plugged. See Torque Converter
Stall Speed Test . (Group 9020-25.)
Solenoid Circuit Leakage Test

Specifications
SPECIFICATIONS
75—85°C
Transmission Oil Temperature at Sump
167—185°F
8595 kg
315SK Weight (approximate)
18 938 lb.
If cooler pressures are low from the cooler in and cooler out pressure test, perform the following test:
[1] - Install test equipment. See Cooler In and Cooler Out Pressure Test . (Group 9020-25.)
(Group 9015-16.)
Transmission Oil Temperature at Sump 75—85°C
167—185°F
[4] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
Raise and support machine so all drive wheels are off the ground.
315SK Weight (approximate) 8595 kg
18 938 lb.
[5] - With transmission control lever (TCL) in neutral, operate engine at specification.
[6] - Operate machine and record pressure and flow for each of the following items:
Forward, reverse, neutral, and speed clutches.

Mechanical front wheel drive (MFWD)
Differential Lock
Park Brake
There should be a momentary fluctuation in pressure and flow if circuit is normal. If cooler pressure and flow (in and out)
remains down, this indicates a leakage in that circuit.
Transmission Pump Flow Test

Specifications
SPECIFICATIONS
75—85°C
167—185°F
40.0 L/min
Transmission Pump Flow
10.6 gpm
JDG596A Filter Adapter
JT07148 Flow meter
[2] - Check Transmission Oil Level. See Check Transmission Oil Level . (Operator’s Manual.)
[3] -
Test Connections
LEGEND:
1 JDG596A Filter Adapter
2 Test Hose (to flow meter inlet)
3 Test Hose (from flow meter outlet)
4 JT07148 Flow meter
Install JDG596A Filter Adapter (1) to transmission oil filter mount.
Filter Adapter
JDG596A
Used to isolate transmission pump flow.
[4] - Install JT07148 Flow meter (4) to JDG596A Filter Adapter (1) using test hoses (2, 3).
Flowmeter
JT07148
Used to measure flow.
[5] -
HYDRAULIC SYSTEM (g) by Belgreen v2.0
IMPORTANT:
Before starting engine, check that flow meter loading valve is open. Starting engine with loading valve
closed will damage transmission pump.
View transmission oil temperature on standard display monitor (SDM). See Standard Display Monitor (SDM)—Diagnostics .
(Group 9015-16.)
167—185°F
[7] - Run engine at specification.

[8] - Measure transmission pump flow. Compare reading to specification.

Transmission Pump Flow 40.0 L/min
10.6 gpm
[9] - Low transmission pump flow can be caused by:
Cold transmission oil.

Plugged intake tube.
Air leak in pump suction tube.
Pump mounting cap screws loose.
Worn transmission pump.
Section 9025 - HYDRAULIC SYSTEM

Table of contents
Hydraulic System Operation ................................................................................................................. 1
Hydraulic Pump Operation .................................................................................................................... 2
Unloading Valve Operation ................................................................................................................... 4
Hydraulic Filter Operation ..................................................................................................................... 8
Steering Valve Operation ................................................................................................................... 12
Ride Control Operation—If Equipped .................................................................................................. 16
System Relief Valve Operation ........................................................................................................... 17
Circuit Relief Valve without Anticavitation—Loader and Backhoe ...................................................... 18
Circuit Relief Valve with Anticavitation—Backhoe Swing, Boom Lower .............................................. 20
Circuit Relief Valve with Anticavitation—Backhoe Bucket Curl and Loader Bucket Dump .................. 21
Backhoe Control Valve Operation ....................................................................................................... 22
Pilot Control Valve Operation—If Equipped ......................................................................................... 38
Pilot Enable and Pattern Select Valve Operation—If Equipped ........................................................... 40
Loader and Stabilizer Control Valve Operation ................................................................................... 42
Sideshift Lock Solenoid Valve—(S.N. —232969) ................................................................................. 55
Sideshift and Boom Lock (SBL) Solenoid Valve Operation—(S.N. 235590— ) ..................................... 56
Group 15 - Diagnostic Information ...................................................................................................... 58
Hydraulic System Schematic .............................................................................................................. 58
Hydraulic System Component Location .............................................................................................. 67
Slow Steering Hydraulics Diagnostic Procedure ................................................................................. 77
No Steering Hydraulics, Loader Hydraulics OK ................................................................................... 77
Hard Steering, Loader Hydraulics OK Diagnostic Procedure ............................................................... 77
Steering Valve Does Not Return to Neutral Diagnostic Procedure ...................................................... 78
No Response When Steering Wheel is Turned, Loader Hydraulics OK Diagnostic Procedure ............. 80
Machine Turns in Opposite Direction Diagnostic Procedure ............................................................... 81
Excessive Vibration of the Steering Wheel Diagnostic Procedure ...................................................... 81
Machine Turns When Steering Valve is in Neutral Diagnostic Procedure ........................................... 81
Steering Wheel Kickback Diagnostic Procedure ................................................................................. 82
Excessive Steering Wheel Turns to Steer Machine Diagnostic Procedure .......................................... 82
Erratic (‘Spongy”) Steering Diagnostic Procedure .............................................................................. 83
Steering Wheel "Locks" Up Diagnostic Procedure .............................................................................. 83
Poor Centering of Steering Wheel (Wheels Continue to Move After Steering Wheel is Stopped)
Diagnostic Procedure ................................................................................................................... 84
Steering Wheel or Front Wheels Slowly Turn by Themselves When Using Backhoe or Loader Diagnostic
Procedure .................................................................................................................................... 84
Steering Wheel Turns Apply Rear Axle Service Brakes Diagnostic Procedure .................................... 85
Steering Wheel Turns Freely With No Resistance or Action On Steered Wheels Diagnostic Procedure
..................................................................................................................................................... 85
Steering Wheel Turns With Slight Resistance and No Action On Steered Wheels Diagnostic Procedure
..................................................................................................................................................... 86
Wander—Machine Will Not Stay in a Straight Line Diagnostic Procedure ........................................... 86
No Loader or Steering Hydraulics Diagnostic Procedure .................................................................... 87
No Loader Hydraulics Diagnostic Procedure ....................................................................................... 87
Low Loader Hydraulic Power Diagnostic Procedure ............................................................................ 88
Low Hydraulic Power Diagnostic Procedure ........................................................................................ 89
Engine Pulls Down Excessively During Loader Operation Diagnostic Procedure ................................ 90
Engine Pulls Down Excessively During Backhoe Operation Diagnostic Procedure .............................. 90
Slow Hydraulic Functions Diagnostic Procedure ................................................................................. 92
Backhoe Operates Slowly in One Function Diagnostic Procedure ....................................................... 94

Loader Operates Slowly in One Function Diagnostic Procedure ......................................................... 96

No Backhoe Power in One Function Diagnostic Procedure ................................................................. 98
No Loader Power in One Function Diagnostic Procedure .................................................................. 100
Slow Loader and Backhoe Hydraulics Diagnostic Procedure ............................................................ 102
Low Hydraulic Power (Low Hydraulic Pressure) Diagnostic Procedure ............................................. 104
Hydraulic Function Makes "Chattering" Noise Diagnostic Procedure ................................................ 106
Functions Drift Diagnostic Procedure ............................................................................................... 108
Control Valve Sticks or Works Hard Diagnostic Procedure ............................................................... 109
Hydraulic Oil Overheats Diagnostic Procedure ................................................................................. 111
Foaming Oil Diagnostic Procedure .................................................................................................... 113
Hydraulic Pump Leaking Diagnostic Procedure ................................................................................ 113
Excessive Pump Noise Diagnostic Procedure ................................................................................... 115
Group 20 - Adjustments ...................................................................................................................... 117
Backhoe Control Lever to Valve Linkage (Two Lever) Adjustment ................................................... 117
Auxiliary Selective Flow Control Valve Adjustment—If Equipped ...................................................... 118
Pilot Control Pressure Adjustment .................................................................................................... 120
Pilot Enable and Pattern Select Valve Accumulator Discharge Procedure ........................................ 122
Loader Bucket Self-Leveling Linkage and Return-To-Dig Switch Adjustment ................................... 123
Loader and Stabilizer Lever Adjustment ........................................................................................... 126
Ride Control Accumulator Charge Procedure ................................................................................... 129
Ride Control Accumulator Charge Check Procedure ......................................................................... 131
Ride Control Accumulator Hydraulic Pressure Release Procedure .................................................... 132
Group 25 - Tests ................................................................................................................................... 133
JT02156A Digital Pressure and Temperature Analyzer Kit Installation .............................................. 133
Hydraulic Oil Warm-up Procedure .................................................................................................... 134
Fluid Sampling Procedure—If Equipped ............................................................................................ 135
Hydraulic Oil Sampling Procedure—If Equipped ............................................................................... 138
Hydraulic Circuit Pressure Release ................................................................................................... 139
Hydraulic Pump Flow Test ................................................................................................................ 141
System Relief Valve Pressure Test ................................................................................................... 144
Hydraulic Pump Unloading Relief Valve Pressure Test ..................................................................... 148
Pilot Control Pressure Test ................................................................................................................ 149
Pilot Control Accumulator Charge Pressure Test .............................................................................. 150
Hydraulic Oil Cooler Restriction Test ................................................................................................ 152
Circuit Relief Valve Test—With Remote Pump .................................................................................. 154
Steering System Leakage Test ......................................................................................................... 158
Steering Cylinder Leakage Test ........................................................................................................ 160
Function Drift Test ............................................................................................................................ 162
Hydraulic Cylinder Leakage Test ...................................................................................................... 169
Loader and Stabilizer Control Valve Lockout Leakage Test .............................................................. 172
Sideshift Lock Solenoid Valve Leakage Test—(S.N. —232969) ......................................................... 174

Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Hydraulic System Operation
See Hydraulic System Component Location . (Group 9025-15.)
See Hydraulic System Schematic . (Group 9025-15.)
This machine has an open-center hydraulic system. The hydraulic pump is a tandem gear pump with an unloading valve. The
main hydraulic pump is a fixed displacement gear pump. The auxiliary pump is a smaller fixed displacement pump that is
driven from the rear of the main pump. An unloading valve housing for the auxiliary pump is located between the pump units.
In an open-center system, the control valve spool is open in the center to allow pump flow to pass through the valve.
See Hydraulic Pump Operation . (Group 9025-05.)
See Unloading Valve Operation . (Group 9025-05.)
Loader and stabilizer functions are mechanically controlled in the loader and stabilizer control valve. Loader auxiliary function
is mechanically or electrohydraulically controlled. Backhoe functions are mechanically or pilot operated by the backhoe control
valve.
See Loader and Stabilizer Control Valve Operation . (Group 9025-05.)
See Backhoe Control Valve Operation . (Group 9025-05.)
The pilot control system includes two pilot controls and a pilot enable and pattern select (PEPS) manifold. System pressure is
reduced to pilot pressure through the pilot pressure reducing valve. With pilot enable solenoid energized, regulated pressure
flows to pilot control levers in the cab. When a function is activated, pilot oil flows to pilot cap of control valve to shift the spool.
The pattern select valve switches (if equipped) the controls of backhoe control valve boom and crowd functions for operator
preference.
See Pilot Control Valve Operation—If Equipped . (Group 9025-05.)
See Pilot Enable and Pattern Select Valve Operation—If Equipped . (Group 9025-05.)
The circuit relief valves are used to protect components from damage caused by high pressure created by external forces.
Relief valves allow a secondary path for high pressure oil to bypass components. Circuit relief valves are present in the loader
and stabilizer control valve and in the backhoe control valve. The backhoe control valve includes a system relief valve to
relieve pressure across the entire control valve.
See System Relief Valve Operation . (Group 9025-05.)
See Circuit Relief Valve without Anticavitation—Loader and Backhoe , see Circuit Relief Valve with Anticavitation—Backhoe
Swing, Boom Lower , and see Circuit Relief Valve with Anticavitation—Backhoe Bucket Curl and Loader Bucket Dump . (Group
9025-05.)
Backhoe priority valve supplies oil to the steering valve. When the steering valve is in neutral no oil is flowing through it.
See Steering Valve Operation . (Group 9025-05.)
Ride control operation (if equipped) allows the boom cylinders oil drain to the reservoir allowing a more comfortable ride.
See Ride Control Operation—If Equipped . (Group 9025-05.)
The return oil from the control valves, flows to the hydraulic oil filter, then to the hydraulic oil cooler, before returning to the
reservoir. The hydraulic oil cooler may be bypassed through the oil cooler bypass if oil cooler is blocked or oil is cold. The oil
cooler is an oil-to-water exchanger.
See Hydraulic Filter Operation . (Group 9025-05.)
Hydraulic Pump Operation
Hydraulic Pump Operation

LEGEND:
1 Pump Inlet
2 Check Valve
3 Unloading Valve Housing
4 Main Pump Outlet Port
5 Unloading Valve Solenoid

6 Inlet Passage
7 Relief Valve Adjustment Screw
113 Hydraulic Pump
212 Auxiliary Pump
213 Auxiliary Pump Test Port
214 Unloading Valve Spool
215 Unloading Valve Relief Valve
604 Return Oil
The main hydraulic pump (113) is a fixed displacement gear-type pump. The auxiliary pump (212) is a smaller fixed
displacement pump that is driven from the rear of the main hydraulic pump (113). An unloading valve housing (5) for the
auxiliary pump (212) is located between the pump units. The entire pump assembly is mounted on the rear of the transmission
and is driven at engine speed by the transmission input shaft.
Oil is drawn from the hydraulic reservoir into a common pump inlet (1) located in the unloading valve housing (3). Flow from
the main pump outlet port (4) is routed to the priority valve inlet on backhoe control valve. If the backhoe control valve is not
being used, oil flows on to the loader and stabilizer control valve. A system relief valve is located at the priority valve and
protects the main hydraulic pump (113) during both lower pressure loader operation and higher pressure backhoe operation.
Oil flow from the auxiliary pump (212) is routed within the unloading valve housing (3) to either the main pump outlet port (4)
or returns through the inlet passage (6) to the pump inlet (1) depending upon the position of the seat. During loader or
transport operation with seat forward, the unloading valve solenoid (7) is energized and remains open. Consequently, auxiliary
pump flow returns back to inlet through the unloading valve spool (214) which reduces hydraulic load requirement on engine.
When the seat is in the backward position, the unloading valve solenoid (5) is de-energized and the unloading valve spool (214)
blocks auxiliary pump flow from returning to pump inlet (1). Therefore, auxiliary pump supplemental oil is provided for backhoe
operation only. As backhoe operating pressure increases, the relief valve (215) senses the pressure increase and opens to
allow auxiliary pump flow to return to pump inlet (1) through the unloading valve spool (214). Since the specified pressure
adjustment for the unloading valve spool (214) to open is below backhoe system relief, the power demanded from the engine
to operate the auxiliary pump (212) is reduced. A one way check valve (2) within the unloading valve housing (3) prevents
backflow of oil from backhoe control valve during high pressure backhoe operation. The external relief valve adjusting screw
(7) is used to control the opening of the unloading valve spool (214). Pressure can be checked at the test port (213) located on
the auxiliary pump (212) housing.
Unloading Valve Operation

Unloading Valve—Backhoe Operation
Unloading Operation
LEGEND:
1 Main Pump Flow
2 Check Valve
3 Pressure Sensing Orifice
4 Solenoid Valve
5 Pump Inlet
6 Auxiliary Pump Flow
604 Return Oil
Oil flow from the auxiliary pump is controlled by the unloading valve during different type of operating conditions. Key
elements involved include solenoid valve (4), unloading valve relief valve (215), unloading valve spool (214), pressure sensing
orifice (3) and check valve (2).
During loader operation, auxiliary pump oil flow is returned to main pump inlet through the unloading valve spool (214). The
operator′s seat has to be in the backhoe position, the solenoid valve (4) is de-energized and blocks oil that flows through the
pressure sensing orifice (3) to pump inlet passage. Consequently, system operating pressure up to the relief valve setting is
trapped between the spring end of unloading valve spool (214), solenoid valve (4), and unloading valve relief valve (215). Since
the same pressure exists on both ends of the spool, spring force holds the unloading spool to the right. In this position, the
spool blocks pump outlet passage (6) from the passage which is connected to pump inlet (5). During this condition, auxiliary
pump flow is routed past the one-way check valve (2) to supplemental main pump flow (1) during backhoe operation.
As operating pressure increases above the relief valve setting, the unloading valve relief valve (215) opens and trapped oil
after the orifice (3) flows to the pump inlet. Since a pressure drop occurs after the orifice restriction (3), the pressure on the
spring end of the unloading valve spool is lower than the pressure on back side of spool before the orifice. Higher pressure
overcomes spring force and moves the unloading valve spool (214) left to open position which allows the return of auxiliary
pump flow back to pump inlet. Check valve (2) closes to prevent backhoe pressure from unloading the auxiliary pump oil to
pump inlet. The relief valve adjusting screw is used to regulate the pressure which allows auxiliary pump flow to be routed back
to pump inlet.
Unloading Valve—Loader Operation
Unloading Valve
LEGEND:
1 Main Pump Flow
2 Check Valve
3 Pressure Sensing Orifice
4 Solenoid Valve
5 Main Pump Inlet
6 Auxiliary Pump Flow

604 Return Inlet Oil
With the operator′s seat in the forward position, the solenoid valve (4) is energized and opens a path to main pump inlet for oil
between unloading valve spool (214) and unloading valve relief valve (215). Since pressure increase is prevented from
occurring on the spring end of the unloading valve spool (214), a pressure imbalance is created which forces the spool left
against the spring. When the spool is held in the open position, auxiliary pump flow (6) returns back to main pump inlet (5).
Power requirement from the engine is reduced to operate loader operating condition because auxiliary pump flow is routed
back to main pump inlet. System operating pressure is not affected by operation of the unloading spool.
Hydraulic Filter Operation

Normal Operation
Normal Operation
LEGEND:
1 Inlet (from backhoe and loader valves)
2 Auxiliary Port (for oil sampling option)

3 Outlet Return to Hydraulic Cooler
4 Outlet Return to Hydraulic Oil Reservoir
5 Filter Element
7 Filter Bypass Valve
118 Hydraulic Oil Filter
604 Return Oil
The hydraulic oil filter element (5) removes contaminants from hydraulic system return oil (604). Filter base (118) contains a
hydraulic filter bypass valve (7), hydraulic oil filter restriction switch (B12) and an auxiliary port (2) for oil sampling option.
Return oil flows from the loader and stabilizer control valve and backhoe control valve into inlet port (1). In normal operation,
oil flows through filter element (5) and out through the auxiliary outlet to hydraulic cooler or out through main outlet to
hydraulic reservoir.
Pressure on inlet side of filter element is sensed on left side of bypass valve. Any pressure at filter outlets (3 and 4) due to line
restriction is sensed on spring side of bypass valve. In normal operation, pressure in outlet passage and the bypass spring hold
the bypass valve closed.
Restricted Operation
Restricted Operation
LEGEND:
1 Inlet (from backhoe and loader valves)
2 Auxiliary Port (for oil sampling option)
3 Outlet Return to Hydraulic Cooler
4 Outlet Return to Hydraulic Oil Reservoir
5 Hydraulic Oil Filter Element
7 Hydraulic Oil Filter Bypass Valve
118 Hydraulic Oil Filter Base

604 Return Oil
As filter element (5) starts to plug or when oil is cold, pressure at the filter inlet increases. When the filter becomes restricted to
the point where pressure at filter inlet increases enough to overcome outlet pressure plus a set spring force, bypass valve (7)
opens allowing unfiltered oil to flow to the reservoir.
The hydraulic oil filter restriction switch (B12) works on the same principle as hydraulic oil filter bypass valve. High pressure oil
is sensed through the high pressure passage. Restricted oil caused by a clogged filter or cold oil will create higher oil pressure
on the inlet side. When this inlet pressure overcomes outlet pressure, plus a set spring force in the hydraulic oil filter restriction
switch, the piston opens up (closes) providing a ground for the filter restriction indicator. The hydraulic oil filter restriction
switch will cause the filter restriction indicator light to illuminate. The indicator switch is set to close at 70 kPa (0.7 bar) (10 psi)
before the hydraulic oil filter bypass valve opens allowing operator to perform maintenance on the hydraulic system before
unclean oil passes through oil system.
Under normal operation, the restriction indicator light will glow when operating hydraulic functions with cold oil. If restriction
indicator light continues to glow after the oil reaches operating temperature, the return filter is being bypassed. Extended
operation in bypass mode will cause damage to hydraulic system.
Steering Valve Operation
Steering Valve (neutral)

LEGEND:
1 Port T
2 Port L
3 Port R
4 Port P
124 Steering Valve
125 Steering Cylinder
218 Steering Valve Control Spool
219 Steering Valve Gerotor Gear Assembly
604 Return Oil
606 Trapped Oil
614 Load Sense Oil
The steering valve (124) is essentially a closed-center valve. The steering valve and priority valve provide a smooth pressure
compensated steering system.
When steering valve is in neutral, there is no oil flowing through it except neutral leakage from priority valve. Neutral leakage
is used for lubrication and cooling steering valve.
Steering Valve (right turn)

LEGEND:
1 Port T
2 Port L
3 Port R
4 Port P
124 Steering Valve
604 Return Oil
614 Load Sense Oil
A right turn on steering wheel activates steering valve gerotor gear assembly (219) to pump metered high pressure oil (600) to
rod end of steering cylinder (125). Return oil (604) from steering cylinder flows through steering valve and back to hydraulic oil
filter.
Steering Valve (left turn)

LEGEND:
1 Port T
2 Port L
3 Port R
4 Port P
124 Steering Valve
604 Return Oil
614 Load Sense Oil
A left turn on steering wheel actuates steering valve gerotor gear assembly (219) to pump metered high pressure oil (600) to
head end of steering cylinder (125). Return oil (604) from steering cylinder flows through steering valve and back to the
hydraulic oil filter.
Steering Valve (secondary steer)

LEGEND:
1 Port T
2 Port L
3 Port R
4 Port P
6 Check Valve
7 Pin
124 Steering Valve
603 Lubrication Oil
604 Return Oil
606 Trapped Oil
614 Load Sense Oil
If there is no power to supply high pressure oil to the steering valve, machine can be turned manually. When steering wheel is
turned, steering valve control spool will come into contact with pin (7). The pin then will provide a direct mechanical connection
to steering valve gerotor gear assembly (219). As gerotor is turned, it pumps hydraulic oil to steering cylinder. Return oil (604)
from cylinder is drawn through a check valve (6) between port P (4) and port T (1) to provide oil for secondary manual steering
operation. Makeup oil is drawn from hydraulic reservoir through return line of steering valve.
Ride Control Operation—If Equipped
Ride Control Solenoid

LEGEND:
1 To Left Boom Cylinder Head End
2 To Left Boom Cylinder Rod End
3 To Right Boom Cylinder Head End
4 To Right Boom Cylinder Rod End
5 To Accumulator
6 To Reservoir
7 To Boom Cylinder Rod End (2 used)
8 To Boom Cylinder Head End (2 used)
9 Solenoid (2 used)
10 Check Valve Poppet
204 Ride Control Valve
205 Ride Control Accumulator
604 Return Oil
606 Trapped Oil
When traveling over rough terrain at high speeds with loaded or empty bucket, machine develops a rocking motion, which is
common to loaders. Ride control allows oil from head end of loader boom cylinders to travel in and out of ride control
accumulator. Ride control allows rod end of boom cylinder to be connected to reservoir, which prevents cylinder cavitation.
This provides a cushioning effect, reducing rocking motion and improving machine ride.
When ride control is OFF, machine is in normal operating mode. In this mode, both ride control solenoids are de-energized. One
solenoid (9) blocks rod end oil of right and left boom cylinders from returning to hydraulic reservoir. The other solenoid blocks
head end oil of boom cylinders from accumulator.
When ride control is ON, both ride control solenoids are energized connecting head end oil of loader boom cylinders to
accumulator and rod end of cylinders to reservoir. Pressure spikes from head ends of boom cylinders flow into accumulator
where they are absorbed. The rod end of boom cylinders are open to bidirectional free oil flow to reservoir. As loader boom is
raised, accumulator is charged with system oil through ride control valve, equalizing cylinder head end pressure and
accumulator pressure. Boom cylinder rod end hoses are connected directly to reservoir. Because of this, power boom down
function will not operate. Boom will lower because of boom weight and gravity. Ride control can be engaged during bucket
loading, but must be turned off if power down operation is desired.
System Relief Valve Operation
System Relief Valve

LEGEND:
1 Valve Body
2 Lock Nut
3 Adjusting Screw
4 Valve Poppet
5 Flat Washer
6 O-Ring (3 used)
7 Seal
8 Spring
9 Backup Ring
10 Valve Plug
600 High-Pressure Oil
604 Return Oil
The system relief valve is used in the backhoe control valve. The relief is direct acting, screw adjustable, and does not have
anticavitation operation.
The pressure set point is adjustable by loosening the lock nut (2) and adjusting screw (3). Turning the screw in increases
pressure setting.
In relief operation, high-pressure oil (600) overcomes valve poppet (4) and oil flows from the pressurized port to tank.
Circuit Relief Valve without Anticavitation—Loader and Backhoe
22.35 mm (0.88 in.) Port Size shown

