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John Deere 644K 4WD Loader Operation & Test Technical Manual TM13052X19 – PDF DOWNLOAD
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John Deere 644K 4WD Loader Operation & Test Technical Manual TM13052X19 – PDF DOWNLOAD
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Description
John Deere 644K 4WD Loader Operation & Test Technical Manual TM13052X19 – PDF DOWNLOAD
FILE DETAILS:
John Deere 644K 4WD Loader Operation & Test Technical Manual TM13052X19 – PDF DOWNLOAD
Language : English
Pages : 1516
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere 644K 4WD Loader Operation & Test Technical Manual TM13052X19 – PDF DOWNLOAD
- READ THIS MANUAL carefully to learn how to operate and service your machine correctly. Failure to do so could result in personal injury or equipment damage. This manual and safety signs on your machine may also be available in other languages. (See your John Deere dealer to order.)
- THIS MANUAL SHOULD BE CONSIDERED a permanent part of your machine and should remain with the machine when you sell it.
- MEASUREMENTS in this manual are given in both metric and customary U.S. unit equivalents. Use only correct replacement parts and fasteners. Metric and inch fasteners may require a specific metric or inch wrench.
- RIGHT-HAND AND LEFT-HAND sides are determined by facing in the direction of forward travel.
- WRITE PRODUCT IDENTIFICATION NUMBERS (P.I.N.) in the Machine Numbers section. Accurately record all the numbers to help in tracing the machine should it be stolen. Your dealer also needs these numbers when you order parts. File the identification numbers in a secure place off the machine.
- WARRANTY is provided as part of John Deere’s support program for customers who operate and maintain their equipment as described in this manual. The warranty is explained on the warranty certificate or statement which you should have received from your dealer.
TABLE OF CONTENTS:
John Deere 644K 4WD Loader Operation & Test Technical Manual TM13052X19 – PDF DOWNLOAD
Contents........................................................................................................................ 5 General Information......................................................................................................... 7 Safety.................................................................................................................. 9 Information for European Union Directives and Eurasian Economic Union Technical Regulations Compliance.............. 9 Recognize Safety Information........................................................................................ 10 Follow Safety Instructions.......................................................................................... 11 Operate Only If Qualified........................................................................................... 11 Wear Protective Equipment........................................................................................... 11 Avoid Unauthorized Machine Modifications............................................................................ 12 Inspect Machine..................................................................................................... 12 Stay Clear of Moving Parts.......................................................................................... 12 Avoid High-Pressure Fluids.......................................................................................... 13 Avoid High-Pressure Oils............................................................................................ 13 Work In Ventilated Area............................................................................................. 14 Avoid Static Electricity Risk When Refueling........................................................................ 14 Prevent Fires....................................................................................................... 15 In Case of Machine Fire............................................................................................. 15 Prevent Battery Explosions.......................................................................................... 16 High Debris Applications............................................................................................ 16 Clean Debris from Machine........................................................................................... 16 Handle Chemical Products Safely..................................................................................... 17 Handle Starting Fluid Safely........................................................................................ 17 Decommissioning — Proper Recycling and Disposal of Fluids and Components............................................ 18 Exhaust Filter Ash Handling and Disposal............................................................................ 18 Prepare for Emergencies............................................................................................. 18 Add Cab Guarding for Special Uses................................................................................... 19 Use Steps and Handholds Correctly................................................................................... 19 Start Only From Operator's Seat..................................................................................... 19 Use and Maintain Seat Belt.......................................................................................... 19 Prevent Unintended Machine Movement................................................................................. 20 Avoid Work Site Hazards............................................................................................. 21 Avoid Power Lines................................................................................................... 21 Use Special Care When Operating Loader.............................................................................. 22 Keep Riders Off Machine............................................................................................. 22 Avoid Backover Accidents............................................................................................ 22 Avoid Machine Tip Over.............................................................................................. 23 Operating on Slopes................................................................................................. 23 Operating or Traveling On Public Roads.............................................................................. 24 Inspect and Maintain ROPS........................................................................................... 24 Travel Safely....................................................................................................... 24 Prevent Acid Burns.................................................................................................. 25 Add and Operate Attachments Safely.................................................................................. 25 Park and Prepare for Service Safely................................................................................. 26 Service Machines Safely............................................................................................. 26 Clean Exhaust Filter Safely......................................................................................... 27 Service Cooling System Safely....................................................................................... 