LEGEND:
1 Main Poppet
2 Adjustment Screw
604 Return Oil
The 22.35 mm (0.88 in.) port size metal to metal seal relief without anticavitation is used on backhoe control valve crowd out
function.
26 mm (1.06 in.) Port Size Shown

LEGEND:
1 Main Poppet
2 Adjustment Screw
604 Return Oil
The 26 mm (1.06 in.) port size O-ring seal relief is used on backhoe control valve boom up, crowd in, bucket curl, and bucket
dump. It is also used on loader control valve boom up and bucket curl.
These reliefs are direct acting, screw adjustable, and do 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, high pressure oil (600) overcomes the main poppet (1) and oil flows from the pressurized port to tank.
Circuit Relief Valve with Anticavitation—Backhoe Swing, Boom Lower
Circuit Relief Valve with Anticavitation—Backhoe Swing, Boom Lower

LEGEND:
1 Anticavitation Poppet
2 Cavity
3 Relief Poppet
4 Orifice
604 Return Oil
This relief valve is direct acting and has anticavitation operation.
During normal operation, pressure oil less than the relief valve setting flows through orifice (4) into cavity (2). At this time, the
oil pressure is equal at both sides of main relief poppet (3) and anticavitation poppet (1). Because the effective area of the
poppets at cavity (2) side is greater than the work port side, the surface area effect and spring tension will hold both poppets in
the closed position.
During relief operation, pressure oil overcomes relief poppet (3) pressure setting and opens a path to return.
During anticavitation operation, the pressure in the work port is less than pressure in the return port. The pressure difference
pushes the anticavitation poppet (1) off its seat allowing oil to flow from return port to work port to prevent cavitation.
Circuit Relief Valve with Anticavitation—Backhoe Bucket Curl and

Loader Bucket Dump
Circuit Relief Valve with Anticavitation—Backhoe Bucket Curl and Loader Bucket Dump
LEGEND:
1 Orifice
2 Main Poppet
3 Anticavitation Poppet
4 Oil Cavity
5 Anticavitation Spring
6 Pilot Spring
7 Pilot Poppet
8 Main Spring
9 Relief Body
10 Piston
604 Return Oil
This pilot operated and screw adjustable relief valve has anticavitation operation.
The relief valve setting is controlled by the pilot spring (6) load holding the pilot poppet (7) on its seat. This setting is adjustable
by turning the adjustment cap at the relief valve.
During normal operation, pressure oil less than relief valve setting, flows through orifice (1) into oil cavity (4). At this time, oil
pressure is equal at both sides of main poppet (2) and anticavitation poppet (3). Because the surface area of the poppets is
greater at the oil cavity side than the work port side, the effective area and spring tension will hold both poppets in the closed
position.
During relief operation, pressure oil pushes pilot poppet off its seat allowing oil to flow from the pressurized port through
orifice, into oil cavity, past the pilot poppet, and then to tank through a path between relief body (9) and anticavitation poppet.
When the pilot poppet is unseated, a pressure drop is produced in the oil cavity. The pressure drop creates a pressure
differential across the piston (10), causing the piston to move against the main spring (8) until the piston seats against the pilot
poppet. When this happens, orifice (1) is closed off which further reduces the pressure in the oil cavity. When the pressure
differential is large enough to overcome the surface area effect and spring tension, the main poppet will move off its seat and
allow oil from the work port to flow to the return port.
During anticavitation operation, the pressure in the work port and the oil cavity is less than pressure in the return port. The
pressure difference pushes the anticavitation poppet off its seat, allowing oil to flow from return port to work port to prevent
cavitation.
Backhoe Control Valve Operation

Inlet Section
Backhoe Control Valve Inlet Section

LEGEND:
1 To Steering Valve
2 From Steering Valve
3 To Backhoe Control Valve Sections
4 From Backhoe Control Valve Sections
5 To Hydraulic Oil Filter
113 Hydraulic Pump
150 System Relief Valve
152 Priority Spool
221 Inlet Section
604 Return Oil
614 Load Sense Oil

The inlet section (221) of backhoe control valve provides a means of connecting backhoe control valve to hydraulic pump
(113). Pump output is routed through priority spool (152). The priority spool senses load sense oil (614) from steering valve and
attachment coupler (if equipped).
The priority valve maintains priority oil to steering valve. When engine is stopped, priority spool (152) is pushed left by a bias
spring restricting oil to backhoe, stabilizer, and loader functions by opening steering supply port.
When machine is first started, almost all pump flow is routed to steering valve through steering supply port. The steering valve
blocks flow except for a small amount of flow to backhoe control valve through an orifice in priority valve. With flow blocked,
pressure increases in steering line between priority valve and orifices in and near steering valve spool. This causes priority
spool (152) to shift right against the bias spring and limits the flow to steering supply port by closing the priority metering
holes. This also opens pressure inlet port to backhoe, stabilizer, and loader functions. As long as the steering valve is in neutral,
limited flow is allowed to pass through the metering holes to maintain steering pressure at the steering supply port that keeps
the spool shifted to the right and balanced against the bias spring.
If the pump is unable to supply adequate flow to maintain steering pressure at steering supply port during use of any hydraulic
functions, priority spool (152) will shift left and restrict flow to backhoe, stabilizer, and loader functions until steering supply
pressure is satisfied.
System relief valve (150) for backhoe functions is located in the priority valve section. The function of the relief is to regulate
system (pump) pressure for backhoe functions.
Auxiliary Selective Flow Control Section—If Equipped
Backhoe Control Valve Auxiliary Selective Flow Control Section (solenoid energized)
LEGEND:
1 Flow Adjustment Control
2 Spring
3 Restrictor Check
4 Orifice
5 Controlled Flow Port
6 Controlled Flow Passage
7 Orifice
8 Metering Notches
9 Supply from Inlet Section
10 Passage
11 Return Passage
12 Spool End Cavity
13 Bias Spring
14 Orifice
15 To Downstream Backhoe Functions
17 Metering Hole (6 used)
19 Spool End Cavity

20 Control Orifice
21 Flow Adjuster Screw
154 Backhoe Auxiliary Selective Flow Control Spool
222 Auxiliary Selective Flow Section (if equipped)
229 Auxiliary Selective Flow Relief Valve (no anticavitation)
601 Medium-Pressure Oil
604 Return Oil
Auxiliary selective flow section (222) provides control for backhoe mounted attachments and also for handheld hydraulic
attachments (if equipped).
The auxiliary selective flow section (222) maintains a specified flow rate to auxiliary hydraulic attachments regardless of
changing loads on the hydraulic system. When engine is stopped, backhoe auxiliary selective flow control spool (154) is pushed
to the right by the bias spring (13), closing pump passage (9) to downstream backhoe functions (15) and opening spool
metering holes (17) to create an oil passage to controlled flow port (5).
When solenoid is not energized, passage (10) is blocked from spool end cavity (12) by selective flow control solenoid (Y53)
valve. Spool end cavity (12) is connected through the orifice (14) and selective flow control solenoid to return passage (11).
When machine is first started, all pump flow is routed through metering holes (17) into spool end cavity (19) and out of control
orifice (20) to flow passage (6). Flow is blocked from controlled flow port (5) by a spring loaded restrictor check (3). The
pressure required to open the restrictor check (3) is designed to be slightly higher than the pressure generated by spool bias
spring (13).
With flow blocked, pressure increases at spool end cavity (19). This causes the backhoe auxiliary selective flow control spool
(154) to shift to the right against bias spring and reduce the opening through spool by closing metering holes (17). This spool
movement simultaneously opens metering notches (8) and creates a passage between the supply from inlet section (9) and
downstream backhoe functions (15). As long as solenoid valve is not activated, spool keeps a position, maintaining a pressure
in spool end cavity (19) that keeps spool shifted to the right and balanced against the bias spring (13).
Backhoe Control Valve Auxiliary Selective Flow Control Section (solenoid de-energized)
LEGEND:
1 Flow Adjustment Control
2 Spring
3 Restrictor Check
4 Orifice
5 Controlled Flow Port
6 Controlled Flow Passage
7 Orifice
8 Metering Notches
9 Supply from Inlet Section
10 Passage
11 Return Passage
12 Spool End Cavity
13 Bias Spring
14 Orifice
17 Metering Hole (6 used)
19 Spool End Cavity

20 Control Orifice
21 Flow Adjuster Screw
222 Auxiliary Selective Flow Section (if equipped)
229 Auxiliary Selective Flow Relief Valve (no anticavitation)
604 Return Oil
606 Trapped Oil
When auxiliary selective flow control solenoid (Y53) is activated, the solenoid spool closes off a return passage and opens
another for trapped oil from passages (6 and 10) to flow into spool end cavity (12), releasing pressure in spool end cavity (19)
against bias spring (13). Bias spring is now free to shift auxiliary selective flow control spool (154) and metering notches (8)
left. This closes supply from inlet section (9) off to downstream backhoe functions (15) and opens supply from inlet to
controlled flow passage (6). Pressure in controlled flow passage is now sufficient to overcome restrictor check (3) and opens to
controlled flow port (5).
With solenoid activated, valve will now sense load induced by auxiliary attachments. Load pressure at controlled flow port (5) is
routed through orifice (7), passage (10), and solenoid to spool end cavity (12). Load pressure and bias spring (13) act against
pilot pressure in spool end cavity (19) to keep backhoe auxiliary selective flow control spool (154) shifted left. This will keep
restricting flow to backhoe functions while metering holes (17) are opened to allow flow to controlled flow port (5). Backhoe
auxiliary selective flow control spool (154) will keep a position that maintains a pressure in the spool end cavity (19) equal to
the combination of load pressure and bias spring (13) pressure.
If pump is unable to supply adequate flow to maintain selected backhoe function speeds and output load pressure at controlled
flow port (5), backhoe auxiliary selective flow control spool (154) will shift left and restrict flow to backhoe functions (15) until
load pressure is restored. If through the use of backhoe functions the inlet pressure rises higher than is required by the
attachment, spool (154) will shift right and restrict flow to the controlled flow port (5).
Flow output is controlled by the size of control orifice (20). As flow is passed through the control orifice (20), there is a pressure
drop from spool end cavity (19) to flow passage (6). When this pressure drop is equal to the effect of bias spring (13), flow rate
will be maintained at that level. Flow rates can be changed by turning flow adjustment control (1) to vary size of control orifice
(20). Flow adjustment control (1) is attached to a flow adjuster screw (21) that can be moved to six distinct positions for flow
control.
Load pressure at controlled flow port (5) is limited by a relief valve (229). When controlled flow port (5) pressure reaches the
relief set point, oil is passed to the return passage (16) through auxiliary selective flow relief valve (229). Orifice (7) limits
amount of oil lost to return when relief valve opens. Auxiliary selective flow relief valve (229) limits the maximum pressure that
is supplied to the spool end cavity (12). At this point, the valve will not be able to supply any greater output pressure at the
controlled flow port (5).
An orifice (4) is located in the restrictor check (3) to eliminate the possibility of high-pressure oil (600) being trapped in the
controlled flow port (5) when flow control is de-energized. Trapped oil would make it difficult to connect or disconnect the
hydraulic quick connect fittings.
When optional selective auxiliary flow section is installed in the backhoe control valve, a relief valve without anticavitation is
also installed in place of cap in the rod end side of bucket curl section of backhoe control valve.
Swing Section
Swing Section (swing left position)

LEGEND:
1 Swing Left Work Port
2 Load Check
3 Supply Inlet Passage
4 Swing Right Work Port
5 Return Passage
6 Supply From Auxiliary Selective Section
7 Return To Tank
8 Supply To Downstream Backhoe Functions
145 Backhoe Control Valve
156 Backhoe Swing Spool
161 Backhoe Swing Cylinder (2 used)
224 Swing Section
230 Swing Circuit Relief Valve (with anticavitation) (2 used)
604 Return Oil
The swing section is a three-position, six-way, open-center spool valve. The swing section contains two circuit relief valves with
anticavitation (230).
When backhoe swing spool (156) is shifted to activate the left swing function, oil flows from supply inlet passage (3), past load
check (2), through backhoe swing spool, and out swing left work port (1) to cylinders. Return oil from cylinders flows in through
swing right work port (4), past backhoe swing spool, into return passage (5), then out of control valve to the hydraulic oil filter.
Boom Section
Backhoe Control Valve Boom Section (boom lower position)

LEGEND:
1 Boom Lower Work Port
2 Load Check
4 Boom Raise Work Port
5 Orifice
6 Vent Passage
7 Work Port Passage
8 Supply From Backhoe Swing Section

9 Return Passage
10 Return To Tank
157 Backhoe Boom Spool
162 Backhoe Boom Cylinder
225 Boom Section
231 Backhoe Boom Circuit Relief (no anticavitation)
232 Backhoe Boom Circuit Relief (with anticavitation)
239 Anti-Drift Check
604 Return Oil
The boom section is a three-position, seven-way spool valve. It contains a load check (2), one circuit relief valve (with
anticavitation) (232), one circuit relief valve (no anticavitation) (231), and an anti-drift check (239).
When boom spool (157) is shifted to activate the boom lower function, oil flows from the supply inlet passage (3), past the load
check (2), through boom spool, and out boom lower work port (1) to cylinder. Return oil (604) from cylinder flows into boom
raise work port (4) past boom spool, then out of control valve to the hydraulic oil filter. The boom spool has radial holes that
meter oil through valve to allow smooth starts and stops.
Anti-drift check (239) is provided to control oil leakage back into boom raise work port (4). With valve in neutral, anti-drift
check is spring loaded to the closed position. Pressure in work port (4) enters orifice (5) and is passed to the spring side of the
anti-drift check. Pressure in the work port passage (7) falls due to oil leakage past the boom spool to the return passage. The
higher work port pressure on the spring side of anti-drift check forces check securely into seat, forming a seal. The spring side
of anti-drift check may be vented to return passage through a vent passage (6). This vent passage is open or closed depending
on position of boom spool. With boom spool in neutral or boom raise position, vent passage (6) is closed to return passage.
When boom spool is moved to boom lower position, vent passage (6) is opened. Oil flows from work port (4), through orifice (5)
in anti-drift check, to return passage. Pressure drop across orifice (5) causes pressure on spring side of anti-drift check to drop
lower than pressure in work port (4). This pressure imbalance causes anti-drift check to open, allowing flow to boom spool.
When boom lower function pressure in circuit is less than return pressure, oil flows from return passage (9), past boom circuit
relief valve with anticavitation (232), and into boom lower circuit.
Backhoe Control Valve Boom Section (boom raise position) (pilot control option shown)
LEGEND:
1 Pilot Cap with Centering Spring
2 Boom Lower Work Port
3 Load Check
5 Boom Raise Work Port
6 Orifice
7 Pilot Cap
8 Vent Passage
9 Return Passage
10 Supply From Backhoe Swing Section
12 Return To Tank
225 Boom Section
231 Boom Circuit Relief (no Anticavitation)
232 Boom Circuit Relief (with Anticavitation)
239 Anti-Drift Check
604 Return Oil
609 Pilot Oil
The boom section is a three-position, seven-way spool valve. It contains a load check (3), two boom circuit relief valves (231
and 232), and an anti-drift check (239).
When pilot controller sends pilot oil (609), the backhoe boom spool (157) is moved and activates boom raise function. Oil flows
from supply inlet passage (4), past load check (3), through backhoe boom spool, and out boom raise work port (5) to backhoe
boom cylinder (162). Return oil (604) from cylinder flows into boom lower work port (2), past the backhoe boom spool, into
return passage, then out from control valve to hydraulic oil filter. The backhoe boom spool has notches that meter oil through
the valve to allow smooth starts and stops.
An anti-drift check valve (239) is provided to significantly reduce oil leakage back from boom raise work port (5). With valve in
neutral, the anti-drift check (239) is spring loaded to closed position. Pressure in boom raise work port (5) enters orifice (6) and
is passed to spring side of anti-drift check. The work port pressure on spring side of anti-drift check forces the anti-drift check
securely into the seat, forming a seal.
The spring side of anti-drift check may be vented to return passage through vent passage (8). Vent passage is open or closed
depending on position of backhoe boom spool. With boom spool in neutral or boom raise position, the vent passage is blocked.
When backhoe boom spool is moved to boom lower position, vent passage is opened to return passage. Oil flows from boom
raise work port (5) through orifice (6) in anti-drift check (239), through vent passage (8), to return passage. Pressure drop
across orifice (6) causes pressure on spring side of anti-drift check to drop lower than pressure in boom raise work port (5). This
pressure imbalance causes anti-drift check (239) to open, allowing flow to backhoe boom spool.
Bucket Section
Backhoe Control Valve Bucket Section (bucket curl position)

LEGEND:
1 Bucket Curl Work Port
2 Load Check
4 Bucket Dump Work Port
5 Supply From Backhoe Boom Section
6 Cap
7 With Selective Flow Option
9 Return To Tank
158 Backhoe Bucket Spool
163 Backhoe Bucket Cylinder
226 Bucket Section
234 Bucket Circuit Relief (no anticavitation)
604 Return Oil
The bucket section is a three-position, six-way spool valve containing a load check (2) and a bucket circuit relief (234). When
optional auxiliary selective flow section is installed in backhoe control valve (145), a second relief valve without anticavitation
is also installed. This second relief valve is installed in place of cap (6) in rod end side of the bucket section (226) of the
backhoe control valve (145).
When backhoe bucket spool (158) is moved to activate bucket curl function, oil flows from supply inlet passage (3), past load
check (2), backhoe bucket spool (158), and out bucket curl work port (1) to the backhoe bucket cylinder (163). Return oil from
backhoe bucket cylinder flows into bucket dump work port (4), past backhoe bucket spool, into return passage, then out of
backhoe control valve to the hydraulic oil filter. Backhoe bucket spool has notches that meter the oil through the valve to allow
smooth starts and stops.
Crowd Section
Backhoe Control Valve Crowd Section (crowd out position)

LEGEND:
1 Crowd Out Work Port
2 Load Check

4 Crowd In Work Port
6 Return Passage
7 Supply From Backhoe Bucket Section
9 Return To Tank
159 Backhoe Crowd Spool
164 Backhoe Crowd Cylinder
227 Crowd Section
236 Crowd Circuit Relief Valve (no anticavitation) (2 used)
604 Return Oil
The crowd section is a three-position, six-way spool valve. It contains a load check (2) and two crowd circuit relief valves (236).
When backhoe crowd spool (159) is shifted to activate crowd out function, oil flows from supply inlet passage (3), past load
check (2), through backhoe crowd spool, and out crowd out work port (1) to backhoe crowd cylinder (164). Return oil (604)
from backhoe crowd cylinder flows into crowd in work port (4), past backhoe crowd spool, into return passage (6), then out of
backhoe control valve (145) to hydraulic oil filter. Backhoe crowd spool has grooves that meter oil through the valve to allow
smooth starts and stops.
When machine is equipped with a four-function valve, crowd section has a power beyond port located on crowd main side of
valve. Port is similar to port on backhoe control valve auxiliary section illustrated in this group.
Auxiliary Sections—Extendable Dipperstick, Attachments—If Equipped
Backhoe Control Valve Auxiliary Section (neutral position with upstream function)
LEGEND:
1 Shut-Off Plug
2 Extend Work Port
3 Load Check
5 Retract Work Port
6 Shut-Off Plug
7 Return Passage
8 Supply From Backhoe Crowd Section
9 To Loader And Stabilizer Control Valve Section
10 Return To Tank
11 Not Used For Extendable Dipperstick Section
160 Backhoe Extendable Dipperstick Spool
165 Backhoe Auxiliary Cylinder (extendable dipperstick)
228 Extendable Dipperstick Auxiliary Section (extendable dipperstick; if equipped)
604 Return Oil

606 Trapped Oil
→NOTE:
This auxiliary section is used for both regular auxiliary and extendable dipperstick sections. The circuit
relief valves are not used for extendable dipperstick section (11) equipped machines.
The auxiliary and extendable dipperstick section is a three-position, six-way spool valve. It contains a load check (3) and two
shut-off plugs (1 and 6).
When backhoe extendable dipperstick spool (160) is moved to activate a function, oil flows from supply inlet passage (4), past
load check (3) and backhoe extendable dipperstick spool, then out to extend work port (2) to backhoe auxiliary cylinder
(extendable dipperstick) (165). Return oil (604) from backhoe auxiliary cylinder (165) flows into retract work port (5), past
backhoe extendable dipperstick spool, then into return passage (7). Oil in return passage goes to main hydraulic filter and
reservoir.
This section has a power beyond port on the valve. When spool is in neutral position, oil is routed through this port to supply
high-pressure oil to loader and stabilizer control valve.
Auxiliary sections and extendable dipperstick sections are the same except extendable dipperstick section does not utilize
circuit relief valves.
Pilot Control Valve Operation—If Equipped
Pilot Control Valve Operation

LEGEND:
1 Wobble Plate
2 Plunger (4 used)
3 Spring Guide (4 used)
4 Return Spring (4 used)
5 Metering Spring (4 used)

6 Metering Spool Orifice (4 used)
7 Internal Pressure Port
8 Spool (4 used)
9 Tank Port
10 Work Port
11 Pressure Port
12 Seal Plunger
13 Bearing Plunger
14 One-Way Orifice (2 used) (boom down and crowd out only)
15 Pilot Control Valve Plunger Assembly (4 used)
135 Pilot Control (left)
136 Pilot Control (right)
604 Return Oil
609 Pilot Oil
Two pilot control valve assemblies are used to control backhoe functions. Each control valve contains four plunger assemblies
(15), one for each direction of each function.
All four pilot control assemblies operate the same with exception of boom lower and crowd out function work ports. Each
contains a one-way orifice (14), which allows for free flow from work port out to main control valve but restricts flow coming
back. This reduces abrupt stops of high inertia functions by slowing them down in boom lower and crowd out functions only.
→NOTE:
Plunger, bearing and O-ring, spring guide, return spring, metering spring, metering spool and integral
washers are serviced as an assembly.
Neutral Operation
In neutral, with no functions activated, return spring (4) holds spool (8) closed. This blocks pilot oil (609) from entering work
ports (10) allowing oil to return to tank.
Metering Operation
During operation, pilot oil from pilot enable and pattern select valve enters pilot control valve at pressure port (11). Wobble
plate (1) depresses plunger (2) contacting spring guide (3). The spring guide compresses both return spring and metering
(pressure control) spring (5). The compressed springs move metering spool down to a metering position allowing oil to flow out
the connected work port. As work port pressure builds to meet spring force, spool moves between neutral and metered position
maintaining commanded pressure. The force it takes to compress the metering spring is directly proportional to the amount of
pressure in the work port acting on the spool.
Pilot Enable and Pattern Select Valve Operation—If Equipped
Pilot Enable and Pattern Select Valve Schematic

LEGEND:
1 From Right Pilot Control (port 3)
2 From Left Pilot Control (port 1)
3 From Right Pilot Control (port 2)
4 From Left Pilot Control (port 3)
5 To Boom Valve Section (raise boom)
6 To Crowd Valve Section (crowd in)
7 To Boom Valve Section (lower boom)
8 To Crowd Valve Section (crowd out)
137 Pilot Enable and Pattern Select (PEPS) Manifold
138 Pilot Control Pressure Reducing Valve
140 Pilot Control Accumulator
141 Pilot Control Pressure Test Port
604 Return Oil
609 Pilot Oil
700 To Loader Auxiliary Manifold (if equipped)
The pilot enable and pattern select (PEPS) manifold receives system pressure from the inlet section of the backhoe control
valve. System pressure oil flows through the adjustable pressure reducing valve and check valve allowing regulated pressure
oil to charge pilot control accumulator. The pressure reducing valve ensures that pressure in the pilot control system and
accumulator is within specification. See Hydraulic System Schematic . (Group 9025-15.)
→NOTE:
Pilot control accumulator is not serviceable. Replace accumulator if necessary.
When system pressure is below pilot control regulated pressure specification, the pressure reducing valve allows unrestricted
flow to pass through the PEPS manifold. When system pressure increases above pilot control regulated pressure specification,
the pressure reducing valve cartridge shifts restricting pressure to pilot controls and bleeding excess pressure to tank.
With pilot enable solenoid de-energized, spring bias holds pilot enable spool left, venting oil in pilot controls to tank. With pilot
enable solenoid energized, spool shifts right, connecting regulated pilot pressure to pilot controls, see Hydraulic System
Schematic . (Group 9025-15.)
The pattern select function of PEPS valve is used to switch control of backhoe boom and crowd functions for operator
preference.
The PEPS manifold contains two solenoids. Both solenoid valves are two-position, four-way valves. These valves are controlled
by the two-position pattern select switch, see Hydraulic System Schematic . (Group 9025-15.)
With pattern select switch in backhoe position, both solenoid valves are de-energized. The valve directs oil to control boom
functions with the left pilot control and crowd functions with the right pilot control.
With pattern select switch in excavator position, both solenoid valves are energized. The valve directs oil to control boom
functions with the right pilot control and crowd functions with the left pilot control.
Loader and Stabilizer Control Valve Operation
5-Function Loader and Stabilizer Control Valve (neutral, electrohydraulic auxiliary shown)
LEGEND:
1 Lift Check Valve (3 used)
2 Neutral Flow Passage
3 Power Passage (2 used)
4 Supply Inlet Port
190 Loader and Stabilizer Control Valve

191 Left Stabilizer Spool
192 Right Stabilizer Spool
193 Loader Boom Spool
194 Loader Bucket Spool
195 Loader Auxiliary Spool (if equipped)
604 Return Oil
606 Trapped Oil
609 Pilot Oil
LEGEND:
1 Lift Check Valve (3 used)
4 Supply Inlet Port
5 Return Outlet Port
6 Plug Fitting (relief port)
7 Power Beyond Port (not used)
5-Function Loader and Stabilizer Control Valve (EH

auxiliary shown)
Loader and stabilizer control valve is an open center, mono-block, spool valve. All function spools are contained within one
main housing.
High pressure oil enters valve at supply inlet port (4). When no functions are activated (neutral) supply oil flows uninterrupted
through control valve to hydraulic reservoir via neutral flow passage (2). Two power passages (3) branch off parallel to neutral
flow passage to provide hydraulic pressure to stabilizer and loader functions. Return oil exits at return outlet (5). Control valve
does not contain a system relief valve. A system relief valve located in backhoe control valve inlet section regulates both
backhoe and loader and stabilizer control valve oil pressure.
Stabilizers only or loader functions only can operate at one time. Stabilizer function takes priority over loader functions. If one
or both stabilizer spools are shifted, oil is blocked to downstream loader functions.
All loader functions can operate simultaneously. When one spool moves only neutral flow passage is blocked from return,
supply oil is still routed to downstream loader spools through the power passage. This passage is dead-ended at last valve
section.
For more information on each spool function operation see the following corresponding sections.
Stabilizer Section
Left Stabilizer Section (stabilizer lowered/lifting machine position)

LEGEND:
2 Nuetral Flow Passage
3 Power Passage
4 Work Port (lower stabilizer)
5 Work Port (raise stabilizer)
6 Return Passage
7 Lockout Piston
8 Centering Spring
9 Poppet (thermal relief)
201 Stabilizer Cylinder (2 used)
249 Lockout Valve
250 Lockout Valve (with thermal relief)
LEGEND:
4 Work Port (lower stabilizer)
5 Work Port (raise stabilizer)
249 Lockout Valve
250 Lockout Valve (with thermal relief)
Stabilizer Sections
There are two stabilizer spools (191, 192), one for each stabilizer cylinder. Each stabilizer section is a three-position, three-way,
spool valve. Valve spool is actuated by a manual lever and is returned to neutral by centering spring (8) in end cap.
In neutral position:
Neutral flow passages (2) are open to return.

Power passages (3) are blocked from work ports (4, 5).
Oil in work ports is trapped and closed off from return.
In stabilizer lower position:
Spool blocks neutral flow passage (2) from returning to tank (middle passage is open to pressure, outside neutral flow
passages are open to return) but continues around to power passage (3).
Spool opens high pressure oil from power passage (3) to lower work port (4) out to cylinder head end.
Spool opens stabilizer raise work port (5) passage to return passage (6). Return oil from cylinder rod end flows to
hydraulic reservoir.
Stabilizer cylinders need to hold oil pressure for long periods of time without any leakage through control valve. When stabilizer
spool is in neutral, lockout valves (249, 250) block cylinder oil from escaping through spools. When spool is shifted to stabilizer
lower position, pressure oil pushes lockout valve (249) open, allowing flow to the work port. Oil returning from raise work port
(5) is trapped by lockout valve (250). Oil pressure builds in lower work port (4), forcing lockout piston (7) against lockout valve
(250). When enough pressure has built, lockout piston opens lockout valve (250) allowing cylinder rod end oil open to return.
Thermal relief lockout valves (250) exist in the cylinder rod end circuits to protect cylinder circuit from high pressures caused
by thermal expansion. A 1° increase in temperature can cause a pressure increase of 345—414 kPa (3.45—4.14 bar) (50—60
psi). When stabilizers are in use lockout valves trap oil in cylinder circuits. Relief function of lockout valves (250) detect any
excess pressure from oil thermal expansion. When circuit oil pressure on backside of lockout valve (250) increases, poppet (9)
is unseated, allowing oil to pass out of circuit through orifice in lockout valve.
Boom Section
Boom Section (boom raise position)

LEGEND:
1 Lift Check Valve
2 Neutral Flow Passage
3 Power Passage
4 Work Port (raise, right cylinder)
5 Work Port (lower, right cylinder)

6 Return Passage
7 Work Port (raise, left cylinder)
8 Work Port (lower, left cylinder)
9 Spool Centering Spring
202 Loader Boom Cylinder (2 used)
251 Relief Valve (no anticavitation)
252 Anticavitation Check Valve
604 Return Oil
LEGEND:
1 Lift Check Valve
4 Work Port (raise, right cylinder)
5 Work Port (lower, right cylinder)
7 Work Port (raise, left cylinder)
8 Work Port (lower, left cylinder)
252 Anticavitation Check Valve
Boom Section (front)
Boom Section (back)
The boom section is a four-position, three-way, spool valve. Notches in spool help meter oil to allow smooth starts and stops.
Valve spool is actuated by a manual lever and is returned to neutral by centering spring (9) in end cap.

Power passage (3) is blocked from work ports (4, 5, 7, 8).
In boom raise position:
Spool blocks neutral flow passage (2) from returning to tank but continues down to beginning of power passage (3)
(middle passage is open to pressure, outside neutral flow passages are open to return).
Spool opens high pressure oil from power passage (3) to raise work ports (4, 7) out to cylinder head end.
Spool opens boom lower work ports (5, 8) to return passage (6). Return oil from cylinder rod end flows to hydraulic
reservoir.
A relief valve (251) opens supply oil to return when a specific pressure is reached, protecting circuit from high pressures.
Supply pressure oil must flow through lift check valve (1) to reach work ports. Lift check will not open until oil pressure in power
passage exceeds pressure in work port, preventing back flow from work ports from escaping out neutral flow passage. This
prevents a cylinder with load from dropping a short distance before enough pressure has built in power passage to lift load.
When spool is in boom lower position supply oil is routed to work ports (5, 8). Gravity acting on a loaded bucket may force
boom to lower faster than hydraulic pump can supply pressure oil to work ports (5, 8), causing cavitation. An anticavitation
check valve (252) is provided in boom lower circuit to prevent this. When boom lower circuit supply pressure is less than
pressure in return passage (6), check valve opens allowing oil from return passage to flow to supply circuit work ports (5, 8),
making up for any needed supply oil.
When spool is in float (detent) position, all work ports are open to return passages, allowing oil to flow freely in and out of
cylinder head and rod ends. Neutral flow passage is open to return.
Bucket Section
Bucket Section (bucket roll back position)

LEGEND:
1 Lift Check Valve
3 Power Passage
4 Work Port (roll back)
5 Work Port (dump)
6 Return Passage
7 Self Level Lever

8 Return-to-Dig Electromagnet
9 Metal Plate
203 Loader Bucket Cylinder
253 Relief Valve (with anticavitation)
604 Return Oil
LEGEND:
1 Lift Check Valve
4 Work Port (roll back)
5 Work Port (dump)
253 Relief Valve (with anticavitation)
Bucket Section (front)
Bucket Section (back)
The bucket section is a three-position, three-way, spool valve. Notches in spool help meter oil to allow smooth starts and stops.
Valve spool is actuated by a manual lever and is returned to neutral by centering spring (10) in end cap.

Power passage (3) is blocked from work ports (4, 5).
In bucket roll back position:
passages are open to return).
Spool opens high pressure oil from power passage (3) to roll back work port (4) flowing to cylinder head end.
Spool opens dump work port (5) to return passage (6). Return oil from cylinder rod end flows to hydraulic reservoir.
Relief valve (251) opens supply oil to return passage when a specific pressure is reached, protecting circuit from high
pressures.
Supply pressure oil must flow through lift check valve (1) to reach work ports (4, 5). Lift check will not open until oil pressure in
power passage exceeds pressure in work port, preventing back flow from work ports from escaping out neutral flow passage.
This prevents a cylinder with load from dropping a short distance before enough pressure has built in power passage to lift
load.
When bucket dump function is activated supply oil is routed to work port (5). Gravity acting on a loaded bucket may force
bucket to dump faster than hydraulic pump can supply pressure oil to work port (5), causing cavitation. A relief valve with
anticavitation (253) is provided in dump circuit to prevent this. When dump circuit supply pressure is less than pressure in
return passage (6), relief valve poppet opens allowing oil from return passage to flow to supply circuit work port (5), making up
for any needed supply oil.
Bucket is equipped with a self level feature. Lever (7) is connected to mechanical linkage from loader boom. When loader boom
reaches a specified position, mechanical linkage pulls bucket spool up (dump position) leveling bucket out with respect to
boom position. For more information on self level see Loader Bucket Self Level Operation. (Group 9025-05.)
Bucket is equipped with a return-to-dig feature. Return-to-dig solenoid (Y12) contains an electromagnet (8). When power is
supplied to solenoid it creates a magnetic field. When loader control lever is moved to bucket roll back position a metal plate
(9) fastened to end of bucket spool contacts magnet. Bucket spool is magnetically held in bucket roll back position until a
specific bucket position is reached, mechanical linkage connected to bucket then opens a switch on loader boom, opening
solenoid power circuit. Without power magnet is de-energized and bucket spool is free to return to neutral via spool centering
spring. For more information on return-to-dig see Loader Bucket Return-to-Dig Operation. (Group 9025-05.)
Auxiliary Section—If Equipped
Auxiliary Section (electrohydraulic section shown)

LEGEND:
1 Lift Check Valve
3 Power Passage
4 Work Port
5 Work Port
6 Return Passage

195 Loader Auxiliary Spool
254 Relief Valve (with anticavitation) (2 used)
604 Return Oil
609 Pilot Oil
LEGEND:
1 Lift Check Valve
4 Work Port
5 Work Port
195 Loader Auxiliary Spool
254 Relief Valve (with anticavitation) (2 used)
Auxiliary Section (EH shown, front)
Auxiliary Section (EH shown, back)
The loader and stabilizer control valve is a combined single mono-block design. If auxiliary is desired, an entire new loader and
stabilizer control valve must be installed.
The loader auxiliary section may be manual (two lever controls) or electrohydraulic (single lever loader control [SLLC]). Loader
auxiliary is used to control multi-purpose buckets or other front-mounted hydraulic attachments. The section is comprised of a
three-position, three-way, spool valve. Notches in spool help meter oil to allow smooth starts and stops. Valve spool is returned
to neutral by centering spring (7) in end cap. Electrohydraulic and manual auxiliary sections function the same except spool is
shifted either by pilot oil from loader auxiliary manifold (SLLC) or mechanically by a second loader lever and linkage
respectively.

Power passage (3) is blocked from work ports (4, 5).
When auxiliary function is commanded:
passages are open to return).
Spool opens high pressure oil from power passage (3) to work port (4).
Spool opens work port (5) to return passage (6).
If supply circuit pressure reaches a specific pressure, relief valve (254) opens supply oil to return passage, protecting
circuit from high pressures.
Supply pressure oil must flow through lift check valve (1) to reach work ports (4, 5). Lift check will not open until oil pressure in
power passage exceeds pressure in work port, preventing back flow from work ports from escaping out neutral flow passage.
This prevents a cylinder with load from retracting a short distance before enough pressure has built in power passage to
extend cylinder.
Gravity acting on a loaded cylinder may force cylinder to extend or retract faster than hydraulic pump can supply pressure oil
to work port, causing cavitation. A relief valve with anticavitation (254) is provided in each circuit to prevent this. When circuit
supply pressure is less than pressure in return passage (6), relief valve poppet opens allowing oil from return passage to flow
to supply circuit work port, making up for any needed supply oil.
Sideshift Lock Solenoid Valve—(S.N. —232969)
Sideshift Lock Solenoid Valve

LEGEND:
1 Inlet
2 Return
3 Relief Valve
4 Outlet
5 Check Valve
169 Sideshift Lock Solenoid Valve
604 Return Oil
When sideshift lock solenoid (Y34) is not energized, spring pressure pushes the valve spool down so oil flows to sideshift
locking pistons. The check valve (5) in the inlet port traps oil to maintain pressure on locking pistons.
When the solenoid is energized, the valve spool is pulled up against spring pressure, blocking inlet oil and releasing pressure
on the sideshift pistons to the reservoir.
The relief valve (3) is a direct acting relief valve. When pressure increases above the pressure setting, pressure overcomes
spring force, and seat is pushed away from the poppet. Oil flows through the seat to the reservoir.
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
Sideshift and Boom Lock (SBL) Solenoid Valve Operation—(S.N.

235590— )
SBL Solenoid Valve Schematic (sideshift lock shown engaged)

LEGEND:
1 Inlet Pressure Oil (from backhoe control valve)
2 Return Oil (to reservoir)
3 To Boom Lock Cylinders
4 To Sideshift Locking Pistons
5 Check Valve (spring biased)
6 Thermal Relief Valve
185 SBL Solenoid Valve
604 Return Oil
Sideshift Lock Solenoid Valve
The sideshift lock solenoid valve (Y34) is a 2-way, normally closed, proportional, poppet-type, load holding cartridge valve. Inlet
pressure oil (1) flows through an orifice, overcomes spring force of check valve (5), and flows to sideshift lock solenoid (Y34)
and sideshift locking pistons. A thermal relief valve (6) protects the sideshift boom lock circuit.
When sideshift lock solenoid is not energized, it acts as a check valve preventing inlet pressure oil from returning to reservoir
while allowing return oil to flow into the sideshift locking piston pressure circuit. This and check valve (5) traps inlet pressure oil
to maintain pressure on locking pistons.
When sideshift lock solenoid is energized inlet pressure oil after check valve (5) is open to return, releasing pressure on
sideshift locking pistons. Any flow from return into sideshift locking piston circuit is severely restricted.
Boom Lock Solenoid Valve
The boom lock solenoid valve (Y35) is a 3-way, spool-type, directional cartridge valve. Inlet pressure oil (1) flows through an
orifice to boom lock solenoid valve. When solenoid valve is energized, circuit is closed to return and inlet pressure oil flows to
boom lock cylinders.
When solenoid valve is not energized, inlet pressure oil is blocked and boom lock circuit is open to return, releasing pressure on
boom lock cylinders.

Hydraulic System Schematic
Hydraulic System Schematic, Manual Control (S.N. —232969) (neutral position)
LEGEND:
1 Relief Valve (if equipped with auxiliary selective flow control option)
70 Transmission
110 Hydraulic Oil Reservoir
111 Breather
112 Fill Screen
113 Hydraulic Pump
124 Steering Valve
128 Power Boost Brake Valve
131 Service Brake Clutch (2 used)
152 Priority Spool
160 Backhoe Extendable Dipperstick (if equipped)
165 Backhoe Auxiliary Cylinder (extendable dipperstick) (if equipped)
167 Boom Lock Solenoid Valve
168 Boom Lock Cylinder (2 used)
170 Sideshift Lock Piston (4 used)
204 Ride Control Valve (if equipped)
205 Ride Control Accumulator (if equipped)
604 Return Oil
606 Trapped Oil
614 Load Sense Oil
708 To Transmission Lube
Hydraulic System Schematic, Manual Control (S.N. 235590— ) (neutral position)
LEGEND:
1 Relief Valve (if equipped with auxiliary selective flow control)
111 Breather
112 Fill Screen
113 Hydraulic Pump
124 Steering Valve
152 Priority Spool
165 Backhoe Auxiliary Cylinder (extendable dipperstick; if equipped)
185 Sideshift and Boom Lock (SBL) Solenoid Valve
604 Return Oil
606 Trapped Oil
614 Load Sense Oil
Y50 Ride Control Solenoid 1 (if equipped)
Hydraulic System Schematic, Pilot Control (S.N. 235590— ) (neutral position) (1 of 2)
LEGEND:
111 Breather
112 Fill Screen
113 Hydraulic Pump
197 Loader Auxiliary Manifold (if equipped)
604 Return Oil
606 Trapped Oil
609 Pilot Oil
700 Steering Valve to Hydraulic Oil Reservoir
701 Hydraulic Pump to Backhoe Control Valve
702 PEPS Manifold to Loader Auxiliary Manifold
703 Backhoe Control Valve to Loader and Stabilizer Control Valve
704 SBL Solenoid Valve to Hydraulic Oil Reservoir
705 PEPS Manifold to Hydraulic Oil Reservoir
706 Backhoe Control Valve to Hydraulic Oil Filter
Hydraulic System Schematic, Pilot Control (S.N. 235590— ) (neutral position) (2 of 2)
LEGEND:
1 Relief Valve (if equipped with auxiliary selective flow control)
124 Steering Valve
138 Pilot Control Pressure Reducing Valve
152 Priority Spool
165 Backhoe Auxiliary Cylinder (extendable dipperstick; if equipped)
185 Sideshift and Boom Lock (SBL) Solenoid Valve
604 Return Oil
606 Trapped Oil
609 Pilot Oil
614 Load Sense Oil
700 Steering Valve to Hydraulic Oil Reservoir
701 Hydraulic Pump to Backhoe Control Valve
702 PEPS Manifold to Loader Auxiliary Manifold
703 Backhoe Control Valve to Loader and Stabilizer Control Valve
704 SBL Solenoid Valve to Hydraulic Oil Reservoir
705 PEPS Manifold to Hydraulic Oil Reservoir
706 Backhoe Control Valve to Hydraulic Oil Filter
Hydraulic System Component Location
Overall Hydraulic System Component Location
LEGEND:
1 Multipurpose Bucket Cylinder (if equipped) (2 used)
70 Transmission
73 Rear Axle
113 Hydraulic Pump
124 Steering Valve
167 Boom Lock Solenoid Valve (S.N. —232969)
169 Sideshift Lock Solenoid Valve (S.N. —232969)
185 Sideshift and Boom Lock (SBL) Solenoid Valve (S.N. 235590— )
Main Hydraulic Component Location

LEGEND:
113 Hydraulic Pump
Loader Hydraulic Component Location

LEGEND:
1 Multipurpose Bucket Cylinder (if equipped) (2 used)
197 Loader Auxiliary Manifold (if equipped; EH auxiliary control only)
198 Loader Auxiliary Accumulator (if equipped; EH auxiliary control only; backhoe manual controls only)
Backhoe Hydraulic Component Location

LEGEND:
70 Transmission
124 Steering Valve
161 Swing Cylinder (2 used)
167 Boom Lock Solenoid Valve (S.N. —232969)
169 Sideshift Lock Solenoid Valve (S.N. —232969)
185 Sideshift and Boom Lock (SBL) Solenoid Valve (S.N. 235590— )
Brakes and Steering Hydraulic Component Location

LEGEND:
70 Transmission
73 Rear Axle
75 Park Brake Valve-to-Park Brake Line
77 Service Brake Valve-to-Service Brake Line (2 used)
124 Steering Valve
Ride Control Hydraulic Component Location (if equipped)

LEGEND:
202 Loader Boom Cylinder
204 Ride Control Valve
205 Ride Control Accumulator
Pilot Controls Component Location

LEGEND:
1 Port 1; Swing Left
2 Port 2; Boom Lower (backhoe pattern)
2 Port 2; Crowd Out (excavator pattern)
3 Port 3; Swing Right
4 Port 4; Boom Raise (backhoe pattern)
4 Port 4; Crowd In (excavator pattern)
5 Port 1; Crowd In (backhoe pattern)

5 Port 1; Boom Raise (excavator pattern)
6 Port 2; Bucket Curl
7 Port 3; Crowd Out (backhoe pattern)
7 Port 3; Boom Lower (excavator pattern)
8 Port 4; Bucket Dump
P Pressure
T To Reservoir
Slow Steering Hydraulics

73
Slow Steering Hydraulics Diagnostic Procedure

( 1 ) Steering Valve Check
Action:
Check steering valve for leaks. See Steering System Leakage Test . (Group 9025-25.)
Is steering valve leaking internally?
Result:
YES:Repair steering valve. See Steering Valve Disassemble and Assemble . (Group 0960.)
NO:Go to Steering Cylinder Check.
( 2 ) Steering Cylinder Check
Action:
Check steering cylinder for leaks.

Is steering cylinder leaking externally?
Result:
YES:Repair steering cylinder. See Non-Powered Axle Steering Cylinder Disassemble and Assemble or see Mechanical Front
Wheel Drive (MFWD) Axle Steering Cylinder Disassemble and Assemble . (Group 0960.)
NO:Go to Steering Cylinder Leakage Check
( 3 ) Steering Cylinder Leakage Check
Action:
Perform steering cylinder leakage test. See Steering Cylinder Leakage Test . (Group 9025-25.)
Is steering cylinder leaking internally?
Result:
NO:Go to Priority Valve Check.
( 4 ) Priority Valve Check
Action:
Check machine steering with bucket loaded with material.

Does steering stall when bucket is loaded with material?
Result:
YES:Check if priority valve shifts correctly. If valve sticks, check for contamination between the spool and sleeve of priority
valve. See Backhoe Inlet Section Disassemble and Assemble . (Group 3360.) Repair or replace as necessary.
NO:Checks complete.
No Steering Hydraulics, Loader Hydraulics OK
73
See No Response When Steering Wheel Is Turned, Loader Hydraulics OK . (Group 9025-15.)
Hard Steering, Loader Hydraulics OK
73
Hard Steering, Loader Hydraulics OK Diagnostic Procedure

( 1 ) Steering Axle Load Check
Action:
Check steering when bucket is full of material.

Is loader bucket full of material, causing steering wheel not to be able to turn?
Result:
YES:Slightly move machine, steering wheel should be able to turn.

NO:Go to Load Sense Line Check.
( 2 ) Load Sense Line Check
Action:
Inspect load sense line for kinks or damage.

Is there a kinked load sense line between priority valve and steering valve?
Result:
YES:Repair kinked load sense line.

NO:Go to Steering Valve Load Sense Port Check.
( 3 ) Steering Valve Load Sense Port Check
Action:
Check steering valve for proper operation. See Steering Valve Operation . (Group 9025-05.)
Is the load sense orifice plugged at the steering valve load sense port?
Result:
YES:Clean plugged orifice.

NO:Go to Priority Valve Check.
Action:
Inspect priority valve spool in backhoe valve inlet section.

Is priority valve spool stuck?
Result:
YES:Repair or replace priority valve. See Backhoe Inlet Section Disassemble and Assemble . (Group 3360.)
NO:Checks complete.
Steering Valve Does Not Return to Neutral
73
Steering Valve Does Not Return to Neutral Diagnostic Procedure

( 1 ) Return Line to Hydraulic Reservoir Check
Action:
Inspect return line for kinks or damage.

Is return line to hydraulic reservoir kinked, causing high back pressure?
Result:
YES:Repair kinked line going to hydraulic reservoir.

NO:Go to Steering Column Check.
( 2 ) Steering Column Check
Action:
Check steering column for damage. See Tilt Steering Column Remove and Install . (Group 0960.)
Is there internal damage to steering column?
Result:
YES:Repair or replace as necessary. See Tilt Steering Wheel and Column Disassemble and Assemble . (Group 0960.)
NO:Go to Steering Valve Check.
Action:
Inspect steering valve. See Steering Valve Disassemble and Assemble . (Group 0960.)
Is there damage to steering valve sleeve or contamination?
Result:
YES:Repair or replace as necessary.

NO:Checks complete.
No Response When Steering Wheel is Turned, Loader Hydraulics OK

73
No Response When Steering Wheel is Turned, Loader Hydraulics OK

Diagnostic Procedure
Action:
Check to see if priority valve is functioning correctly.

Is priority valve functioning correctly?
Result:
YES:Go to Steering Valve Check.

NO:Repair or replace priority valve. See Backhoe Inlet Section Disassemble and Assemble . (Group 3360.)
Action:
Perform steering system leakage test. See Steering System Leakage Test . (Group 9025-25.)
Result:
YES:Repair steering valve. See Steering Valve Remove and Install—Tilt Steering and see Steering Valve Disassemble and
Action:
Perform steering cylinder leakage test. See Steering Cylinder Leakage Test . (Group 9025-25.)
Result:
NO:Go to Steering Valve Spline Check.
( 4 ) Steering Valve Spline Check
Action:
Check steering column splines for damage. See Steering Valve Remove and Install—Tilt Steering . (Group 0960.)
Is there damage to the steering splines?
Result:
YES:Repair or replace as necessary. See Tilt Steering Wheel and Column Disassemble and Assemble . (Group 0960.)
NO:Go to Steering Valve Pin Check.
( 5 ) Steering Valve Pin Check
Action:
Inspect steering valve for damage. See Steering Valve Disassemble and Assemble . (Group 0960.)
Is there a broken pin inside the steering valve?
Result:
YES:Repair or replace steering valve as necessary.

NO:Checks complete.
Machine Turns in Opposite Direction
73
Machine Turns in Opposite Direction Diagnostic Procedure

( 1 ) Steering Cylinder Connections Check
Action:
Check steering connection lines. See Non-Powered Axle Steering Cylinder Remove and Install or see Mechanical Front Wheel
Drive (MFWD) Axle Steering Cylinder Disassemble and Assemble . (Group 0960.)
Are the steering cylinder lines connected properly?
Result:
NO:Connect steering cylinder lines to opposite ports.
Excessive Vibration of the Steering Wheel
73
Excessive Vibration of the Steering Wheel Diagnostic Procedure

( 1 ) Tracking Angle and Alignment Check
Action:
Perform tracking angle check and adjustment to verify that machine is properly aligned. See Tracking Angle Check And Adjust .
(Group 9020-20.)
Is machine aligned properly?
Result:
YES:Go to Steering Valve Gerotor Check.

NO:Align machine to specifications.
( 2 ) Steering Valve Gerotor Check
Action:
Inspect steering valve gerotor. See Steering Valve Remove and Install—Tilt Steering . (Group 0960.)
Is steering valve gerotor misaligned?
Result:
YES:Put steering valve gerotor in alignment. See Steering Valve Disassemble and Assemble . (Group 0960.)
NO:Checks complete.
Machine Turns When Steering Valve is in Neutral
73
Machine Turns When Steering Valve is in Neutral Diagnostic Procedure

Action:
Perform steering system leakage test to determine if steering valve is leaking. See Steering System Leakage Test . (Group
9025-25.)
Result:
YES:Repair steering valve. See Steering Valve Remove and Install—Tilt Steering and see Steering Valve Disassemble and
NO:Checks complete.
Steering Wheel Kickback
73
Steering Wheel Kickback Diagnostic Procedure

( 1 ) Check Valve Check
Action:
Inspect check valve ball in steering valve. See Steering Valve Disassemble and Assemble . (Group 0960.)
Is check valve missing from inside the steering valve?
Result:

NO:Checks complete.
Excessive Steering Wheel Turns to Steer Machine
73
Excessive Steering Wheel Turns to Steer Machine Diagnostic Procedure

Action:
Perform steering cylinder leakage test to determine if steering cylinder is leaking. See Steering Cylinder Leakage Test . (Group
9025-25.)
Result:
YES:Repair steering cylinder. See Non-Powered Axle Steering Cylinder Remove and Install or see Mechanical Front Wheel Drive
(MFWD) Axle Steering Cylinder Disassemble and Assemble . (Group 0960.)
Action:
Perform steering system leakage test to determine if steering valve is leaking. See Steering System Leakage Test . (Group
9025-25.)
Is the steering valve leaking internally?
Result:
YES:Repair or replace steering valve. See Steering Valve Disassemble and Assemble . (Group 0960.)
NO:Checks complete.
Erratic (“Spongy”) Steering

73
Erratic (“Spongy”) Steering Diagnostic Procedure

( 1 ) Hydraulic Oil Level Check
Action:
Check hydraulic reservoir oil level. See Check Hydraulic Reservoir Oil Level . (Operator′s Manual.)
Is hydraulic oil level too low?
Result:
YES:Add hydraulic oil. See Hydraulic Oil . (Operator′s Manual.)

NO:Go to Correct Hydraulic Oil Check.
( 2 ) Correct Hydraulic Oil Check
Action:
Determine if correct oil is in machine. See Hydraulic Oil . (Operator′s Manual.)

Is correct hydraulic oil in machine?
Result:
YES:Go to Hydraulic Pump Suction Hose Check.

NO:Drain and refill. See Change Hydraulic Reservoir Oil . (Operator′s Manual.)
( 3 ) Hydraulic Pump Suction Hose Check
Action:
Inspect hydraulic pump suction hose. See Hydraulic System Component Location . (Group 9025-15.)
Is hydraulic pump suction hose loose or leaking?
Result:
YES:Tighten hydraulic pump suction hose.

Action:
Check steering cylinder operation. See Non-Powered Axle Steering Cylinder Remove and Install or see Mechanical Front Wheel
Drive (MFWD) Axle Steering Cylinder Disassemble and Assemble . (Group 0960.)
Is cylinder piston loose or damaged?
Result:

NO:Checks complete.
Steering Wheel "Locks" Up
73
Steering Wheel "Locks" Up Diagnostic Procedure

( 1 ) Priority Valve Spool Check
Action:
Inspect valve spool. See Backhoe Inlet Section Disassemble and Assemble . (Group 3360.)
Is there a stuck spool or contamination between spool and sleeve?
Result:

Action:
Inspect steering valve for damage. See Steering Valve Disassemble and Assemble . (Group 0960.)
Is there a broken pin inside the steering valve?
Result:

NO:Checks complete.
Poor Centering of Steering Wheel (Wheels Continue to Move After Steering Wheel is Stopped)
73
Poor Centering of Steering Wheel (Wheels Continue to Move After

Steering Wheel is Stopped) Diagnostic Procedure
( 1 ) Return Line to Hydraulic Reservoir Check
Action:
Inspect line to reservoir for damage or kinks.

Is return line to hydraulic reservoir kinked causing high back pressure?
Result:
YES:Repair kinked line going to hydraulic reservoir.

NO:Go to Steering Column Check.
( 2 ) Steering Column Check
Action:
Check steering column for proper alignment. See Steering Valve Remove and Install—Tilt Steering . (Group 0960.)
Is there misalignment or binding in steering column?
Result:
YES:Repair steering column. See Tilt Steering Wheel and Column Disassemble and Assemble . (Group 0960.)
Action:
Inspect steering valve for damage or contamination.

Is there damage to steering valve sleeve or contamination?
Result:
YES:Repair or replace as necessary. See Steering Valve Disassemble and Assemble . (Group 0960.)
NO:Checks complete.
Steering Wheel or Front Wheels Slowly Turn by Themselves When Using Backhoe or Loader
73
Steering Wheel or Front Wheels Slowly Turn by Themselves When Using

Backhoe or Loader Diagnostic Procedure
( 1 ) Steering System Check
Action:
Verify whether machine turns during backhoe or loader operation.

Does steering wheel or front wheel turn during backhoe or loader operation?
Result:
YES:This is normal operation of steering valve, but it should not exceed one half rotation of steering wheel with hydraulic oil
exceeding 93°C (200°F). If beyond limits replace steering valve. See Steering Valve Remove and Install—Tilt Steering . (Group
0960.)
NO:Checks complete.
Steering Wheel Turns Apply Rear Axle Service Brakes
73
Steering Wheel Turns Apply Rear Axle Service Brakes Diagnostic

Procedure
( 1 ) Return Line to Hydraulic Reservoir
Action:
Is the brake valve to hydraulic reservoir return line kinked causing hydraulic oil pressure from the steering valve to apply the
rear service brakes? Brake Valve Remove and Install . (Group 1060.)
Result:

NO:Check return line for internal blockage.
Steering Wheel Turns Freely With No Resistance or Action On Steered Wheels
73
Steering Wheel Turns Freely With No Resistance or Action On Steered

Wheels Diagnostic Procedure
Action:
Determine if steering valve has hydraulic oil following repair.

Is there hydraulic oil in steering valve following repair work?
Result:
YES:Go to Steering Wheel Check.

NO:Rotate steering wheel back and forth to fill steering valve with hydraulic oil.
( 2 ) Steering Wheel Check
Action:
Inspect steering wheel attachment nut. See Tilt Steering Wheel and Column Disassemble and Assemble . (Group 0960.)
Is steering wheel attachment nut properly torqued?
Result:
YES:Go to Steering Valve Spline Check.

NO:Torque steering wheel nut to specification.
( 3 ) Steering Valve Spline Check
Action:
Inspect steering valve spline for damage.

Is the lower steering valve spline disengaged or broken?
Result:
YES:Repair or replace steering valve as necessary. See Steering Valve Disassemble and Assemble . (Group 0960.)
NO:Checks complete.
Steering Wheel Turns With Slight Resistance and No Action On Steered Wheels
73
Steering Wheel Turns With Slight Resistance and No Action On Steered

Wheels Diagnostic Procedure
Action:
Inspect steering cylinder. See Non-Powered Axle Steering Cylinder Remove and Install or see Mechanical Front Wheel Drive
Is steering cylinder piston seal damaged?
Result:
YES:Repair steering cylinder as necessary.

NO:Checks complete.
Wander—Machine Will Not Stay in a Straight Line
73
Wander—Machine Will Not Stay in a Straight Line Diagnostic Procedure

Action:
Check hydraulic oil level. See Check Hydraulic Reservoir Oil Level . (Operator′s Manual.)
Result:
YES:Add or remove as necessary. See Hydraulic Oil . (Operator′s Manual.)

NO:Go to Tracking Angle Check.
( 2 ) Tracking Angle Check
Action:
Verify if machine’s tracking angle is within specifications. See Tracking Angle Check and Adjust . (Group 9020-20.)
Is tracking angle within specification?
Result:
YES:Go to Steering Cylinder Check.

NO:Adjust tracking angle.
Action:
Inspect steering cylinder. See Non-Powered Axle Steering Cylinder Remove and Install or see Mechanical Front Wheel Drive

Are there worn or loose parts in steering cylinder?
Result:

NO:Checks complete.
No Loader or Steering Hydraulics
73
No Loader or Steering Hydraulics Diagnostic Procedure

Action:
Check hydraulic oil level in reservoir. See Check Hydraulic Reservoir Oil Level . (Operator′s Manual.)
Result:
YES:Add oil as necessary. See Hydraulic Oil . (Operator′s Manual.)

NO:Go to Backhoe System Relief Valve Check.
( 2 ) Backhoe System Relief Valve Check
Action:
Test backhoe system relief valve. See System Relief Valve Pressure Test . (Group 9025-25.)
Is backhoe system relief valve pressure within specification?
Result:
YES:Go to Hydraulic Pump Check.

NO:Adjust backhoe system relief valve setting, as necessary.
( 3 ) Hydraulic Pump Check
Action:
Remove hydraulic filter and inspect. See Replace Hydraulic Oil Filter . (Operator′s Manual.)
Does the filter contain excessive amounts of metal material?
Result:
YES:Determine if hydraulic pump is operating to specification. See Hydraulic Pump Flow Test . (Group 9025-25.) If not, repair
or replace as necessary.
NO:Checks complete.
No Loader Hydraulics
73
No Loader Hydraulics Diagnostic Procedure

Action:
Result:
YES:Add oil as necessary. See Hydraulic Oil . (Operator′s Manual.)

NO:Go to Hydraulic Oil Lines and Valves Check.
( 2 ) Hydraulic Oil Lines and Valves Check
Action:
Inspect hydraulic lines for damage or kinks, also inspect valve for stuck spools.
Are there pinched lines or stuck valve spools?
Result:
YES:Repair or replace hydraulic lines. Repair stuck valve spools. See Loader and Stabilizer Control Valve Disassemble and
NO:Go to Hydraulic Pump Check.
( 3 ) Hydraulic Pump Check
Action:
Remove hydraulic filter and inspect. See Replace Hydraulic Oil Filter . (Operator′s Manual.)
Does the filter contain excessive amounts of metal material?
Result:
YES:Determine if hydraulic pump is operating to specification. See Hydraulic Pump Flow Test . (Group 9025-25.) If not, repair
or replace as necessary.
NO:Checks complete.
Low Loader Hydraulic Power
73
Low Loader Hydraulic Power Diagnostic Procedure

Action:
Test backhoe system relief valve pressure setting to determine if pressure setting is to specifications. See System Relief Valve
Pressure Test . (Group 9025-25.)
Is backhoe system relief valve pressure setting to specifications?
Result:
YES:Go to Loader Circuit Relief Valves Check.

NO:Adjust backhoe system relief valve pressure setting, as necessary.
( 2 ) Loader Circuit Relief Valves Check
Action:
Test loader circuit relief valves. See Circuit Relief Valve Test—With Remote Pump . (Group 9025-25.)
Are loader circuit relief valve pressures within specifications?
Result:
NO:Adjust loader circuit relief valve settings, as necessary.
Low Hydraulic Power

73
Low Hydraulic Power Diagnostic Procedure

( 1 ) Hydraulic Oil Level Low Check
Action:
Result:
YES:Add hydraulic oil to correct level. See Hydraulic Oil . (Operator′s Manual.)
Action:

Result:

Action:
Result:

Action:
Result:
YES:Go to Loader and Backhoe Circuit Relief Valves Check.

NO:Adjust backhoe system valve relief setting, as necessary.
( 5 ) Loader and Backhoe Circuit Relief Valves Check
Action:
Test loader and backhoe circuit relief valves. See Circuit Relief Valve Test—With Remote Pump . (Group 9025-25.)
Are circuit relief valve pressures within specifications?
Result:
YES:Go to Hydraulic Cylinder Check.
NO:Adjust circuit relief valve settings, as necessary.

( 6 ) Hydraulic Cylinder Check
Action:
Perform hydraulic cylinder leakage test. See Hydraulic Cylinder Leakage Test . (Group 9025-25.)
Is there a hydraulic cylinder leaking?
Result:
YES:Repair cylinder. See Backhoe Boom Cylinder Disassemble and Assemble . (Group 3360.)
NO:Go to System Leakage Check.
( 7 ) System Leakage Check
Action:
Perform the necessary test to determine if system is leaking. See Function Drift Test , see Steering System Leakage Test , see
Steering Cylinder Leakage Test and see Loader and Stabilizer Control Valve Lockout Leakage Test . (Group 9025-25.)
Is there a leak in the hydraulic system?
Result:
YES:Inspect hydraulic system and repair as necessary.

NO:Checks complete.
Engine Pulls Down Excessively During Loader Operation
73
Engine Pulls Down Excessively During Loader Operation Diagnostic

Procedure
Action:
Test backhoe system relief valve pressure setting. See System Relief Valve Pressure Test . (Group 9025-25.)
Is backhoe system relief valve pressure setting to specifications?
Result:
YES:Go to Engine Performance Check.

NO:Adjust backhoe system relief valve pressure setting, as necessary.
( 2 ) Engine Performance Check
Action:
→NOTE:
Low combined torque converter stall speed can indicate an engine performance issue.
Check combined torque converter stall speed. See Torque Converter Stall Speed Test . (Group 9020-25.)
Is combined torque converter stall speed within specification (not low)?
Result:
NO:Diagnose cause of low combined torque converter stall speed as directed by test.
Engine Pulls Down Excessively During Backhoe Operation
73
Engine Pulls Down Excessively During Backhoe Operation Diagnostic

Procedure
Action:
Result:

Action:
→NOTE:
Result:
Slow Hydraulic Functions

73
Slow Hydraulic Functions Diagnostic Procedure

Action:
Is hydraulic oil level low?
Result:
YES:Add as necessary. See Hydraulic Oil . (Operator′s Manual.)

NO:Go to Hydraulic Pump Suction Hose Check.
Action:
Is the hydraulic pump suction hose loose or leaking?
Result:

NO:Go to Loader and Backhoe Circuit Relief Valves Check.
Action:
Result:
YES:Go to Backhoe System Relief Valve Check.

Action:
Result:
YES:Go to Hydraulic Pump Flow Check.

( 5 ) Hydraulic Pump Flow Check
Action:
Perform hydraulic pump flow test to determine if pump flow is to specification. See Hydraulic Pump Flow Test . (Group
9025-25.)
Is the hydraulic pump flow low?
Result:
YES:Adjust, repair or replace as necessary.

NO:Go to Pilot Control Pressure Check.
( 6 ) Pilot Control Pressure Check
Action:
Test pilot control pressure. See Pilot Control Pressure Adjustment . (Group 9025-20.)
Does pilot pressure meet specifications?
Result:
YES:Go to Pilot Control Accumulator Check—If Equipped or Engine Performance Check.

NO:Adjust pilot pressure.
( 7 ) Pilot Control Accumulator Check—If Equipped
Action:
Test charge pressure of pilot accumulator. See Pilot Control Accumulator Charge Pressure Test . (Group 9025-25.)
Does accumulator charge pressure meet specifications?
Result:

NO:Replace accumulator.
Action:
→NOTE:
Result:
Backhoe Operates Slowly in One Function

73
Backhoe Operates Slowly in One Function Diagnostic Procedure

Action:
Check cycle time of problem function. See Operational Checkout Procedure . (Group 9005-10.)
Are function cycle times within specification?
Result:
YES:Normal machine operation. Checks complete.

NO:For manual backhoe controls, go to Control Lever Linkage Check. For pilot controllers, go to Pilot Controllers (if equipped)
Check .
( 2 ) Control Lever Linkage Check
Action:
Inspect manual control lever linkage. See Backhoe Control Lever-to-Valve Linkage Adjustment—Two Lever or see Backhoe
Control Lever-to-Valve Linkage Adjustment—Four Lever, If Equipped . (Group 9025-20.)
Is linkage out of adjustment?
Result:
YES:Adjust as necessary.
Action:
Inspect hydraulic oil lines for damage or kinks. Determine if valve spools are sticking.
Are there kinked lines or stuck valve spools?
Result:
YES:Repair or replace hydraulic lines. Repair stuck valve spools. See Backhoe Control Valve Disassemble and Assemble .
(Group 3360.)
NO:Go to Backhoe Circuit Relief Valves Check.
( 4 ) Backhoe Circuit Relief Valves Check
Action:
Test backhoe circuit relief valves. See Circuit Relief Valve Test—With Remote Pump . (Group 9025-25.)
Result:
YES:Go to Hydraulic Control Valve Seals Check.

( 5 ) Hydraulic Control Valve Seals Check
Action:
Inspect hydraulic control valve seals for damage.

Are hydraulic control valve seals leaking?
Result:
YES:Repair hydraulic control valve seals. See Backhoe Control Valve Spool Seals Remove and Install . (Group 3360.)
NO:Go to Hydraulic Cylinder Check.
Action:
Result:
YES:Repair cylinder. See appropriate cylinder disassemble and assemble.- See Backhoe Boom Cylinder Disassemble and
- See Backhoe Bucket Cylinder Disassemble and Assemble . (Group 3360.)
- See Backhoe Crowd Cylinder Disassemble and Assemble . (Group 3360.)
- See Backhoe Stabilizer Cylinder Disassemble and Assemble . (Group 3360.)
- See Backhoe Swing Cylinder Disassemble and Assemble . (Group 3360.)
- See Backhoe Extendable Dipperstick Cylinder Disassemble and Assemble . (Group 3360.)
NO:Checks complete.
( 7 ) Pilot Controllers (if equipped) Check
Action:
Inspect pilot controller for sticking valve spool. See Backhoe Pilot Control Valve Disassemble and Assemble . (Group 3315.)
Does pilot controller spool move correctly?
Result:
YES:Go to Pattern Select Valve (if equipped) Check.

NO:Repair or replace pilot controller.
( 8 ) Pattern Select Valve (if equipped) Check
Action:
Press pattern select valve switch on sealed switch module (SSM) and see if problem moves to another function.
Does problem move to another function?
Result:
YES:Repair or replace pattern select solenoid valve. See Pilot Enable and Pattern Select Valve Disassemble and Assemble .
(Group 3360.)
NO:Go to Backhoe Valve Pilot Cap (if equipped) Check.
( 9 ) Backhoe Valve Pilot Cap (if equipped) Check
Action:
Remove and inspect pilot caps of problem function. See Hydraulic System Component Location . (Group 9025-15.)
Do pilot caps move valve spool as required?
Result:
YES: Go to Hydraulic Oil Lines and Valves Check

NO:Repair or replace pilot cap.
Loader Operates Slowly in One Function

73
Loader Operates Slowly in One Function Diagnostic Procedure

Action:
Check cycle time of problem function. See Operational Checkout Procedure . (Group 9005-10.)
Are function cycle times within specification?
Result:

NO:Go to Control Lever Linkage Check.
Action:
Inspect manual control lever linkage. See Loader and Stabilizer Lever Adjustment . (Group 9025-20.)
Result:
Action:
Result:
NO:Go to Loader Circuit Relief Valves Check.
Action:
Result:

Action:

Result:
YES:Repair hydraulic control valve seals. See Loader and Stabilizer Control Valve Disassemble and Assemble . (Group 3160.)
Action:
Result:
YES:Repair cylinder. See Loader Boom Cylinder Disassemble and Assemble . (Group 3160.)
NO:Checks complete.
No Backhoe Power in One Function

73
No Backhoe Power in One Function Diagnostic Procedure

Action:
Inspect manual control lever linkage. See Backhoe Control Lever-to-Valve Linkage Adjustment—Two Lever or see Backhoe
Control Lever-to-Valve Linkage Adjustment—Four Lever, If Equipped . (Group 9025-20.)
For pilot controls, go to Pilot Controllers (if equipped) Check
Result:
NO:Go to Backhoe Circuit Relief Valves Check.
( 2 ) Backhoe Circuit Relief Valves Check
Action:
Test backhoe circuit relief valves. See Circuit Relief Valve Test—With Remote Pump . (Group 9025-25.)
Result:

Action:

Result:
See Backhoe Control Valve Spool Seals Remove and Install . (Group 3360.)
Action:
Result:
YES:Repair cylinder. See appropriate cylinder disassemble and assemble.- See Backhoe Boom Cylinder Disassemble and
- See Backhoe Bucket Cylinder Disassemble and Assemble . (Group 3360.)
- See Backhoe Crowd Cylinder Disassemble and Assemble . (Group 3360.)
- See Backhoe Stabilizer Cylinder Disassemble and Assemble . (Group 3360.)
- See Backhoe Swing Cylinder Disassemble and Assemble . (Group 3360.)
- See Backhoe Extendable Dipperstick Cylinder Disassemble and Assemble . (Group 3360.)
Action:
Result:
YES:Repair or replace hydraulic lines. Repair stuck valve spools. See Backhoe Control Valve Disassemble and Assemble .
(Group 3360.)
NO:Checks complete.
( 6 ) Pilot Controllers (if equipped) Check
Action:
Inspect pilot controller for sticking valve spool. See Backhoe Pilot Control Valve Disassemble and Assemble . (Group 3315.)
Does pilot controller spool move correctly?
Result:
YES:Go to Pattern Select Valve (if equipped) Check.

NO:Repair or replace pilot controller.
( 7 ) Pattern Select Valve (if equipped) Check
Action:
Press pattern select valve switch on sealed switch module (SSM) and see if problem moves to another function.
Does problem move to another function?
Result:
YES:Repair or replace pattern select solenoid valve. See Pilot Enable and Pattern Select Valve Disassemble and Assemble .
(Group 3360.)
NO:Go to Backhoe Valve Pilot Cap (if equipped) Check.
( 8 ) Backhoe Valve Pilot Cap (if equipped) Check
Action:
Remove and inspect pilot caps of problem function. See Hydraulic System Component Location . (Group 9025-15.)
Do pilot caps move valve spool as required?
Result:
YES: Go to Backhoe Circuit Relief Valves Check .

NO:Repair or replace pilot cap.
No Loader Power in One Function

73
No Loader Power in One Function Diagnostic Procedure

Action:
Inspect control lever linkage. See Loader and Stabilizer Lever Adjustment . (Group 9025-20.)
Result:
NO:Go to Loader Circuit Relief Valves Check.
Action:
Result:
YES:Go to Hydraulic Oil Lines and Valves Check.

Action:
Result:
NO:Go to Hydraulic Control Valve Seals Check.
Action:

Result:
Action:
Result:
YES:Repair cylinder. See Loader Boom Cylinder Disassemble and Assemble . (Group 3160.)
NO:Checks complete.
Slow Loader and Backhoe Hydraulics

73
Slow Loader and Backhoe Hydraulics Diagnostic Procedure

Action:
Result:
YES:Tighten suction hose.

Action:
Result:

Action:
Result:
YES:Go to Pilot Control Pressure Check.

( 4 ) Pilot Control Pressure Check
Action:
Test pilot control pressure. See Pilot Control Pressure Adjustment . (Group 9025-20.)
Does pilot pressure meet specifications?
Result:
YES:Go to Pilot Control Accumulator Check.

NO:Adjust pilot pressure.
( 5 ) Pilot Control Accumulator Check
Action:
Test charge pressure of pilot accumulator. See Pilot Control Accumulator Charge Pressure Test . (Group 9025-25.)
Does accumulator charge pressure meet specification?
Result:
YES:Go to Hydraulic Pump Flow Check.
NO:Replace accumulator.
( 6 ) Hydraulic Pump Flow Check
Action:
Test hydraulic pump flow. See Hydraulic Pump Flow Test . (Group 9025-25.)
Is hydraulic pump flow low?
Result:
YES:Adjust, repair or replace as necessary.

NO:Go to Engine Performance Check.
Action:
→NOTE:
Result:
Low Hydraulic Power (Low Hydraulic Pressure)

73
Low Hydraulic Power (Low Hydraulic Pressure) Diagnostic Procedure

Action:
Result:
YES:Add hydraulic oil to correct level. See Hydraulic Oil . (Operator′s Manual.)
Action:

Result:

Action:
Inspect hydraulic pump suction hose for leaks. See Hydraulic System Component Location . (Group 9025-15.)
Result:

Action:
Perform the necessary test to determine if system is leaking. See Function Drift Test , see Steering System Leakage Test , see
Steering Cylinder Leakage Test and see Loader and Stabilizer Control Valve Lockout Leakage Test . (Group 9025-25.)
Is there a leak in hydraulic system?
Result:
YES:Inspect hydraulic system and repair as necessary.

Action:
Test backhoe system relief valves. See System Relief Valve Pressure Test . (Group 9025-25.)
Result:
YES:Go to Hydraulic Cylinder Check.

Action:
Is hydraulic cylinder leaking?
Result:
YES:Repair cylinder. See Backhoe Boom Cylinder Disassemble and Assemble . (Group 3360.)
Action:
Result:
Hydraulic Function Makes "Chattering" Noise

73
Hydraulic Function Makes "Chattering" Noise Diagnostic Procedure

Action:
Result:

Action:

Result:

Action:
Result:

Action:
Result:

Action:
Result:
Functions Drift
73
Functions Drift Diagnostic Procedure

( 1 ) Machine Specification Check
Action:
Check to make sure function drift is within machine specification. See Function Drift Test . (Group 9025-25.)
Is function drift within specification?
Result:

NO:Go to Cylinder Leakage Check.
( 2 ) Cylinder Leakage Check
Action:
Perform cylinder leakage test to determine if leakage is in hydraulic cylinder or control valve. See Hydraulic Cylinder Leakage
Test . (Group 9025-25.)
Does cylinder leak excessively?
Result:
YES:Repair cylinder as necessary. See Backhoe Boom Cylinder Disassemble and Assemble . (Group 3360.)
NO:Go to Control Valve Seals Check.
( 3 ) Control Valve Seals Check
Action:
Inspect control valve seals for damage. See Loader and Stabilizer Control Valve Relief Valves Remove and Install . (Group
3160.) See Backhoe Control Valve Relief Valves Remove and Install . (Group 3360.)
Do seals have any visible damage?
Result:
YES:Replace seals. See Loader and Stabilizer Control Valve Relief Valves Remove and Install . (Group 3160.) See Backhoe
Control Valve Relief Valves Remove and Install . (Group 3360.)
NO:Go to Control Valve Spool Check.
( 4 ) Control Valve Spool Check
Action:
Inspect section spool and bore for scoring and scratches. See Loader and Stabilizer Control Valve Disassemble and Assemble .
(Group 3160.) See Backhoe Control Valve Disassemble and Assemble . (Group 3360.)
Is there any visible scoring or scratches on spool and bore?
Result:
YES:Repair as necessary. See Backhoe Control Valve Disassemble and Assemble . (Group 3360.)
NO:Return to Cylinder Leakage Check.
Control Valve Sticks or Works Hard

73
Control Valve Sticks or Works Hard Diagnostic Procedure

Action:
Inspect control lever linkage. See Loader and Stabilizer Lever Adjustment and see Backhoe Control Lever to Valve Linkage (Two
Lever) Adjustment . (Group 9025-20.)
Result:
NO:Go to Return Spring Rubbing Check.
( 2 ) Return Spring Rubbing Check
Action:
Inspect control valve spring for damage or rubbing. See Backhoe Control Valve Disassemble and Assemble . (Group 3360.) See
Loader and Stabilizer Control Valve Disassemble and Assemble . (Group 3160.)
Is return spring rubbing on spring cap, inside control valve?
Result:
YES:Repair or replace return spring as necessary.

NO:Go to Return Spring Broken Check.
( 3 ) Return Spring Broken Check
Action:
Inspect return spring for damage. See Backhoe Control Valve Disassemble and Assemble . (Group 3360.) See Loader and
Stabilizer Control Valve Disassemble and Assemble . (Group 3160.)
Is return spring broken inside control valve?
Result:
YES:Replace return spring.

NO:Go to Hydraulic Control Valve Contamination Check.
( 4 ) Hydraulic Control Valve Contamination Check
Action:
Check for contamination in control valve. See Loader and Stabilizer Control Valve Spool Disassemble and Assemble . (Group
3160.) See Backhoe Control Valve Disassemble and Assemble . (Group 3360.)
Is valve spool scored or bent?
Result:
YES:Repair or replace hydraulic control valve as necessary.

NO:Go to Scored Valve Bore or Bent Spool Check.
( 5 ) Scored Valve Bore or Bent Spool Check
Action:
Inspect valve spool for damage. See Backhoe Control Valve Disassemble and Assemble . (Group 3360.) See Loader and
Is valve bore scored or bent?
Result:

NO:Go to Spool Alignment Check.
( 6 ) Spool Alignment Check
Action:
Determine if spool is aligned correctly. See Backhoe Control Valve Disassemble and Assemble . (Group 3360.) See Loader and
Does valve spool have proper alignment inside control valve?
Result:
YES:Go to Spool Centering Spring Check.

NO:Repair or replace as necessary.
( 7 ) Spool Centering Spring Check
Action:
Determine if spool is aligned correctly. See Backhoe Control Valve Disassemble and Assemble . (Group 3360.) See Loader and
Is spool centering spring aligning spool inside control valve?
Result:
YES:Go to Spool Seals Check.

( 8 ) Spool Seals Check
Action:
Inspect spool seals for damage.

Are spool seals leaking or out of alignment?
Result:
YES:Inspect and repair seals. See Backhoe Control Valve Spool Seals Remove and Install . (Group 3360.) See Loader and
NO:Go to Backhoe Valve Twisted Check.
( 9 ) Backhoe Valve Twisted Check
Action:
Check backhoe valve mounting plate to see if it is twisted.

Is backhoe valve twisted?
Result:
YES:Loosen control valve tie bolts and torque to specification. See Backhoe Control Valve Disassemble and Assemble . (Group
3360.)
NO:Checks complete.
Hydraulic Oil Overheats

73
Hydraulic Oil Overheats Diagnostic Procedure

( 1 ) Excessive Load Check
Action:
Determine if machine is being operated under heavy load.

Are hydraulic functions continuously operated under heavy load?
Result:
YES:Reduce load on hydraulic functions.

NO:Go to Operator Holding Hydraulic System Over Relief Check.
( 2 ) Operator Holding Hydraulic System Over Relief Check
Action:
Determine if machine functions are being held over relief.

Is operator continuously holding hydraulic system over relief during machine operation?
Result:
YES:Return hydraulic control levers to neutral when not in use.

NO:Go to Hydraulic Oil Level Low Check.
Action:
Check hydraulic system oil level.

Is hydraulic oil level low?
Result:

NO:Go to Hydraulic Oil Viscosity Check.
( 4 ) Hydraulic Oil Viscosity Check
Action:
Determine if correct oil is being used. See Hydraulic Oil . (Operator′s Manual.)
Is correct oil viscosity being used?
Result:
YES:Go to Hydraulic Oil Cooler Plugged Check.

NO:Drain and refill hydraulic system. See Change Hydraulic Reservoir Oil . (Operator′s Manual.)
( 5 ) Hydraulic Oil Cooler Plugged Check
Action:
Perform hydraulic oil cooler restriction test. See Hydraulic Oil Cooler Restriction Test . (Group 9025-25.)
Is hydraulic oil cooler restricted?
Result:
YES:Repair or replace hydraulic oil cooler as necessary.
NO:Go to Hydraulic/Transmission Radiator Plugged Check.

( 6 ) Hydraulic/Transmission Radiator Plugged Check
Action:
Inspect hydraulic/transmission radiator for debris or obstructions.

Is hydraulic/transmission radiator obstructed?
Result:
YES:Clean hydraulic/transmission radiator.

NO:Go to Variable speed Fan Operation Check (if equipped).
( 7 ) Variable Speed Fan Operation Check (if equipped)
Action:
Determine if variable speed fan is operating correctly. Visually inspect or see Variable Speed Fan Test . (Group 9010-25.)
Is variable speed fan operating correctly?
Result:

Action:
Result:
YES:Go to Loader and Backhoe Circuit Relief Valves Check.

Action:
Result:
YES:Go to Priority Valve Check.

Action:
Test operation of priority valve.

Is priority valve functioning correctly?
Result:
YES:Go to Hydraulic System Leakage Check.

( 11 ) Hydraulic System Leakage Check
Action:
Check for system leakage in hydraulic cylinders, loader and stabilizer control valve, and backhoe control valve. See Function
Drift Test and see Hydraulic Cylinder Leakage Test . (Group 9025-25.)
Is there excessive leakage in hydraulic system?
Result:
YES:Repair system leakage.

NO:Checks complete.
Foaming Oil
73
Foaming Oil Diagnostic Procedure

Action:
Result:
YES:Add hydraulic oil as needed. See Hydraulic Oil . (Operator′s Manual.)

NO:Go to Hydraulic Oil Type Check.
( 2 ) Hydraulic Oil Type Check
Action:
Determine if correct oil is being used in machine. See Hydraulic Oil . (Operator′s Manual.)
Result:

Action:
Result:

NO:Checks complete.
Hydraulic Pump Leaking
73
Hydraulic Pump Leaking Diagnostic Procedure

( 1 ) Cap Screws Check
Action:
Check hydraulic pump mounting cap screws. See Hydraulic Pump Disassemble and Assemble . (Group 2160.)
Are cap screws holding pump together loose?
Result:
YES:Tighten cap screws to specifications. See Hydraulic Pump Remove and Install . (Group 2160.)
NO:Go to Shaft Seal Check.
( 2 ) Shaft Seal Check
Action:
Inspect shaft seal for damage. See Hydraulic Pump Disassemble and Assemble . (Group 2160.)
Is shaft seal worn?
Result:
YES:Replace seal.
NO:Go to Pump Seal Check.
( 3 ) Pump Seal Check
Action:
Inspect hydraulic pump seals and gaskets for damage. See Hydraulic Pump Disassemble and Assemble . (Group 2160.)
Is pump seal or backup gasket broken?
Result:
YES:Replace seal or gasket. See Hydraulic Pump Remove and Install . (Group 2160.)
NO:Checks complete.
Excessive Pump Noise

73
Excessive Pump Noise Diagnostic Procedure

Action:
Result:

NO:Go to Hydraulic Oil Lines Check.
( 2 ) Hydraulic Oil Lines Check
Action:
Inspect hydraulic lines to determine if they are contacting with machine.

Are hydraulic oil lines contacting with operator’s station?
Result:
YES:Check and secure hydraulic oil lines. See Operator′s Station Remove and Install . (Group 1800.)
NO:Go to Hydraulic Filter Assembly Check.
( 3 ) Hydraulic Filter Assembly Check
Action:
Inspect hydraulic filter assembly for proper operation. See Hydraulic Filter Assembly Remove and Install . (Group 2160.)
Is hydraulic filter bypass valve chattering?
Result:
YES:Inspect, clean, and repair hydraulic filter bypass valve.

NO:Go to Hydraulic Pump Hardware Check.
( 4 ) Hydraulic Pump Hardware Check
Action:
Check hydraulic pump hardware to determine if torqued to specification.

Is hydraulic pump attaching hardware loose?
Result:
YES:Tighten pump attaching hardware to specifications. See Hydraulic Pump Remove and Install . (Group 2160.)
NO:Go to Hydraulic Pump Drive Check.
( 5 ) Hydraulic Pump Drive Check
Action:
Check hydraulic pump drive for damage. See Hydraulic Pump Remove and Install . (Group 2160.)
Is hydraulic pump drive worn?
Result:
YES:Repair or replace as necessary. See Hydraulic Pump Disassemble and Assemble . (Group 2160.)
Section 9025 - HYDRAULIC SYSTEM Group 20: Adjustments

Action:
Perform function drift test to check for leakage within hydraulic circuits. See Function Drift Test . (Group 9025-25.)
Is there a leak in hydraulic circuits?
Result:

NO:Checks complete.
Backhoe Control Lever to Valve Linkage (Two Lever) Adjustment
Specifications
SPECIFICATIONS
240 mm
Knob Edge-to-Tape Distance
9.5 in.
260 mm
Knob Center to Knob Center Distance
10.25 in.
Backhoe Control Lever-to-Valve Linkage Check

LEGEND:
1 Knob Edge-to-Tape Distance
2 Knob Center-to-Knob Center Distance
Two Lever Configuration Shown
→NOTE:
Levers must be adjusted correctly to ensure clearance with seat and allow full lever travel.
[1] -
CAUTION:
Prevent possible injury from unexpected machine movement. NEVER rely on transmission control lever
(TCL) alone to keep machine from moving. Always set park brake to hold machine.
Engage park brake. Lower all equipment to ground. Turn engine OFF.
[2] - Release hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[3] - Move backhoe control levers to neutral.
[4] - Attach a piece of masking tape across rear surface of rear ROPS posts at height of backhoe lever knobs.
[5] - Measure knob edge-to-tape distance (1). Compare measurement to specification, if adjustment is needed, follow
procedure in Backhoe Control Lever-to-Valve Linkage Adjustment in this procedure.
Knob Edge to Tape Distance 240 mm
9.5 in.
[6] - Measure knob center to knob center distance (2). Compare measurement to specification, if adjustment is needed, follow
procedure in Backhoe Control Lever Adjustment in this procedure.
Knob Center to Knob Center Distance 260 mm
10.25 in.
[7] - Check levers for full travel and proper operation. Linkage rods should not contact each other at any lever position.
Backhoe Control Lever-to-Valve Linkage Adjustment

LEGEND:
1 Jam Nut (2 used per linkage rod)
2 Linkage Rod (1 used per control valve)
Two Lever Configuration Shown
[1] - Remove rear floor mat and backhoe lever console cover.
[2] - Move upper rear window, middle rear window, and lower rear window to maximum UP position. Install screw to hold lower
rear window in UP position.
[3] - Adjust knob edge-to-tape distance for each backhoe control lever, then adjust knob center to knob center distance.
For each linkage adjustment:
a. Loosen jam nuts (1).

b. Turn linkage rod (2) to adjust lever position.
c. Measure lever position. Repeat procedure as necessary to meet specifications.
Knob Edge to Tape Distance 240 mm
9.5 in.
Knob Center to Knob Center Distance 260 mm
10.25 in.
d. Tighten jam nuts.
[4] - Move rear windows to suit operator′s preference.
[5] - Install backhoe lever console cover and rear floor mat.
Auxiliary Selective Flow Control Valve Adjustment—If Equipped
LEGEND:
1 Auxiliary Selective Flow Control Valve
2 Adjustment Knob
3 Lock Nut
Auxiliary Selective Flow Control Valve Section
Adjustment Knob
[1] - Turn switched power off.
[2] - Turn selective flow control switch to OFF position. See Backhoe Auxiliary Hydraulic Selective Flow Operation—If Equipped .
[3] -
→NOTE:
The auxiliary selective flow control valve is equipped with six different flow settings. Each setting is
identified with a number on the adjustment knob that represents a value in gallons per minute (gpm).
Loosen lock nut (3).
[4] - Turn adjustment knob (2) until desired flow setting is observed.
34 L/min. (9 gpm)
49 L/min. (13 gpm)
61 L/min. (16 gpm)
68 L/min (18 gpm)
83 L/min. (22 gpm)
95 L/min. (25 gpm)
[5] - Tighten lock nut.
Pilot Control Pressure Adjustment

Specifications
SPECIFICATIONS
40°C
Hydraulic Oil Temperature (minimum)
104°F
3700—4100 kPa
Pilot Control Pressure 37.2—41.4 bar
540—600 psi
JT02156A Digital Pressure and Temperature Analyzer (or equivalent)
JDG1385 Snap-to-Connect (STC) ™ Hose and Line Fitting Tool
Use this procedure to check and adjust pilot control pressure. Access to valve is from under machine.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 9000-01.)
[2] - Discharge pilot enable and pattern select valve accumulator. See Pilot Enable and Pattern Select Valve Accumulator
Discharge Procedure . (Group 9025-20.)
[3] -
Pilot Enable and Pattern Select (PEPS) Manifold
Pressure Reducing Relieving Valve Adjustment Screw

LEGEND:
1 PEPS Manifold Supply Hose
2 Elbow Fitting
3 Adjustment Screw
139 Pressure Reducing Relieving Valve
Connect JT02156A Digital Pressure and Temperature Analyzer
Digital Pressure and Temperature Analyzer (or equivalent)
JT02156A
Used to measure hydraulic system pressure.
(or equivalent) to pilot control pressure test port (141). See JT02156A Digital Pressure and Temperature Analyzer Kit
Installation . (Group 9025-25.)
[4] - Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)
Hydraulic Oil Temperature (minimum) 40°C
104°F

[6] - Check pressure with pilot operated function held over relief. Compare pressure reading to specifications.
Pilot Control Pressure 3700—4100 kPa
37.2—41.4 bar
540—600 psi
[7] - Turn switched power OFF.
[9] - Disconnect PEPS manifold supply hose (1). See Service Recommendations For Snap-To-Connect (STC®) Fittings .
Snap-to-Connect (STC) ™ Hose and Line Fitting Tool
JDG1385
Disconnect Snap-to-Connect® Fittings.
[10] - Remove elbow fitting (2).
[11] - Turn adjustment screw (3) in to increase pressure or out to decrease pressure.
[12] - Install elbow fitting and connect PEPS manifold supply hose.
[13] - Repeat steps 4—12 until pressure is to specification.
Pilot Enable and Pattern Select Valve Accumulator Discharge Procedure

[1] - Lower backhoe to the ground or to a safe stored position and stop engine.
[2] -
CAUTION:
Prevent possible injury from unexpected backhoe boom or bucket movement when equipped with pilot
controls. Pilot enable and pattern select valve accumulator energy must be discharged when working on
hydraulic components.
Turn switched power to ON position; do not start engine.
[3] - Rotate operator′s seat to backhoe position.
[4] - Cycle pilot enable switch from OFF to ON position.
[5] - Cycle pilot functions a minimum of 10 times in each direction to relieve system pressure.
[6] - Turn key switch to OFF position.
Loader Bucket Self-Leveling Linkage and Return-To-Dig Switch

Adjustment
Specifications
SPECIFICATIONS
2 mm
Pickup Pin Adjustment Distance
0.08 in.
85—90 mm
Actuator Plate Adjustment Distance
3.35—3.54 in.
Adjusted correctly, the self-leveling linkage causes the loader control lever to move from bucket roll back to neutral when
boom is fully raised. In neutral, the bucket is automatically leveled preventing spilling of material.
With both the self-leveling linkage and return-to-dig switch adjusted correctly, the bucket will roll back to a slightly dumped or
flat on ground position as boom lowers.
→NOTE:
For proper adjustment of loader bucket self-leveling linkage and return-to-dig switch, perform loader
bucket self-leveling linkage adjustment before return-to-dig switch adjustment.
Loader Bucket Self-Leveling Linkage Adjustment
[1] - Position loader bucket flat on ground.
[2] - Turn machine OFF.
[4] -
Self-Leveling Linkage Adjustment

LEGEND:
1 Actuator Tube Turnbuckle
2 Actuator Plate
3 Actuator Plate Adjustment Distance
4 Pickup Pin Adjustment Lock Nut (2 used)
5 Pickup Pin Adjustment Distance

6 Vertical Link
7 Pickup Pin
Push pickup pin (7) on vertical link (6) down, so that loader valve spool is lifted to maximum height.
[5] - While holding pickup pin down, adjust lock nuts (4) so that bottom of pickup pin is within specification of bottom of pickup
pin adjustment distance (5).
Pickup Pin Adjustment Distance 2 mm
0.08 in.
[6] - Release pickup pin.
[7] - Adjust actuator tube turnbuckle (1) so actuator plate (2) to actuator plate adjustment distance (3) is within specification.
Actuator Plate Adjustment Distance 85—90 mm
3.4—3.5 in.
Return-to-Dig Switch Adjustment
[1] -
LEGEND:
1 Cap Screw
2 Return-to-Dig Switch Bracket
3 Cam Surface
4 Return-to-Dig Switch Roller
5 Self-Leveling Acuator
6 Yoke
7 Pin
Return-to-Dig Switch Adjustment (top view)
Return-to-Dig Switch Adjustment

Loosen cap screw (1) and move return-to-dig switch bracket (2) so return-to-dig switch roller (4) is touching cam surface (3) as
shown.
[2] - Tighten cap screw without moving return-to-dig switch bracket out of position.
[3] - Test operation of the return-to-dig switch.
a. Remove pin (7) and disconnect yoke (6) from self-leveling actuator (5).
→NOTE:
Be sure that switch arm and roller do not bottom on switch housing.
Turn self-leveling actuator back and forth while watching return-to-dig switch roller move on cam surface. If cam surface
hits return-to-dig switch bracket, or if return-to-dig switch roller arm bottoms against switch housing when depressed,
reposition return-to-dig switch. Repeat procedure.
c. Install pin and yoke to self-leveling actuator.
Loader and Stabilizer Lever Adjustment

Specifications
SPECIFICATIONS
694 mm
Right Front ROPS-to-Loader Lever Length
27.3 in.
568 mm
Right Rear ROPS-to-Loader Lever Length
22.4 in.
670 mm
Right Front ROPS-to-Auxiliary Loader Lever Length
26.4 in.
532 mm
Right Rear ROPS-to-Auxiliary Loader Lever Length
20.9 in.
Loader Lever Adjustment
[1] - Park machine on level surface. Lower attachments and stabilizers to ground.
[2] - Stop engine and release hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[3] - Remove front and rear floor mats.
[4] -
LEGEND:
1 Floor Access Plate
2 Floor Access Plate
Floor Plates
Remove floor access plate (1).
[5] - Remove rear floor access plate (2).
[6] -
LEGEND:
1 Loader Linkage
Loader Lever Linkage

Locate loader lever linkage adjustment turnbuckle.
[7] -
→NOTE:
Measuring distance is from center of loader lever to level area shown on ROPS post.
Adjust linkage turnbuckle to specification using ROPS posts as a reference.

LEGEND:
1 Right Front ROPS-to-Loader Lever
Right Front ROPS Post-to-Loader Lever

LEGEND:
1 Right Rear ROPS Post-to-Loader Lever
Right Rear ROPS Post-to-Loader Lever
Right Front ROPS Post-to-Loader Lever Length 694 mm
27.3 in.
Right Rear ROPS Post-to-Loader Lever Length 568 mm
22.4 in.
Auxiliary Loader Lever Adjustment
[1] - Locate auxiliary loader lever linkage.
[2] - Adjust linkage turnbuckle to specification using ROPS posts as reference.

LEGEND:
1 Right Front ROPS Post-to-Auxiliary Loader Lever
Right Front ROPS Post-to-Auxiliary Loader Lever
LEGEND:
1 Right Rear ROPS Post-to-Auxiliary Loader Lever
Right Rear ROPS-to-Auxiliary Loader Lever
Right Front ROPS Post-to-Auxiliary Loader Lever Length 670 mm
26.4 in.
Right Rear ROPS Post-to-Auxiliary Loader Lever Length 532 mm
20.9 in.
Stabilizer Lever Adjustment
[1] -
LEGEND:
1 Stabilizer Lever (2 used)
2 Center Location
Stabilizer Lever Adjustment

Adjust stabilizer linkage turnbuckles until stabilizer levers (1) are in center location (2) between stops.
[2] - Install floor plates.
[3] - Install floor mats.
Ride Control Accumulator Charge Procedure

Specifications
SPECIFICATIONS
345 kPa
Ride Control Accumulator Charge Pressure (below measured pressure on loader boom cylinder head end) 3.5 bar
50 psi
JT05420 Nitrogen Accumulator Charging Kit
Dry Nitrogen Tank
Nitrogen Tank Pressure Regulator
This procedure is used to charge the ride control accumulator with dry nitrogen. New machines have an accumulator precharge
of 2930 kPa (29.3 bar) (425 psi). Replacement accumulators are shipped without precharge and can be charged before they
are installed on a machine.
[1] - Check and record charge pressure required for ride control accumulator. See Ride Control Accumulator Charge Check
Procedure . (Group 9025-20.)
[2] -
→NOTE:
Accumulator will not allow correct amount of gas to be installed if piston is not at bottom of accumulator
before charging. Performing ride control accumulator hydraulic pressure release procedure will move the
piston to bottom.
Release hydraulic pressure in ride control accumulator. See Ride Control Accumulator Hydraulic Pressure Release Procedure .
(Group 9025-20.)
[3] -
LEGEND:
Ride Control Accumulator

Move loader control lever to float position and leave it there until accumulator charging is complete.
[4] - Remove cover and cap from top of ride control accumulator (if equipped) (205).
[5] -
Nitrogen Accumulator Charging Kit
JT05420
Charge ride control accumulator
Dry Nitrogen Tank

Nitrogen Tank Pressure Regulator
LEGEND:
45 Gas Cock
46 Hose to Nitrogen Tank
Gas Cock
Close gas cock (45) by turning it counterclockwise.
[6] -
IMPORTANT:
Charge accumulator using only dry nitrogen. Dry nitrogen does not mix with oil and is non-combustible. It
will not cause oxidation or condensation inside accumulator and is not harmful to piston seal. DO NOT
use air or any combustible gas as these can cause oxidation and condensation. Oxidation and
condensation are harmful to piston seal and accumulator.
Attach hose to nitrogen tank (46), and gas cock (45) to ride control accumulator (if equipped) (205).
[7] - Slowly open regulator valve and gas cock to pressurize ride control accumulator.
[8] -
→NOTE:
Accumulator charge requirement will vary with loader bucket size and attachments. Accumulator charge
must be set 345 kPa (3.5 bar) (50 psi), below boom cylinder head end pressure measured with bucket
approximately 1 m (3 ft.) off ground during Ride Control Accumulator Charge Check Procedure . (Group
9025-20.)
Pressurize ride control accumulator to 345 kPa (3.5 bar) (50 psi) below head end pressure measured on loader boom cylinder.
Ride Control Accumulator Charge Pressure (below measured pressure on loader boom cylinder head end) 345 kPa
3.5 bar
50 psi
[9] - Close gas cock and shut off gas pressure from the nitrogen tank.
[10] - Slowly loosen the connector at the regulator valve to release pressure from hose.
[11] - Remove gas cock from ride control accumulator and install cap.
Ride Control Accumulator Charge Check Procedure

Specifications
SPECIFICATIONS
40°C
104°F
0.9—1.2 m
Loader Bucket Height
3—4 ft.
This procedure is used to determine dry nitrogen charge pressure required for the ride control accumulator.
[1] - Release hydraulic pressure from ride control accumulator. See Ride Control Accumulator Hydraulic Pressure Release
[2] - Stop engine.
[3] -
CAUTION:
Escaping Fluid
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.
Move loader control lever to float position to release hydraulic system pressure in loader circuit. See Hydraulic Circuit Pressure
Release . (Group 9025-25.)
[4] -
LEGEND:
1 Loader Boom Cylinder Hydraulic Hose (head end)
2 JT02156A Digital Pressure and Temperature Analyzer
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
Loader Boom Cylinder With Digital Pressure and

Temperature Analyzer
Disconnect loader boom cylinder hydraulic hose (1) from loader boom cylinder (202).
[5] - Install test tee and JT02156A Digital Pressure and Temperature Analyzer (2) (or equivalent) to loader boom cylinder.
JT02156A
Used for pressure and temperature measurement.
[6] - Connect loader boom cylinder hydraulic hose to tee.
[7] - Start engine and warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)
104°F
[8] - Move ride control switch to OFF position.
[9] - Raise loader bucket to specified height off ground. Wait for 20 seconds until hydraulic pressure gauge reading stabilizes.
Record lowest head end hydraulic pressure required to support loader bucket.
Loader Bucket Height 0.9—1.2 m
3—4 ft.
[10] - Move loader control lever to float position to release hydraulic system pressure in loader circuit. See Hydraulic Circuit
Pressure Release . (Group 9025-25.)
[11] - Remove test equipment and connect loader boom cylinder hydraulic hose to loader boom cylinder.
[12] -
→NOTE:
Accumulator charge requirement will vary with loader bucket size and attachments. Accumulator charge
must be set 345 kPa (3.5 bar) (50 psi) below boom cylinder head end pressure measured during this
procedure. New machines have an accumulator precharge of 2930 kPa (29.3 bar) (425 psi).
Adjust ride control accumulator pressure as required. See Ride Control Accumulator Charge Procedure . (Group 9025-20.)
Ride Control Accumulator Hydraulic Pressure Release Procedure

This procedure is used to release hydraulic pressure on the ride control accumulator.
[1] -
CAUTION:
Prevent possible injury from unexpected boom or bucket movement when equipped with ride control.
Ride control accumulator energy must be discharged when working on hydraulic components.
With engine running, position loader bucket flat on the ground.
[2] - Activate ride control switch to the ON position.
[3] - Put the loader into float position.
[4] - Turn the engine OFF.
Group 25 - Tests
JT02156A Digital Pressure and Temperature Analyzer Kit Installation
JT02156A Digital Pressure and Temperature Analyzer Kit

LEGEND:
A Digital Pressure and Temperature Analyzer
B Transducer
JT02156A Digital Pressure and Temperature Analyzer Kit
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.
Digital Pressure and Temperature Analyzer Kit

JT02156A
Kit contains the analyzer, cable, two transducers, thermo-coupler, and a carry case.
JT02158
display digital readings for temperature and single, multiple, or differential hydraulic oil pressure. Also reads vacuum when
used with 500 psi transducer.
6 m (20 ft.) Cable with Couplers
JT02159
connect tranducers to digital pressure and temperature analyzer.
3400 kPa (35 bar) (500 psi) Transducer
JT02161
measure hydraulic oil pressure and vacuum.
34 000 kPa (350 bar) (5000 psi) Transducer
JT02162
measure hydraulic oil pressure.
Thermo-Coupler
JT05969
measure hydraulic oil temperature.
70 000 kPa (700 bar) (10 000 psi) Transducer (Optional, Order Separately)
JT02160
measure hydraulic oil pressure.
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.
Hydraulic Oil Warm-up Procedure

Specifications
SPECIFICATIONS
Engine Speed Fast Idle
60—70°C
Hydraulic Oil Temperature
140—160°F
[1] - Engage park brake and put transmission control lever (TCL) in neutral.
[2] - Start engine and run to specification.

[3] - Lower loader bucket to the ground.
[4] - Place backhoe in transport position and apply boom lock. Stall the boom down circuit by pushing the boom down lever
fully for one minute, then cycle function to reduce localized overheating in control valve and to equalize temperature in circuits
being tested. Repeat cycle until hydraulic oil is to specification.
140—160°F
Fluid Sampling Procedure—If Equipped

Specifications
SPECIFICATIONS
100 mL
System Fluid Purge Volume (approximate)
3.4 oz
75 mL
Fluid Sample Volume (approximate)
2.5 oz
This is the recommended procedure for obtaining oil samples using the John Deere sampling valve. A cap probe, plastic bag,
and oil sampling kit for the appropriate system are needed for this procedure. Part numbers for the required items can be
found at the end of this procedure.
Fluid systems should be sampled at the following intervals:
Each system at every oil change prior to changing oil.

Engine oil: 250 hours (recommended); 500 hours (maximum).
Hydraulics: 250 hours.
Power train; engine coolant: 500 hours.
Machine Preparation
[1] - Start the machine and warm system to normal operating temperature. Operate machine functions so that the fluid is
agitated throughout the system.
[2] - Once the system has reached operating temperature, operate engine at slow idle.
[3] - Locate sample valve on unit and clean the area around the valve prior to removing dust cap. This will reduce additional
fluid sample contamination. See Fluid Sampling Test Ports—If Equipped . (Operator′s Manual.)
[4] - Once the area has been cleaned, remove the dust cap from the valve.
Priming Sample Valve
Oil must be purged from the system to ensure a representative sample is collected in the test collection bottle. The appropriate
amount of waste oil is determined by the distance of the sampling valve from the flow of the system. It is recommended one
full sample bottle, equal to 100 mL (3.4 oz), be purged from a remotely mounted valve prior to collecting the sample.
[1] - Connect probe to sample valve by placing the probe end into the valve port.
[2] -
System Fluid Purge (excavator shown)
Press and hold the probe to release an appropriate amount of fluid into a waste container.
System Fluid Purge Volume (approximate) 100 mL
3.4 oz
[3] - Properly dispose of collected waste fluid.
[4] - If oil flow needs to be increased to obtain a representative sample, accelerate the flow of the system by increasing the
engine speed to high idle while taking the sample.
Obtaining Fluid Sample
[1] -
→NOTE:
This step is best done in a clean environment, rather than at the sample site.
Place the sample bottle from the sample kit into plastic bag. Seal plastic bag.
Place Sample Bottle in Plastic Bag
[2] -
Remove Lid of Sample Bottle (in plastic bag)

Remove the lid from the sample container, while keeping bottle inside plastic bag. Move the lid aside within the plastic bag, so
that the bottle opening is accessible.
When collecting hydraulic or power train samples, be careful to hold the sheet of plastic (located under the lid) to the top of the
bottle. This will ensure that the protective plastic is not removed when the lid is taken off.
[3] -
→NOTE:
The plastic bag creates a protective covering for the sample so that external contaminants are not
introduced into the fluid sample.
Holding bag tight across bottle, puncture hole in bag with cap probe line and insert line about 13 mm (0.5 in.) into the sample
bottle.
Puncture Plastic Bag with Cap Probe Line
[4] -
Collect Sample Fluid (excavator shown)

While holding cap probe line inside the bottle, press and hold the cap probe to the valve to release the sample fluid into the
bottle that is still secured within the plastic bag.
[5] - Fill the sample bottle about 3/4 full of fluid.

Fluid Sample Volume (approximate) 75 mL
2.5 oz
[6] - Once a representative sample has been obtained, remove the tube and return the lid to the container, leaving the lid and
bottle inside the plastic bag and the protective plastic sheet attached underneath the lid (if applicable).
When properly performed, sample oil will be warm, indicating that all stagnant fluid was removed during the purge process and
not sent to the lab.
[7] -
→NOTE:
Cap probes are to be used for only one sampling procedure.
Install the dust cap to the sample valve, and properly dispose of the cap probe.
[8] - Fill out the sample information form completely, and submit the form and sample to the designated regional lab for
testing.
Fluid Analysis Sampling Materials Summary
Part Number Description
AT317904 Engine Test Kit
AT303189 Hydraulic and Power Train Test Kit
AT180344 Diesel Fuel Test Kit
AT183016 Coolant Test Kit
TY26349 1/4" Suction Pump Tubing, 100ft.
AT308579 120 mL Sample Bottle
AT315231 Poly Cap Probe
AT321211 Probe Style Sample Valve with Attached Cap, -4 SAE O-Ring
AT306111 Probe Style Sample Valve with Attached Cap, -6 SAE O-Ring
TY26363 Probe Style Sample Valve with Attached Cap, 1/4"-20 NPT
AT306133 Probe Style Sample Valve with Attached Cap, 1/8"-27 NPT
TY26364 90° Push Button Sample Valve with attached Cap, 1/8"-27 NPT
TY26365 Sample Valve Actuator Tubing Adaptor Fitting, KST Series Probe
N/A Plastic Bag
Hydraulic Oil Sampling Procedure—If Equipped

For hydraulic oil sampling procedure, see Fluid Sampling Procedure—If Equipped . (Group 9010-25.)
Hydraulic Circuit Pressure Release

Manual Controls
[1] -
CAUTION:
pressure.
Park machine on level surface and engage park brake.
[2] - Lower loader and backhoe to ground or to a stored safe position.
[3] - Stop engine.
[4] - Manually move control levers in all directions until loader or backhoe completely releases all hydraulic pressure.
Pilot Controls
[1] -
LEGEND:
1 Pilot Control Enable/Disable Switch
2 Pilot Control (2 used)
Pilot Controls
[2] - Lower the loader and backhoe to the ground or to a stored safe position.
[3] - Stop engine.
[4] - Manually move control lever in all directions until the loader completely releases all hydraulic pressure.
[5] - For backhoe pressure release, turn switched power ON, but do not start engine.
[6] - Rotate operator′s seat to the backhoe position.
[7] - Push pilot control enable/disable switch (1) to unlock position.
[8] - Rotate pilot controls (2) 5 to 10 rotations to release hydraulic system pressure.
[9] - Push pilot control enable/disable switch to locked position.
Electrohyraulic (EH) Loader Auxiliary Control
[1] -
LEGEND:
3 Loader Auxiliary Flow Control Switch
4 Single Lever Loader Controller (SLLC)
Single Lever Loader Controller (SLLC)

[2] - Lower loader and backhoe to ground or to a stored safe position.
[3] - Stop engine.
[4] - Turn switched power ON, but do not start engine.
[5] - Position seat in locked forward position.
[6] - Roll loader auxiliary flow control switch (3) to full forward and backward positions a minimum of 10 times to release
auxiliary pressure.
Hydraulic Pump Flow Test

Specifications
SPECIFICATIONS
60—70°C
140—160°F
13 720—13 860 kPa

Hydraulic System Test Pressure 137.2—138.6 bar
1990—2010 psi
Seat in Forward Position
101.6 L/min.
Hydraulic Pump Flow Rate (new, typical)
26.8 gpm
83.7 L/min.
Hydraulic Pump Flow Rate (used, minimum)
22.1 gpm
Seat in Rear Position
132.7 L/min.
Hydraulic Pump Flow Rate (new, typical)
35.1 gpm
109.3 L/min.
Hydraulic Pump Flow Rate (used, minimum)
28.9 gpm
JT07148 Flowmeter (or equivalent)
Test Hose (2 used)
[2] -
CAUTION:
Escaping Fluid
pressure.
Release hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[3] -
Hydraulic Pump Flow Test (bottom view)

LEGEND:
1 Supply Hose
113 Hydraulic Pump
Disconnect supply hose (1) from hydraulic pump (113).
[4] -
LEGEND:
2 Flowmeter Inlet Test Hose
3 Flowmeter
4 Flowmeter Outlet Test Hose
5 Flowmeter Restriction Valve
Flowmeter Test Connections

Install flowmeter inlet test hose (2) to hydraulic pump outlet and flowmeter (3) inlet.
[5] - Install flowmeter outlet test hose (4) to flowmeter outlet.
[6] - Remove cap from hydraulic oil reservoir.
[7] - Place flowmeter outlet test hose in hydraulic oil reservoir.

[8] -
IMPORTANT:
Flow control valve on flowmeter MUST be fully open. Damage to pump will result if valve is not fully open.
Fully open flowmeter restriction valve (5).
[9] - Start engine.
[10] - Warm hydraulic oil to specification by partially closing flowmeter restriction valve.
140—160°F
[11] - Run engine to specification.

[12] - Slowly close flowmeter restriction valve until pressure is to specification with seat forward. Record flow reading.
Hydraulic System Test Pressure 13 720—13 860 kPa
137.2—138.6 bar
1990—2010 psi
Hydraulic Pump Flow Rate (new, typical) 101.6 L/min.
26.8 gpm
Hydraulic Pump Flow Rate (used, minimum) 83.7 L/min.
22.1 gpm
[13] - Repeat procedure for seat in rear position.

Hydraulic System Test Pressure 13 720—13 860 kPa
137.2—138.6 bar
1990—2010 psi
Hydraulic Pump Flow Rate (new, typical) 132.7 L/min.
35.1 gpm
Hydraulic Pump Flow Rate (used, minimum) 109.3 L/min
28.9 gpm
[14] - If hydraulic pump is not to specifications, replace pump. See Hydraulic Pump Remove and Install . (Group 2160.)
System Relief Valve Pressure Test

Specifications
SPECIFICATIONS
24 304—25 684 kPa

System Relief Valve Pressure Setting 243—257 bar
3525—3725 psi
Adapter (1-1/16-12 M 37° x -8 F ORFS) (2 used)
Union (-8 M x -8 M ORFS)
Tee (-6 M x -6 M x -6 F ORFS)
→NOTE:
System relief valve (150) regulates the entire machine hydraulic system (backhoe, loader, steering and
auxiliary).
[1] - Park machine on level surface and engage park brake.
[2] - Stop engine and put transmission control lever (TCL) in neutral.
[3] -
CAUTION:
pressure.
[4] -
→NOTE:
Hydraulic system pressure can be read from monitor. See Standard Display Monitor (SDM)—Diagnostics .
(Group 9015-16.)
→NOTE:
Backhoe control valve test ports may be blocked depending on machine configuration.
Backhoe Control Valve Test Ports
Hydraulic Pump Test Port

LEGEND:
1 Test Port
2 Test Port
3 Test Port
113 Hydraulic Pump
Install JT02156A Digital Pressure and Temperature Analyzer (or equivalent) to available test port (1, 2, or 3).
Adapter (2 Used)
1-1/16 -12 M 37° x -8 F ORFS
Used to connect gauge
Union
-8 M x -8 M ORFS
Tee Fitting
-6 M x -6M x -6 F ORFS

[7] - Fully raise backhoe boom and hold over relief. Record gauge reading.
[8] - Lower backhoe boom.
[9] -
Relief Valve Adjustment

LEGEND:
4 Lock Nut
5 Adjustment Screw
Adjust system relief valve using procedure below.
a. Loosen lock nut (4).

b. Turn adjustment screw (5) to adjust pressure. Turning adjustment screw in increases pressure, turning adjustment screw
out decreases pressure.
c. Hold adjustment screw stationary and tighten lock nut.

Backhoe Relief Valve Pressure Setting 24 304—25 684 kPa
243—257 bar
3525—3725 psi
Hydraulic Pump Unloading Relief Valve Pressure Test

Specifications
SPECIFICATIONS
60—70°C
140—160°F
20 000—21 400 kPa

Hydraulic Pump Unloading Relief Valve Pressure Setting 200—214 bar
2900—3100 psi
JT02162 5000 psi Transducer
[3] -
→NOTE:
For location of hydraulic pump, see Hydraulic System Component Location . (Group 9025-15.)
Unloading Valve Relief Valve

LEGEND:
1 Unloading Valve Test Port
2 Jam Nut
3 Adjustment Screw
Remove plug from unloading valve test port (1).
[4] - Install quick coupler to unloading valve test port.
[5] - Connect JT02156A Digital Pressure and Temperature Analyzer (or equivalent) to quick coupler. See JT02156A Digital

JT02156A
Used to check pressure.
5000 psi Transducer
JT02162
Used to measure pressure
140—160°F

[8] - Raise backhoe boom and hold over relief. Watch pressure gauge and record maximum pressure before gauge needle
drops off (unloading). R
[9] - Compare pressure reading to specification.

Hydraulic Pump Unloading Relief Valve Pressure Setting 20 000—21 400 kPa
200—214 bar
2900—3100 psi
[11] - Unloading valve relief valve (215) is screw adjustable. Loosen jam nut (2) and turn adjustment screw (3) to make
adjustments.
Pilot Control Pressure Test

To test pilot control pressure, see Pilot Control Pressure Adjustment . (Group 9025-20.)
Pilot Control Accumulator Charge Pressure Test

Specifications
SPECIFICATIONS
40°C
104°F
1034 kPa
Pilot Control Accumulator Charge Pressure (minimum) 10.34 bar
150 psi
[1] - With engine off, discharge pilot control accumulator. See Pilot Enable and Pattern Select Valve Accumulator Discharge
[2] -
Pilot Control Pressure Test Port

LEGEND:
Connect JT02156A Digital Pressure and Temperature Analyzer (or equivalent) to pilot control pressure test port (141) from
under machine. See JT02156A Digital Pressure and Temperature Analyzer Kit Installation . (Group 9025-25.)

JT02156A
104°F
[4] - Run engine at slow idle.

[5] - Verify pilot control pressure is to specification. See Pilot Control Pressure Adjustment . (Group 9025-20.)
[6] -
IMPORTANT:
Perform this test slowly to get accurate accumulator charge pressure. The pilot pressure will decrease
with every application of pilot controller and then make a sudden large pressure drop when accumulator
is discharged. The highest reading before sudden large pressure drop will be accumulator charge
pressure. Test may have to be repeated several times to get accurate reading.
Check the charge of the accumulator using the following procedure:
a. Stop engine.
b. Power machine ON.
c. Cycle pilot enable switch from OFF to ON position.
d. Observe pressure gauge reading while cycling bucket pilot function slowly to bleed off pilot pressure. When pressure
approaches 1380 kPa (13.8 bar) (200 psi), watch for sudden large drop in pressure.
e. Compare highest pressure reading observed before sudden drop to specifications.
Pilot Control Accumulator Charge Pressure (minimum) 1034 kPa
10.34 bar
150 psi
→NOTE:
Repeat test procedure if unable to detect sudden pressure drop.
[7] - If accumulator charge is below minimum specifications, replace accumulator.
[8] - Remove test equipment.
Hydraulic Oil Cooler Restriction Test

Specifications
SPECIFICATIONS
60—70°C
140—160°F
379—412 kPa
Hydraulic Oil Cooler Differential Pressure (maximum) 3.8—4.1 bar
55—60 psi
[3] - Apply vacuum to hydraulic oil reservoir. See Apply Vacuum to Hydraulic Oil Reservoir . (Group 2160.)
[4] -
Hydraulic Oil Cooler Connections

LEGEND:
1 Hydraulic Return Hose
2 Hydraulic Supply Hose
Install identification tag and disconnect hydraulic return hose (1) from hydraulic oil cooler (120).
[5] - Install tee fitting to hydraulic return hose.
[6] - Install quick coupler and connect test hose to tee fitting.
[7] - Connect test hose to hydraulic oil cooler.
[8] - Install identification tag and disconnect hydraulic supply hose (2) from hydraulic oil cooler.
[9] - Install tee fitting to hydraulic oil cooler supply hose.
[10] - Install quick coupler and connect test hose to tee fitting.
[11] - Connect test hose to hydraulic oil cooler.
[12] - Install JT02156A Digital Pressure and Temperature Analyzer to quick couplers. See JT02156A Digital Pressure and
Temperature Analyzer Kit Installation . (Group 9025-25.)
JT02156A
Used to check pressure differential.
[13] - Disconnect or shut off vacuum to hydraulic oil reservoir.
140—160°F

[16] - Record pressure differential.

Hydraulic Oil Cooler Differential Pressure (maximum) 379—412 kPa
3.8—4.1 bar
55—60 psi
[17] - If pressure differential is above specification, hydraulic oil cooler flow is restricted.
Flush or replace hydraulic oil cooler. See Hydraulic and Transmission Oil Coolers Remove and Install . (Group 2160.)
[18] - Turn on or apply vacuum to hydraulic oil reservoir.
[19] - Remove test equipment, fittings, and test hoses.
[20] - Connect hydraulic hoses to appropriate ports using identification tags.
Circuit Relief Valve Test—With Remote Pump

Specifications
SPECIFICATIONS
Loader Circuits
26 200—27 580 kPa

Auxiliary Extend Pressure 262—275.8 bar
3800—4000 psi
31 715—33 095 kPa

Bucket Curl Pressure 317—330.9 bar
4600—4800 psi
31 715—33 095 kPa

Bucket Dump Pressure 317—330.9 bar
4600—4800 psi
35 163—36 543 kPa

Boom Up Pressure 352—365.4 bar
5100—5300 psi
Backhoe Circuits
32 800—34 180 kPa

Crowd Out Pressure 328—341.8 bar
4757—4957 psi
31 715—33 095 kPa

Bucket Curl Pressure 317—330 bar
4600—4800 psi
14 800—16 180 kPa

Boom Down Pressure 148—161.8 bar
2147—2347 psi
28 960—30 340 kPa

Swing Left Pressure 290—303.4 bar
4200—4400 psi
28 960—30 340 kPa

Swing Right Pressure 290—303.4 bar
4200—4400 psi
34 500—35 880 kPa

Boom Raise Pressure 345—358.8 bar
5003—5204 psi
31 700—33 080 kPa

Bucket Dump Pressure 317—330.8 bar
4598—4798 psi
26 200—27 580 kPa

Crowd In Pressure 262—275.8 bar
3800—4000 psi
13 100—14 479 kPa

Thumb Cylinder Close Pressure (adjustable)—If Equipped 131—145 bar
1900—2100 psi
25 511—26 890 kPa

Thumb Cylinder Open Pressure (adjustable)—If Equipped 255—269 bar
3700—3900 psi
19 300—20 700 kPa

Selective Flow—If Equipped 193—207 bar
2799—3002 psi
Specifications
SPECIFICATIONS
60—70°C
140—160°F
Gauge (or equivalent) 35 000 kPa (350 bar) (5000 psi)
JT02160 Transducer 10 000 psi
JT02162 Transducer 5000 psi
JT07192 Electric/Hydraulic Pump (or equivalent)
Nut (-10 ORFS)
Reducer (-10 F x -6 M ORFS)
Nut (-12 ORFS)
Nut (-8 ORFS)
[1] -
IMPORTANT:
The circuit relief valve is flow sensitive. A flow rate greater than 7.5 L/min (2 gpm) will flood the valve
causing an inaccurate pressure reading. A hydraulic source that will provide a continuous flow must be
used to get an accurate reading.
Backhoe bucket curl and loader bucket dump circuit reliefs require 19 L/min (5 gpm) flow rate.
Hydraulic Cylinder Connections
Remote Pump Connections

LEGEND:
1 Hydraulic Hose (rod end)
2 Hydraulic Hose (head end)
3 Hydraulic Cylinder
4 Test Pump Pressure Hose
5 Tee
6 Transducer
Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 9000-01.)
140—160°F
[3] - Stop engine and put transmission control lever (TCL) in neutral.
[4] -
CAUTION:
pressure.
[5] -
CAUTION:
Prevent possible injury from unexpected machine movement. If circuit being tested involves loader
boom, swing, or multipurpose bucket cylinders, disconnect lines to other cylinder within the circuit.
Disconnect hydraulic hose (1 or 2), for circuit being tested, from hydraulic cylinder (3). Disconnect hoses to other cylinder in
circuit, if applicable. See Hydraulic System Schematic . (Group 9025-15.)
[6] - Connect test pump pressure hose (4) to hydraulic hose for circuit being tested.
[7] - Close all openings using caps and plugs.
[8] - Install tee (5) and transducer (6) to remote pump. See JT02156A Digital Pressure and Temperature Analyzer Kit
Installation . (Group 9025-25.)
Gauge (or equivalent) 3500 kPa (350 bar) (5000 psi)
JT02156A
Transducer 5000 psi
JT02162
Transducer 10 000 psi
JT02160
Electric/Hydraulic Pump (or equivalent)
JT07192
Delivers Hydraulic Fluid.
Nut
-10 ORFS
Used to connect gauge.
Reducer
-10 F x -6 M ORFS
Nut
-12 ORFS
Reducer
-12 F x -6 M ORFS
Nut
-8 ORFS
Reducer
-8 F x -6 M ORFS
[9] - Connect test pump pressure hose to tee.
[10] -
→NOTE:
Take reading when pressure on gauge starts to decrease. The point at which pressure decreases is the
opening pressure of the relief valve.
Start remote pump to pressurize valve inlet. Record pressure reading.
[11] - Adjust circuit relief valves according to specification. Repair or replace as necessary. See Loader and Stabilizer Control
Valve Relief Valves Remove and Install . (Group 3160.) See Backhoe Control Valve Relief Valves Remove and Install . (Group
3360.)
Steering System Leakage Test

Specifications
SPECIFICATIONS
60—70°C
140—160°F
Steering Wheel Speed (maximum with 11.3 N·m (100 lb-in.) applied torque) 7 revolutions per minute (rpm)
140—160°F
[2] - Apply park brake and put transmission control lever (TCL) in neutral.

[4] -
Turning the Steering Wheel

Remove steering wheel cap.
[5] - Bend locking tab away from steering wheel nut.
[6] - Turn wheels to the maximum right position against the stop.
[7] - Continue to turn the steering wheel clockwise at a constant specified torque. While maintaining specified torque, continue
to turn the steering wheel and count steering wheel revolutions per minute (rpm).
Steering Wheel Speed (maximum with 11.3 N·m (100 lb-in.) applied torque) 7 rpm
[8] - Turn the steering wheel to the maximum left position and repeat previous two steps.
If the steering wheel cannot be turned faster than 7 revolutions per minute (rpm) in both directions, the steering valve
and steering cylinder are within specifications. Stop test here.
If the steering wheel can be turned faster than 7 revolutions per minute (rpm) in either direction, excessive leakage is
indicated. Perform the following steps to isolate steering valve or steering cylinder leakage.
[9] - Stop engine.
[10] -
CAUTION:
Avoid High-Pressure Fluids

pressure.
[11] -
LEGEND:
1 Steering Cylinder Line (2 used)
MFWD Axle Shown (left side)

Disconnect lines (1) from steering cylinder and install caps and plugs as shown.

[13] - Turn steering wheel counterclockwise, then clockwise, at previously specified torque. Count the steering wheel
revolutions per minute (rpm).
[14] - If steering wheel can be turned faster than specification, in either direction, steering valve is leaking. See Steering Valve
Remove and Install—Tilt Steering or see Steering Valve Remove and Install—Standard Steering . (Group 0960.)
[15] - If the steering wheel revolutions per minute (rpm) are less than specification. See Steering Cylinder Leakage Test .
(Group 9025-25.)
Steering Cylinder Leakage Test

Specifications
SPECIFICATIONS
60—70°C
140—160°F
5 ml/min
Steering Cylinder Leakage (maximum)
0.3 cu in./min
140—160°F
[2] - Put transmission control lever (TCL) in neutral and engage park brake.
[3] -
CAUTION:
Escaping Fluid
pressure.
Stop engine. Move steering wheel back and forth to relieve hydraulic pressure.
[4] -
LEGEND:
1 Hose
2 Fitting
3 Plug
MFWD Axle (left side shown)

Disconnect pressure hose on right side of cylinder and install plug (3).
[5] - Install hose (1) to steering cylinder fitting (2) and route into a calibrated container.

[7] - Using constant pressure, hold steering wheel in full left turn for 1 minute.
[8] - Stop engine and measure oil collected. Compare to specification.

Steering Cylinder Leakage (maximum) 5 ml/min
0.3 cu in./min
[9] - If oil collected is over specified amount, repair cylinder. For machines with a non-powered axle, see Non-Powered Axle
Steering Cylinder Remove and Install . (Group 0960.)
For machines with a mechanical front wheel drive (MFWD) axle, see Mechanical Front Wheel Drive (MFWD) Axle Steering
Cylinder Disassemble and Assemble . (Group 0960.)
[10] -
→NOTE:
Following a repair or test procedure, steering wheel should be turned in both directions to refill steering
system components with oil.
Repeat procedure for opposite end of steering cylinder and connect hose.
Function Drift Test

Specifications
SPECIFICATIONS
60—70°C
140—160°F
25 mm/min.
Backhoe Function Drift (maximum)
1 in./min.
10 mm/min.
Loader Function Drift (maximum)
0.40 in./min.
1 mm/min.
Backhoe Boom (standard dipper) Drift (maximum)
0.04 in./min.
1.5 mm/min.
Backhoe Crowd (standard dipper) Drift (maximum)
0.06 in./min.
1.5 mm/min.
Backhoe Bucket Drift (maximum)
0.06 in./min.
3 mm/min.
Extendable Dipper Cylinder Drift (maximum)
0.12 in./min.
75 mm/min.
Backhoe Swing Cylinder (right or left) Drift (maximum)
2.95 in./min.
1.5 mm/min.
Loader Boom Cylinder Drift (maximum)
0.06 in./min.
1.5 mm/min.
Loader Bucket Cylinder Drift (maximum)
0.06 in./min.
3 mm/min.
Multipurpose Bucket Cylinder Drift (maximum)
0.12 in./min.
0.25 mm/min.
Stabilizer Cylinder Rod Drift (maximum)
0.010 in./min.
Dial Indicator
The following tests are used to check leakage past the cylinder piston seals and through the main control valve spool and
reliefs.
Putting additional weight in bucket is not required to perform these tests.
On extendible dipperstick machines, fully retract dipperstick for all testing.
IMPORTANT:
If drift test exceeds specifications, remove attachments and repeat test. Backhoe and loader attachments
will have significant impact on the drift test, depending on the additional weight added by the
attachment.
Drift specs are based upon a standard machine without attachments such as couplers, 4-in-1 buckets,
thumbs, swingers, and clamps as examples.
Function Drift Check
[1] -
→NOTE:
The function drift check for the loader or the backhoe hydraulic circuits can be performed separately or
at the same time.
When checking function drift, the complete hydraulic circuit of the loader or backhoe is being checked for
excessive leakage.
Warm hydraulic oil to specification. See Hydraulic Oil Warm-Up Procedure . (Group 9025-25.)
140—160°F
[3] -
→NOTE:
For normal operation of machines equipped with ride control, see Ride Control Operation—If Equipped .
(Group 9025-05.)
Function Drift Check Points

Position loader bucket so bucket is level and cutting edge is approximately 51 mm (2.0 in.) off ground.
[4] - Position backhoe bucket side cutters at a approximate 45° angle to ground and dipperstick extended as shown. Lower
boom until bucket cutting edge is 51 mm (2.0 in.) off ground.
[5] - Operate engine to specification and observe bucket cutting edges for 1 minute.
[6] - If the buckets do not drop or if it takes more than 1 minute for the bucket cutting edges to contact the ground, the
leakage within the hydraulic circuits are acceptable—test is complete.
Backhoe Function Drift (maximum) 25 mm/min.
1 in./min.
Loader Function Drift (maximum) 10 mm/min.
0.40 in./min.
If either bucket cutting edge touches the ground within 1 minute, excessive leakage is indicated in the cylinders or control
valve for that particular hydraulic system—continue testing drift for each circuit to determine location of problem.
Backhoe Circuit Boom, Crowd, and Bucket Cylinders Drift Check
[1] -
Backhoe Cylinder Drift

Position the boom, crowd, and bucket cylinders so the rod of each cylinder extends 20—50 mm (0.75—2.00 in.) from the fully
retracted position. Mark the cylinder rods with tape as shown.
[2] - Measure movement of boom, crowd, and bucket cylinder rods after 5 minutes. Divide measured rod drift by five to
determine drift per minute.
Backhoe Boom (standard dipper) Drift (maximum) 1 mm/min.
0.04 in./min.
Backhoe Crowd (standard dipper) Drift (maximum) 1.5 mm/min.
0.06 in./min.
Backhoe Bucket Drift (maximum) 1.5 mm/min.
0.06 in./min.
[3] - Compare drift to specification.

If drift is above specification, see Hydraulic Cylinder Leakage Test (Group 9025-25) to determine if leakage is in the cylinder or
the control valve.
Backhoe Circuit Extendable Dipperstick Cylinder Drift Check
[1] - With machine in transport position, fully curl backhoe bucket.
[2] - Remove extendable dipperstick locking pin.
[3] - Measure drift from end of dipperstick to ground after 5 minutes. Divide measured drift by five to determine drift per
minute.
Extendable Dipper Cylinder Drift (maximum) 3 mm/min.
0.12 in./min.

If drift is above specification, see Hydraulic Cylinder Leakage Test (Group 9025-25) to determine if leakage is in cylinder or
control valve.
Backhoe Swing Cylinder Drift Check
[1] -
Swing Cylinder Drift Check Point

Tilt machine by fully extending right stabilizer.
[2] - Fully extend dipperstick and bucket straight behind and following centerline of machine.
[3] - Position bucket approximately 300 mm (12 in.) off ground with boom parallel to ground.
[4] - Raise left stabilizer to 75 mm (2.95 in.) off ground.
[5] - Insert a rod vertically into ground next to bucket (see illustration).
[6] - Measure swing drift from side of bucket to vertical rod next to bucket after 5 minutes. Divide measured drift by five to
determine drift per minute.
Backhoe Swing Cylinder (right or left) Drift (maximum) 75 mm/min.
2.95 in./min.
[7] - Measure swing drift in opposite direction by reversing stabilizer positions and vertical rod.

control valve.
Loader Boom and Bucket Cylinders Drift Check
[1] -
Measure Bucket Pivot Pin to Ground Clearance
Measure Cylinder Drift

Position the loader boom so bucket pivot pin is 1 meter (36 in.) above ground and bucket is level as shown.
[2] - Mark boom and bucket cylinder rods with tape as shown. Measure movement of cylinder rods after 5 minutes. Divide
measured rod drift by five to determine drift per minute.
Loader Boom Cylinder Drift (maximum) 1.5 mm/min.
0.06 in./min.
Loader Bucket Cylinder Drift (maximum) 1.5 mm/min.
0.06 in./min.

control valve.
Multipurpose Bucket Cylinder Drift Check
Bucket Position For Cylinder Drift Test
Measure Cylinder Drift
[1] - Position loader boom so bucket is approximately 300 mm (12 in.) off ground and open bucket as shown.
[2] - Mark bucket cylinder rods with tape as shown. Measure movement of cylinder rods after 5 minutes. Divide measured rod
drift by five to determine drift per minute.
Multipurpose Bucket Cylinder Drift (maximum) 3 mm/min.
0.12 in./min.
[3] - Compare drift to specification. If drift is above specification, perform Hydraulic Cylinder Leakage Test . (Group 9025-25) to
determine if leakage is in cylinder or control valve.
Stabilizer Cylinders Drift Check
Stabilizer Cylinder With Dial Indicator Installed
[1] - Lower stabilizers to lift machine off ground.
[2] - Check for stabilizer cylinder rod movement with dial indicator.
Dial Indicator
Measures cylinder rod movement.
Stabilizer Cylinder Rod Drift (maximum) 0.25 mm/min.
0.010 in./min.

If drift is above specification, see Hydraulic Cylinder Leakage Test (Group 9025-25) to determine if leakage is in cylinder.
If cylinder leakage is higher than specification, check for contamination in the thermal relief poppet seat and cylinder packing.
If cylinder leakage is OK, remove the lockout and check for scratches on the seat and poppet. Replace if required. Check that
the lockout plunger, which slides between the two lockouts, is not sticking.
Hydraulic Cylinder Leakage Test
Rod End Cylinder Port Leakage Measurement
Specification
Specification
60—70°C
140—160°F
5 mL/min
Hydraulic Cylinder Leakage (maximum)
0.2 oz./min
Nut (-6 ORFS)
Plug (-6 ORFS)
Nut (-8 ORFS)
Plug (-8 ORFS)
Nut (-10 ORFS)
Plug (-10 ORFS)
Nut (-12 ORFS)
Plug (-12 ORFS)
140—160°F
[3] - Fully extend cylinder rod.
[4] - Stop engine.
[5] -
CAUTION:
Escaping Fluid
pressure.
[6] - Disconnect rod end hose and install a plug in hose end.
Nut
-6 ORFS
Used to plug hose.
Plug
-6 ORFS
Used to plug hose.
Nut
-8 ORFS
Used to plug hose.
Plug
-8 ORFS
Used to plug hose.
Nut
-10 ORFS
Used to plug hose.
Plug
-10 ORFS
Used to plug hose.
Nut
-12 ORFS
Used to plug hose.
Plug
-12 ORFS
Used to plug hose.
[7] -
→NOTE:
This procedure can also be done at the control valve which would require capping the control valve port
and putting the hose end into a measuring beaker after hydraulic oil stops dripping.
After hydraulic oil stops dripping from cylinder port, put a measuring beaker under the cylinder port to catch hydraulic oil.

[9] - Actuate the cylinder extend function for 1 minute.
[10] - Stop engine. Measure hydraulic oil collected and connect hose.
Hydraulic Cylinder Leakage (maximum) 5 mL/min
0.2 oz./min
[11] - If measured hydraulic oil is not within specification, repair or replace cylinder as necessary.
See Loader Bucket Cylinder Remove and Install . (Group 3160.)

See Loader Boom Cylinder Remove and Install . (Group 3160.)
See Backhoe Bucket Cylinder Remove and Install . (Group 3360.)
See Backhoe Crowd Cylinder Remove and Install . (Group 3360.)
See Backhoe Boom Cylinder Remove and Install . (Group 3360.)
See Backhoe Swing Cylinder Remove and Install . (Group 3360.)
See Backhoe Stabilizer Cylinder Remove and Install . (Group 3360.)
See Backhoe Extendable Dipperstick Cylinder Remove and Install . (Group 3360.)
[12] - Repeat procedure to test each cylinder.
Loader and Stabilizer Control Valve Lockout Leakage Test
Stabilizer Cylinder
Specifications
SPECIFICATIONS
60—70°C
140—160°F
0.25 mm/min
Stabilizer Cylinder Rod Drift (maximum)
0.010 in./min
Dial Indicator
The loader and stabilizer control valve has lockouts to prevent stabilizer cylinder drift up or down. Lockouts reduce leakage in
circuit and require a dial indicator to test cylinder rod travel (drift).
140—160°F

[3] - Lower stabilizers to lift machine off ground.
[4] - Check for stabilizer cylinder rod movement with dial indicator.
Dial Indicator
Measures cylinder rod movement.
Stabilizer Cylinder Rod Drift (maximum) 0.25 mm/min
0.010 in./min

If distance is above specification, see Hydraulic Cylinder Leakage Test (Group 9025-25) to determine if leakage is in cylinder.
If cylinder leakage is higher than specification, check for contamination in the thermal relief poppet seat and cylinder packing.
See Backhoe Stabilizer Cylinder Disassemble and Assemble . (Group 3360.)
If cylinder leakage is OK, remove the lockout and check for scratches on the seat and poppet. See Loader and Stabilizer Control
Valve Spool Disassemble and Assemble . (Group 3160.) Repair or replace as necessary. Check that lockout plunger, which
slides between the two lockouts, is not sticking.
Sideshift Lock Solenoid Valve Leakage Test—(S.N. —232969)

Specifications
SPECIFICATIONS
125 mL
Sideshift Lock Solenoid Valve Leakage (maximum)
4.2 oz.
Measuring Beaker
[3] -
Return Line
LEGEND:
2 Return Line
167 Boom Lock Solenoid Valve
Remove cap screws (1) and lay boom lock solenoid valve (167) aside.
[4] - Disconnect return line (2) and install cap or plug on hose end.
[5] - Connect a hose to open fitting on sideshift lock solenoid valve (169) to drain any leakage into measuring beaker.
HEATING AND AIR CONDITIONING (g) by Belgreen v2.0
Measuring Beaker
To measure leakage.

[7] - Hold boom raise function over relief for 1 minute.
[8] - Measure oil. If leakage is greater than specification, repair or replace valve as necessary. See Backhoe Sideshift Lock
Valve Disassemble and Assemble . (Group 3360.)
Sideshift Lock Solenoid Valve Leakage (maximum) 125 mL
4.2 oz.
Section 9031 - HEATING AND AIR CONDITIONING

Table of contents
Air Conditioning System Cycle Of Operation ........................................................................................ 1
Group 15 - Diagnostic Information ........................................................................................................ 3
Air Conditioning and Heater System Component Location ................................................................... 3
Air Conditioning System Does Not Operate Diagnostic Procedure ....................................................... 5
Air Conditioner Does Not Cool Interior of Cab Diagnostic Procedure .................................................... 7
Air Conditioner Runs Constantly, Too Cold Diagnostic Procedure ......................................................... 8
Heater System Does Not Operate Diagnostic Procedure ...................................................................... 9
Heater Does Not Warm Interior of Cab Diagnostic Procedure ............................................................ 10
Interior Windows Continue to Fog Diagnostic Procedure .................................................................... 10
Group 25 - Tests ..................................................................................................................................... 12
Refrigerant Cautions and Proper Handling ......................................................................................... 12
R134a Refrigerant Cautions ............................................................................................................... 12
R134a Oil Charge Capacity ................................................................................................................. 13
R134a Refrigerant Charge Capacity ................................................................................................... 13
Visual Inspection Of Components ....................................................................................................... 14
Air Conditioner Compressor Clutch Test ............................................................................................. 16
Air Conditioner High/Low Pressure Switch Test .................................................................................. 17
Air Conditioner Freeze Control Switch Test ........................................................................................ 20
R134a Air Conditioning System Test .................................................................................................. 22
Operating Pressure Diagnostic Chart .................................................................................................. 24
Expansion Valve Test ......................................................................................................................... 25
Blower Motor Speed Switch Test ........................................................................................................ 27
Blower Motor Resistor Test ................................................................................................................. 28
Blower Motor Test ............................................................................................................................... 30
Air Conditioning Mode Switch Test ..................................................................................................... 31
Air Conditioning System Leak Test ..................................................................................................... 32
Refrigerant Hoses and Tubing Inspection ........................................................................................... 32

Section 9031 - HEATING AND AIR CONDITIONING Group 05: Theory of Operation

Air Conditioning System Cycle Of Operation
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 air conditioner compressor (2) 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.)
The compressor draws low pressure gas (10) from evaporator and compresses it into high pressure gas (8). 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 (3) by fan. Cooling refrigerant causes it to condense and refrigerant leaves condenser as high
pressure liquid (7).
High pressure liquid flows into receiver-dryer (6) 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
Section 9031 - HEATING AND AIR CONDITIONING Group 15: Diagnostic Information
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 (5) to evaporator. Expansion valve senses refrigerant
temperature and pressure to modulate refrigerant flow. Expansion valve changes refrigerant to low pressure liquid (9) 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.
For location of machine heater and air conditioning components, See Heater and Air Conditioner Harness (W19) Component
Location . (Group 9015-10)

Air Conditioning and Heater System Component Location
AC Component Location
LEGEND:
1 Expansion Valve
2 Evaporator
3 Air Conditioner Freeze Switch Probe

4 Hose Line (low pressure gas)
5 Hose Line (high pressure liquid)
6 Receiver-Dryer
7 Hose Line (high pressure liquid)
8 Hose Line to Engine Block
9 Air Conditioner Compressor
10 Hose Line to Water Pump
11 Hose Line (high pressure gas)
12 Condenser
13 Hose Line to Hydraulic Oil Cooler
M10 Blower Motor
Air Conditioning System Does Not Operate

70
Air Conditioning System Does Not Operate Diagnostic Procedure

( 1 ) Fuse Check
Action:
Is the blower motor 30 A fuse (F44) in working order? See Fuse and Relay Location and Specifications . (Group 9015-10.)
Result:
YES:Go to Blower Motor Switch Check.

NO:Replace fuse.
( 2 ) Blower Motor Switch Check
Action:
Is the blower switch working correctly? See Blower Motor Speed Switch Test . (Group 9031-25.)
Result:
YES:Go to Blower Motor Resistor Check.

NO:Replace blower motor switch.
( 3 ) Blower Motor Resistor Check
Action:
Has the blower motor resistor malfunctioned? See Blower Motor Resistor Test . (Group 9031-25.)
Result:
YES:Replace blower motor resistor.

NO:Go to Blower Motor Check.
( 4 ) Blower Motor Check
Action:
Does heater blower motor operate? See Blower Motor Test . (Group 9031-25.)
Result:
YES:Go to Air Conditioner Freeze Switch Check.

NO:Replace the blower motor.
( 5 ) Air Conditioner Freeze Switch Check
Action:
Has the air conditioner freeze control switch malfunctioned? See Air Conditioner Freeze Control Switch Test . (Group 9031-25.)
Result:
YES:Replace freeze control switch.

NO:Go to Air Conditioner Mode Switch Check.
( 6 ) Air Conditioner Mode Switch Check
Action:
Has the air conditioner Mode switch malfunctioned? See Air Conditioning Mode Switch Test . (Group 9031-25.)
Result:
YES:Replace air conditioner mode switch.

NO:Go to Air Conditioner High/Low Pressure Switch Check.
( 7 ) Air Conditioner High/Low Pressure Switch Check
Action:
Has the air conditioner high/low pressure switch malfunctioned? See Air Conditioner High/Low Pressure Switch Test . (Group
9031-25.)
Result:
YES:Replace air conditioner high/low pressure switch.

NO:Go to Air Conditioner Compressor Clutch Check.
( 8 ) Air Conditioner Compressor Clutch Check
Action:
Has the air conditioner compressor clutch malfunctioned? See Air Conditioner Compressor Clutch Test . (Group 9031-25.)
Result:
YES:Replace air conditioner compressor clutch.

NO:Go to Air Conditioner Circuit Check
( 9 ) Air Conditioner Circuit Check
Action:
Is there a problem in the air conditioner circuit wiring? See System Functional Schematic and Section Legend . (Group
9015-10.)
Result:
YES:Repair as necessary.
NO:Go to Blower Motor Circuit Check.
( 10 ) Blower Motor Circuit Check
Action:
Is there a problem in the blower motor circuit wiring? See System Functional Schematic and Section Legend . (Group 9015-10.)
Result:
NO:Checks complete.
Air Conditioner Does Not Cool Interior of Cab

70
Air Conditioner Does Not Cool Interior of Cab Diagnostic Procedure

( 1 ) Fresh Air Filter Check
Action:
Is the fresh air filter restricted? See Clean Cab Fresh Air and Recirculation Filters—If Equipped . (Operator′s Manual.)
Result:
YES:Clean or replace filter.

NO:Go to Recirculating Air Filter Check.
( 2 ) Recirculating Air Filter Check
Action:
Is the recirculating air filter restricted? See Clean Cab Fresh Air and Recirculation Filters—If Equipped . (Operator′s Manual.)
Result:

NO:Go to Condenser Fins Check.
( 3 ) Condenser Fins Check
Action:
Are the condenser fins restricted with debris? See Air Conditioning and Heater System Component Location . (Group 9031-15.)
Result:
YES:Clean condenser fins.

NO:Go to Refrigerant Hose Check.
( 4 ) Refrigerant Hose Check
Action:
Are the refrigerant hoses kinked or collapsed? See Air Conditioning and Heater System Component Location . (Group 9031-15.)
Result:
YES:Repair or replace refrigerant hoses as necessary.

NO:Go to Evaporator Core Fins Check.
( 5 ) Evaporator Core Fins Check
Action:
Are the evaporator core fins restricted with debris? See Air Conditioning and Heater System Component Location . (Group
9031-15.)
Result:
YES:Clean evaporator core fins.

Action:
Does heater blower motor operate? See Blower Motor Test . (Group 9031-25.)
Result:
YES:Go to Air Conditioner Compressor Clutch Check.

NO:Replace the heater blower motor.
Action:
Has compressor clutch coil malfunctioned? See Air Conditioner Compressor Clutch Test . (Group 9031-25.)
Result:
YES:Replace air conditioner compressor clutch.

NO:Go to Air Leakage Check.
( 8 ) Air Leakage Check
Action:
Is warm outside air leaking into the cab?
Result:
YES:Repair as necessary. See Non-Fixed Window Adjustment . (Group 1810.)

NO:Go to Refrigerant (R134a) Charge Check.
( 9 ) Refrigerant (R134a) Charge Check
Action:
Is the refrigerant (R134a) charge too low? See R134a Air Conditioning System Test . (Group 9031-25.)
Result:
YES:Recharge air conditioning system.

NO:Checks complete.
Air Conditioner Runs Constantly, Too Cold
70
Air Conditioner Runs Constantly, Too Cold Diagnostic Procedure

( 1 ) Capillary Tube Check
Action:
Is the capillary tube position correctly in the evaporator coil? See Air Conditioner Freeze Control Switch Remove and Install .
(Group 1830.)
Result:
YES:Go to Air Conditioner Compressor Clutch Check.

NO:Reposition capillary tube.
Action:
Is the compressor clutch engaged constantly? See Air Conditioner Freeze Control Switch Test . (Group 9031-25.)
Result:

NO:Checks complete.
Heater System Does Not Operate

70
Heater System Does Not Operate Diagnostic Procedure

( 1 ) Fuse Check
Action:
Is the blower motor 30 A fuse (F44) in working order? See Fuse and Relay Location and Specifications . (Group 9015-10.)
Result:
YES:Go to Blower Motor Switch Check.

NO:Replace fuse.
( 2 ) Blower Motor Switch Check
Action:
Is the blower motor switch working correctly? See Blower Motor Speed Switch Test . (Group 9031-25.)
Result:
YES:Go to Air Conditioner Circuit Check.

NO:Replace blower motor switch.
( 3 ) Air Conditioner Circuit Check
Action:
Is there a problem in the air conditioner circuit wiring? See System Functional Schematic and Section Legend . (Group
9015-10.)
Result:
NO:Go to Blower Motor Circuit Check.
( 4 ) Blower Motor Circuit Check
Action:
Is there a problem in the blower motor circuit wiring? See System Functional Schematic and Section Legend . (Group 9015-10.)
Result:
NO:Checks Complete.
Heater Does Not Warm Interior of Cab

70
Heater Does Not Warm Interior of Cab Diagnostic Procedure

Action:
Result:

NO:Go to Recirculating Air Filter Check.
( 2 ) Recirculating Air Filter Check
Action:
Is the recirculating air filter restricted? See Clean Cab Fresh Air and Recirculation Filters—If Equipped . (Operator′s Manual.)
Result:

NO:Go to Heater Hose Check.
( 3 ) Heater Hose Check
Action:
Are the heater hoses kinked or collapsed? See Air Conditioning and Heater System Component Location . (Group 9031-15.)
Result:
YES:Repair or replace heater hoses as necessary.

NO:Go to Heater Core Fins Check.
( 4 ) Heater Core Fins Check
Action:
Are the heater core fins restricted with debris? See Air Conditioning and Heater System Component Location . (Group 9031-15.)
Result:
YES:Clean heater core fins.

Action:
Does the blower motor operate? See Blower Motor Test . (Group 9031-25.)
Result:
NO:Replace the blower motor.
Interior Windows Continue to Fog
70
Interior Windows Continue to Fog Diagnostic Procedure

Section 9031 - HEATING AND AIR CONDITIONING Group 25: Tests
Action:
Result:

NO:Go to Air Conditioning System Check.
( 2 ) Air Conditioning System Check
Action:
Is the air conditioner system turned off?
Result:
YES:Put the air conditioning mode switch to the A/C position.

NO:Checks Complete.
Group 25 - Tests
Refrigerant Cautions and Proper Handling
JT02167A Prism Pro Refrigerant Identification Instrument
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.
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.
IMPORTANT:
To meet government standards relating to the use of refrigerants, R134a is used in the air conditioning
system. Because it does not contain chlorine, R134a is not detrimental to the ozone in the atmosphere.
However, it is illegal to discharge any refrigerant into the atmosphere. It must be recovered using the
appropriate recovery stations.
Use correct refrigerant recovery, recycling and charging stations. Never mix refrigerants, hoses, fittings,
components or refrigerant oils.
Use only John Deere approved R134a refrigerant products. Mixing of products not compatible will cause
system damage and contaminate recovery, recycling and charging station equipment. Care must be
taken to identify and use equipment, refrigerant oil and refrigerant designed only for R134a refrigerant
systems. Refrigerant should be tested for type and purity before recovery, recycling or charging of
system. JT02167A refrigerant test instrument should be used before any testing or repair to system is
performed.
Prism Pro Refrigerant Identification Instrument

JT02167A
To safely identify type and check purity of refrigerant prior to recovery, recycling, and recharging of air conditioning systems.
R134a Refrigerant Cautions

Specifications
SPECIFICATIONS
52°C
R134a Refrigerant in a Closed Container—Temperature (maximum)
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.
R134a Refrigerant in a Closed Container Temperature (maximum) 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.
R134a Oil Charge Capacity

System (total) Capacity 363 mL
12.3 fl oz.
Compressor (precharge) Capacity 160 mL
5.4 fl oz.
R134a Refrigerant Charge Capacity

→NOTE:
Recommended specification charge includes additional 0.11 kg (0.25 lb) of R134a refrigerant remaining in
charge station hoses.
Refrigerant Charge (recommended) Capacity 2.5 kg
5.50 lb.
Refrigerant Charge (actual) Capacity 2.38 kg
5.25 lb.
Air Conditioner and Heater Operational Checks

Visual Inspection Of Components
( 1 ) Lines and Hoses Check
Action:
Inspect all lines and hoses.

sss:
Are all lines and hoses straight and in good condition, NOT kinked, worn from rubbing, or weather checked?
sss:
Are hose and line connections clean and NOT showing signs of leakage, such as dirt, oil, or refrigerant dye?
sss:
Are all hose and line clamps in place and tight, with cushions or rubber inserts in place to prevent crushing or scuffing hoses or
lines?
Result:

NO:Position hoses and lines as necessary. Replace, adjust, and tighten clamps as necessary. Note any hoses or lines that will
require replacement.
( 2 ) Air Conditioner Compressor Check
Action:
Inspect air conditioner compressor.

sss:
Is belt properly tensioned on pulley?
sss:
Is belt in good condition, NOT frayed, worn, or glazed?
sss:
Is belt tensioner in good condition, NOT worn or damaged?
sss:
Is compressor pulley in good condition, and properly aligned with belt drive pulley on engine?
sss:
Are compressor mounting brackets in good condition, and is mounting hardware properly tightened?
sss:
Are electrical connections to compressor clean and tight? Is wiring in good condition?
Result:

NO:Note any components that will require repair or replacement.
( 3 ) Condenser Check
Action:
Inspect condenser core.

sss:
Is core free of dirt and debris?
sss:
Is core NOT showing signs of leakage, such as dirt, oil, or refrigerant dye?
sss:
Are fins of core straight, NOT bent or damaged?
Result:

NO:Clean and straighten fins if necessary. Note any components that will require repair or replacement.
( 4 ) Engine Fan Check
Action:
Inspect engine fan.

sss:
Are fan blades in good condition, NOT worn, bent, broken, or missing?
sss:
Is fan securely installed?
Result:

NO:Note any components that will require repair or replacement.
( 5 ) Heater/Evaporator Core Check
Action:
Inspect heater/evaporator core.

sss:
Is core free of dirt and debris?
sss:
Is core NOT showing signs of leakage, such as dirt, oil, or refrigerant dye?
sss:
Are fins of core straight, NOT bent or damaged?
sss:
Is condensation drain tube attached and in good condition, NOT kinked, damaged, or clogged?
Result:

NO:Clean and straighten fins if necessary. Note any components that will require repair or replacement.
( 6 ) Cab Air Filter(s) Check
Action:
Inspect cab air filter(s).

sss:
Is filter(s) clean and free of debris?
Result:

NO:Replace cab air filter(s).
( 7 ) Cab Door and Windows Check
Action:
Open and close cab door and windows. Inspect seals.

sss:
Are seals present, properly installed, and in good condition?
sss:
Do door and windows contact seals evenly?
Result:
NO:Adjust door and windows if necessary. Replace components as necessary.
Air Conditioner Compressor Clutch Test

LEGEND:
3 Air Conditioner Compressor Clutch Solenoid Connector
Air Conditioner Compressor
[1] - Disconnect air conditioner compressor clutch solenoid 2-pin connector (3).
[2] - Apply 12 V to grey wire of air conditioner compressor clutch solenoid connector (3).
[3] - Apply ground to black wire of air conditioner compressor clutch solenoid connector.
[4] - If air conditioner compressor clutch solenoid “clicks”, check air conditioner compressor clutch harness (W39) wiring
harness. See Air Conditioner Compressor Clutch Harness (W39) Wiring Diagram . (Group 9015-10.)
If air conditioner compressor clutch solenoid does not “click”, check compressor harness.
Also, check air conditioner compressor clutch diode and air conditioner compressor clutch solenoid. See Electrical Component
Air Conditioner High/Low Pressure Switch Test

Specifications
SPECIFICATIONS
138—228 kPa
Switch Opens—Low Pressure 1.38—2.28 bar
20—33 psi
159—255 kPa
Switch Closes—Low Pressure 1.59—2.55 bar
23—37 psi
2620—2896 kPa
Switch Opens—High Pressure 26.2—28.96 bar
380—420 psi
1379—2068 kPa
Switch Closes—High Pressure 13.79—20.68 bar
200—300 psi
Essential Tools
ESSENTIAL TOOLS
JT02148 Straight Connector
Multimeter
→NOTE:
Air conditioner high/low pressure switch (B3) is normally open when removed from machine. When
installed the switch becomes closed due to normal system pressure.
Air Conditioner High/Low Pressure Switch

LEGEND:
1 Refrigerant Line
2 2-pin Connector
[1] - Push engine start switch once, but do not start engine.
[2] - Turn blower motor speed switch to ON position.
[3] - Turn temperature control switch to the maximum cooling position.
[4] - Disconnect 2-pin connector from air conditioner high/low pressure switch (B3). Compressor clutch must disengage (click).
[5] - Connect 2-pin connector to high/low pressure switch. Compressor clutch must engage (click).
[6] - Disconnect 2-pin connector from high/low pressure switch.
[7] -
→NOTE:
Refrigerant line (1) is equipped with a Schrader valve at the high/low pressure switch port to prevent
system from discharging when switch is removed.
Remove high/low pressure switch from refrigerant line (1).
[8] - Connect 2-pin connector to high/low pressure switch. Compressor clutch must not engage (click).
[9] - Connect high/low pressure switch to regulated air supply or dry nitrogen using JT02148 Straight Connector.
Straight Connector
JT02148
Switch Testing
[10] - Slowly apply pressure. High/low pressure switch must not have continuity between terminals until pressure increases to
switch closing (low) pressure specification.
Switch Closes Low Pressure 159—255 kPa
1.59—2.55 bar
23—37 psi
Multi-Meter
Used for measuring continuity.
[11] - Slowly release pressure. High/low pressure switch must have continuity until pressure decreases to switch opening (low)
pressure specification.
Switch Opens Low Pressure 138—228 kPa
1.38—2.28 bar
20—33 psi
[12] - Slowly increase pressure. High/low pressure switch must have continuity between terminals until pressure increases to
switch opening (high) pressure specification.
Switch Opens High Pressure 2620—2896 kPa
26.2—28.96 bar
380—420 psi
[13] - Slowly release pressure. High/low pressure switch must not have continuity until pressure decreases to switch closing
(high) pressure specification.
Switch Closes High Pressure 1379—2068 kPa
13.79—20.68 bar
200—300 psi
[14] -
→NOTE:
The air conditioner high/low pressure switch can also be checked when installed in air conditioning
system; however, pressure is slow to increase to test specification.
a. Connect an air conditioner gauge set to service fittings at compressor.

b. Cover condenser with paper or plastic to stop air flow.
c. Operate air conditioning on maximum cooling.

d. Note high-side pressure when high-pressure switch opens and then closes.
If switch does not operate within specifications, replace air conditioner high/low pressure switch.
Air Conditioner Freeze Control Switch Test

Specifications
SPECIFICATIONS
-1.7—0.5°C
Freeze Control Switch Opens—Temperature
29—33°F
2.8—5.0°C
Freeze Control Switch Closes—Temperature
37—41°F
Multimeter
Air Conditioner Freeze Control Switch (rear controls shown removed)
Air Conditioner Freeze Control Switch Connector
Air Conditioner Freeze Control Switch Test

LEGEND:
[1] - Remove air conditioner freeze control switch (B2) from evaporator. See Air Conditioner Freeze Control Switch Remove and
Install . (Group 1830.)
[2] - Apply 12 V to pin A and ground pin C on freeze control switch connector.
[3] - Using a voltmeter, measure voltage at Pin B; make sure negative lead is grounded. If temperature is above 5°C (41°F),
meter reading must be 12 V.
[4] - Place end of probe into ice and saltwater solution. When temperature cools to or below specification, freeze control switch
opens. Meter must read zero volts.
Freeze Control Switch Opens Temperature -1.7—0.5°C
29—33°F
[5] - Increase temperature of solution. When temperature rises to or above specification, freeze control switch closes. Meter
must read 12 V.
Freeze Control Switch Closes Temperature 2.8—5.0°C
37—41°F
[6] - If switch does not operate within specifications, replace freeze control switch.
R134a Air Conditioning System Test

Essential Tool
ESSENTIAL TOOL
JDG10555 R134a Refrigerant Recover, Recycle, and Charge Station
JT02167A Prism Pro Refrigerant Identification Instrument
Specifications
SPECIFICATIONS
[1] -
IMPORTANT:
Use correct refrigerant recovery, recycling, and charging stations. Do not mix refrigerant, hoses, fitting,
components or refrigerant oils to avoid air conditioning system damage.
Park machine on flat, level surface. Lower loader and backhoe attachments to ground, place machine in park, and stop engine.
[2] - Clean the cooling compartment top and rear access panels, and fins of hydraulic oil cooler, radiator, condenser, and
evaporator to ensure proper air flow.
[3] - Inspect the cab air filter. Replace if necessary. See Clean Cab Fresh Air and Recirculation Filters—If Equipped . (Operator’s
Manual.)
[4] - Follow refrigerant cautions and proper handling procedures. See Refrigerant Cautions and Proper Handling . (Group
9031-25.)
[5] - Identify refrigerant type using JT02167A Prism Pro Refrigerant Identification Instrument.
Prism Pro Refrigerant Identification Instrument
JT02167A
Identify type of refrigerant used in air conditioning system prior to recovery, recycling, and charging.
→NOTE:
Follow manufacturer′s instructions when operating refrigerant recovery, recycling, and charging station.
[6] - Connect JDG10555 R134a Refrigerant Recovery, Recycling, and Charging Station. See R134a Refrigerant Recover,
Recycle, and Charge Station Installation Procedure . (Group 1830.)
R134a Refrigerant Recover, Recycle, and Charge Station

JDG10555
Used to remove refrigerant from system.
[7] - Open both low and high pressure valves on refrigerant recovery, recycling, and charging station.
[8] -
→NOTE:
ECONOMY MODE must be set to OFF in primary display unit (PDU) to allow machine to reach standard fast
idle.
If equipped, disable ECONOMY MODE. See Engagement and Monitor Unit (EMU)—Main Menu—Setup—Economy Mode or see
Standard Display Monitor (SDM)—Main Menu—Setup—Economy Mode (If Equipped) . (Operator’s Manual.)
[9] - Start engine and run at specification.

[10] - Press air conditioner mode switch to air conditioner position.
[11] - Turn the temperature control dial to maximum cooling position (blue).
[12] - Turn blower motor speed switch to maximum position.
[13] - Open cab doors and windows.
[14] - Run system for at least 5 minutes.
[15] - Measure and record air temperatures at cab air filter inlet and at air ducts in cab. Compare to specifications.
Air Conditioner Air Inlet and Outlet Temperatures
Ambient Temperature Maximum Expected Air Temperature
27—29°C 11°C
81—85°F 53°F
30—32°C 13°C
86—90°F 56°F
33—35°C 14°C
92—95°F 58°F
36—38°C 16°C
97—101°F 60°F
39—40°C 17°C
102—104°F 63°F
41—43°C 20°C
106—110°F 68°F
[16] - Observe low-side and high-side pressure on gauges. Compare to specifications.
Low-Side and High-Side Pressure Readings
Ambient Air Temperature Low-Side Pressure High-Side Pressure
83—100 kPa 1164—1409 kPa

27—29°C
0.82—1.00 bar 11.64—14.09 bar
81—85°F
12—14 psi 169—204 psi
92—111 kPa 1313—1590 kPa

30—32°C
0.92—1.11 bar 13.13—15.90 bar
86—90°F
13—16 psi 190—231 psi
96—116 kPa 1382—1673 kPa

33—35°C
0.96—1.16 bar 13.82—16.73 bar
92—95°F
14—17 psi 200—243 psi
102—123 kPa 1487—1800 kPa

36—38°C
1.02—1.23 bar 14.87—18.00 bar
97—101°F
15—18 psi 216—261 psi
107—130 kPa 1586—1920 kPa

39—40°C
1.07—1.30 bar 15.86—19.20 bar
102—104°F
16—19 psi 230—278 psi
120—145 kPa 1742—2108 kPa

41—43°C
1.20—1.45 bar 17.42—21.08 bar
106—110°F
17—21 psi 253—306 psi
[17] - If measurements do not meet specifications, diagnose malfunction. See Operating Pressure Diagnostic Chart . (Group
9031-25.)
Operating Pressure Diagnostic Chart

Pressure Diagnostic Chart
Low Side High Side

Receiver- Discharge
Condition kPa (bar) kPa (bar) Sight Glass Suction Line Liquid Line Discharge Air
Dryer Line
(psi) (psi)
Lack of Refrigerant Very Low Very Low Clear Slightly Cool Slightly Warm Slightly Warm Slightly Warm Warm
Loss of Refrigerant Low Low Bubbles Cool Warm to Hot Warm Warm to Hot Slightly Cool
Cool,
Cool, Sweating Hot to Point of
High Side Restriction Low Low Clear Cool Sweating or Slightly Cool
or Frosting Restriction
Frosting
Cold, Sweating
or Frosting
Expansion Valve Closed Low Low Clear Warm Warm Hot Slightly Cool
Heavily at Valve
Outlet
Loose Belt or Compressor

High Low Clear Cool Warm Warm Warm Slightly Cool
Malfunction
Clear to
Slightly Cool to
Condenser Malfunction High High Occasional Hot Hot Hot Warm
Warm
Bubbles
Refrigerant Contaminated
High High Bubbles Warm to Hot Warm Warm Hot Warm
and Air in System
Cold, Sweating
Expansion Valve Open High High Clear or Frosting Warm Warm Hot Slightly Cool
Heavily
Plugged Condenser,
Normal High Clear Cool Warm Warm Hot Slightly Cool
Overcharge of Refrigerant
Normal (May Normal

Moisture in System Clear Cool Warm Warm Hot Cool to Warm
Drop) (May Drop)
Heater Valve Stuck Open Normal Normal Clear Cool Warm Warm Hot Warm
Lack of Refrigerant and Air Normal (No Occasional

Normal Warm to Hot Warm Warm Warm Slightly Cool
in System Drop) Bubbles
Expansion Valve Test

Essential Tool
ESSENTIAL TOOL
JDG10555 R134a Refrigerant Recover, Recycle, and Charge Station
Specifications
SPECIFICATIONS
IMPORTANT:
Use correct refrigerant recovery, recycling, and charging stations. Never mix refrigerants, hoses, fittings,
components or refrigerant oils. Mixing of products not compatible will cause system damage and
contaminate recovery, recycling and charging station equipment.
[1] - Connect JDG10555 R134a Refrigerant Recover, Recycle, and Charge Station. See R134a Refrigerant Recover, Recycle,
and Charge Station Installation Procedure . (Group 1830.)
R134a Refrigerant Recover, Recycle, and Charge Station
JDG10555
Used to remove refrigerant from system.
[2] -
Expansion Valve (seat shown removed)

LEGEND:
1 Expansion Valve
Warm diaphragm and valve body with appropriate warming device (heat gun, halogen lamp).
[3] -
→NOTE:
ECONOMY MODE must be set to OFF in primary display unit (PDU) to allow machine to reach standard fast
idle.
If equipped, disable ECONOMY MODE. See Engagement and Monitor Unit (EMU)—Machine Options or see Standard Display
Monitor (SDM)—Machine Options . (Group 9015-16.)
[4] - Start engine and operate at rated engine speed.
[5] - Turn blower motor speed switch to maximum position.
[6] - Turn temperature knob to maximum cooling position.
[7] - Activate air conditioning system.
[8] - Observe low side pressure. If pressure increases, valve is opening.
[9] -
→NOTE:
Any method of producing sub-zero cooling, not contributing to deterioration of the ozone layer, is
acceptable for this test.
Cool diaphragm and valve body with appropriate cooling device [ice pack, liquid nitrogen, any substance below 0°C (32°F)].
[10] - Observe low side pressure. If pressure decreases, valve is closing.
[11] - If expansion valve does not open and close as described, replace valve. See Expansion Valve Remove and Install .
(Group 1830.)
Blower Motor Speed Switch Test
Blower Switch Terminals
Multimeter
[1] - Disconnect 5-pin connector from blower motor speed switch (S42).
[2] - Move blower motor speed switch knob to each position 1—4, checking continuity between terminals for each position
according to table.
Multimeter
Used to measure continuity.
Continuity Check of Blower Motor Speed Switch
Position Continuity Between Terminals
0 Off —
1 Low B and 1
2 Medium B and 1, 2
3 High B and 1, 2, 3
4 Purge B and 1, 2, 3, 4
[3] - If continuity is not present between terminals indicated, replace blower motor speed switch.
Blower Motor Resistor Test

Multimeter
Blower Motor Speed Resistor Specifications
BLOWER MOTOR SPEED RESISTOR SPECIFICATIONS
Blower Motor Speed Resistor Resistance (between terminals 2 and 4) 0.65—0.75 ohm
[1] - Disconnect battery power.
[2] -
Blower Motor Speed Resistor
Blower Motor Speed Resistor Terminals

LEGEND:
1 Terminal 1
2 Terminal 2
3 Terminal 3
4 Terminal 4
Disconnect 4-pin connector from blower motor speed resistor (R10). See Cab Harness (W14) Wiring Diagram . (Group 9015-10.)
[3] -
Multimeter
Used to measure resistance.
Using a multimeter, measure resistance between the following terminals:
Terminals 2 and 4
Terminals 1 and 2
Terminals 2 and 3
Compare resistance to specifications.

Resistance (between terminals 1 and 2) 0.25—0.32 ohm
Resistance (between terminals 2 and 3) 0.13—0.17 ohm
If resistance doe not meet specification, replace blower motor speed resistor.
Blower Motor Test

LEGEND:
1 Pin 1
2 Pin 2
3 Blower Motor Connector
M10 Blower Motor
Blower Motor
Blower Motor Connector
[1] - Disconnect 2-pin connector (1) from blower motor (M10).
[2] - Apply 12 V to red wire in pin 2 of blower motor lead connector.
[3] - Apply ground to black wire in pin 1 of blower motor lead connector.
[4] - If blower motor does not operate, replace blower motor. See Evaporator or Heater Core Remove and Install . (Group
1830.)
Air Conditioning Mode Switch Test

Multimeter
Air Conditioner Mode Switch

LEGEND:
1 Terminal 1
2 Terminal 2
3 Terminal 3
4 Terminal 4
5 Terminal 5
6 Terminal 6
Air Conditioner Mode Switch Test (S.N. —256801)
[1] - Disconnect 10-pin connector from air conditioner mode switch (S9).
[2] - Press switch to defrost position. Using a multimeter, check for continuity between following terminals:
Multimeter
Between terminals 2 and 3.

[3] - Press switch to heater position. Check for continuity between following terminals:
[4] - Press switch to air conditioner position. Check for continuity between following terminals:

[5] - If continuity is not present between terminals indicated, replace air conditioner mode switch.
Air Conditioner Mode Switch Test (S.N. 256802— )
[1] - Disconnect 10-pin connector from air conditioner mode switch (S9).
[2] - Press switch to defrost position. Using a multimeter, check for continuity between following terminals:
Multimeter

[3] - Press switch to air conditioner position. Check for continuity between following terminals:
[4] - If continuity is not present between terminals indicated, replace air conditioner mode switch.
Air Conditioning System Leak Test

Specifications
SPECIFICATIONS
25 mm per second
Move Leak Detector Speed
1 in. per second
Inspect all lines, fittings, and components for oily or dusty spots. When refrigerant leaks from system, a small amount of oil is
carried out with it.
A soap and water solution can be sprayed on components in system to form bubbles at source of leak.
If leak detector is used, move leak detector probe under hoses and around connections at rate of 25 mm (1 in.) per second.
Move Leak Detector Speed 25 mm per second
1 in. per second
Some refrigerant manufacturers add dye to refrigerant to aid in leak detection.

Repair or replace components as necessary to correct identified leaks.
Refrigerant Hoses and Tubing Inspection

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.
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.
IMPORTANT:
Chlorinated solvents (such as trichloroethylene) are contaminants, and must not be used for cleaning.
The use of these solvents will cause deterioration of hoses.
Fittings that have grease or dirt on them should be wiped clean with a cloth dampened with alcohol.
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.

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315SK Backhoe Loader

OPERATION AND TEST MANUAL

Backhoe Loaders (T3/S3A) models 315SK (PIN: 1T0315SK**D229820-;

TM12471 27 DEC 15 (ENGLISH)

For complete service information also see:

John Deere Construction and Forestry

<- Go to Global Table of contents 315SK Backhoe Loader Diagnostic

<- Go to Global Table of contents 315SK Backhoe Loader Diagnostic

Manual Identiﬁcation—READ THIS FIRST!

Choosing the Correct Supporting Manuals

PIN Plate Location

Example of PIN Plate

<- Go to Global Table of contents 315SK Backhoe Loader Diagnostic

PIN Identiﬁcation Table

17 Digit PIN Example

(3) (4) (5) (4) (6) (7) (8) (9)

(3)—World Code —Identiﬁes location where machine is manufactured.

1T0 .......... World Code (manufacturing location)

1DW .......... Davenport Works

1T8 .......... Thibodaux Works

1T0 .......... Dubuque Works

315_K .......... Machine Model Identiﬁer

S .......... Machine Option Code

X .......... Base Machine

S .......... Super Duty

E .......... Easy Power (EP)

T .......... Total Machine Control (TMC) Conﬁguration

_ .......... Check Letter (variable)

_ .......... Manufacturing Year Code (variable)

C .......... Engine Emission Code

C .......... Tier 2 and Stage II

D .......... Tier 3 and Stage III A

E .......... Interim Tier 4 and Stage III B

G .......... Interim Tier 4 and Stage III A (19-56 kW)

219607 .......... Machine Serial Number

Section 9000 - GENERAL INFORMATION

<- Go to Global Table of contents 315SK Backhoe Loader Diagnostic

Safety alert Symbols

Safety Alert Symbols

Follow Safety Instructions

Operate Only If Qualiﬁed

Wear Protective Equipment

Avoid Unauthorized Machine Modiﬁcations

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

Stay Clear of Moving Parts

Stay Clear of Moving Parts

Entanglements in moving parts can cause serious injury.

Avoid High-Pressure Oils

Avoid High Pressure Oils

Avoid High-Pressure Oils

Avoid High-Pressure Fluids

Work In Ventilated Area

Engine exhaust fumes

Handle Fuel Safely

Clean Machine Regularly

Carry A Fire Extinguisher

Prevent Battery Explosions

Handle Chemical Products Safely

Material Safety Data Sheet

Decommissioning: Proper Recycling and Disposal of Fluids and

Prepare for Emergencies

First Aid Kit

Be prepared if a ﬁre starts.