28 Service Tires Safely................................................................................................ 28 Use Proper Lifting Equipment........................................................................................ 29 Remove Paint Before Welding or Heating.............................................................................. 29 Make Welding Repairs Safely......................................................................................... 29 Drive Metal Pins Safely............................................................................................. 30 Diagnostics................................................................................................................. 49 Engine Control Unit (ECU) Diagnostic Trouble Codes...................................................................... 51 Engine Control Unit (ECU) Diagnostic Trouble Codes.................................................................. 51 000091.03 — Accelerator Pedal Short to Power........................................................................ 52 000091.04 — Accelerator Pedal Open or Short......................................................................... 53 000091.14 — Accelerator Pedal Sensor Invalid........................................................................ 53 000111.01 — Coolant Level Extremely Low............................................................................. 54 000111.07 — Coolant Out of Range.................................................................................... 56 000111.18 — Coolant Level Very Low.................................................................................. 57 000168.01 — Battery Voltage Extremely Low........................................................................... 59 000168.16 — Battery Voltage Very High............................................................................... 60 000168.17 — Battery Voltage Low.................................................................................... 61 000168.18 — Battery Voltage Very Low................................................................................ 62 000237.02 — Vehicle Identification Conflict......................................................................... 63 000237.13 — Vehicle Identification Fault............................................................................ 63 000237.31 — Invalid Vehicle Identification Number (VIN)............................................................. 63 001321.05 — Starter Relay Open Circuit.............................................................................. 64 Starter Relay Open Circuit Diagnostic Procedure................................................................. 64 001321.06 — Starter Relay High Current.............................................................................. 65 Starter Relay High Current Diagnostic Procedure................................................................. 65 001321.09 — Starter Signal Invalid.................................................................................. 66 Starter Signal Invalid Diagnostic Procedure..................................................................... 66 001321.16 — Too Long to Start....................................................................................... 68 Too Long to Start Diagnostic Procedure.......................................................................... 68 001761.01 — Diesel Exhaust Fluid is Extremely Low................................................................... 69 001761.18 — Diesel Exhaust Fluid is Very Low........................................................................ 69 002003.09 — Controller Area Network (CAN) Communication Lost For Transmission Control Unit (TCU).................... 69 Controller Area Network (CAN) Communication Lost For Transmission Control Unit (TCU) Diagnostic Procedure....... 69 002033.09 — Controller Area Network (CAN) Communication Lost For Vehicle Control Unit (VCU)......................... 71 Controller Area Network (CAN) Communication Lost For Vehicle Control Unit (VCU) Diagnostic Procedure............ 71 003031.12 — Diesel Exhaust Fluid Temperature Sensor Fault........................................................... 73 003353.31 — Alternator Excitation Condition Exists.................................................................. 73 Alternator Excitation Condition Exists Diagnostic Procedure..................................................... 73 003516.01 — Diesel Exhaust Fluid Concentration is Low............................................................... 75 003516.09 — Diesel Exhaust Fluid Tank Header Communication Fault.................................................... 75 003516.12 — Diesel Exhaust Fluid Tank Quality Sensor Fault.......................................................... 76 003516.14 — Improper Fluid in Diesel Exhaust Fluid Tank............................................................. 76 003516.16 — Diesel Exhaust Fluid Concentration is High.............................................................. 76 003517.12 — Diesel Exhaust Fluid Tank Level Sensor Fault............................................................ 77 003587.05 — Ether Solenoid Open or Short............................................................................ 77 Ether Solenoid Open or Short Diagnostic Procedure............................................................... 77 003587.06 — Ether Solenoid Shorted to Ground........................................................................ 78 Ether Solenoid Shorted to Ground Diagnostic Procedure........................................................... 78 Transmission Control Unit (TCU) Diagnostic Trouble Codes................................................................ 81 Transmission Control Unit (TCU) Diagnostic Trouble Codes............................................................ 81 000091.09 — Timeout EEC2 Message.................................................................................... 81 Timeout EEC2 Message Diagnostic Procedure....................................................................... 81 000161.00 — Engine Speed Extremely High............................................................................. 82 000513.02 — Percent Torque Invalid.................................................................................. 82 Percent Torque Invalid Diagnostic Procedure..................................................................... 82 000513.09 — Timeout EEC1 Message.................................................................................... 83 Timeout EEC1 Message Diagnostic Procedure....................................................................... 83 000514.02 — Friction Invalid........................................................................................ 84 Friction Invalid Diagnostic Procedure........................................................................... 84 000514.09 — Timeout EEC3 Message.................................................................................... 85 Time out EEC3 Message Diagnostic Procedure...................................................................... 85 000544.02 — Reference Torque Invalid................................................................................ 86 Reference Torque Invalid Diagnostic Procedure................................................................... 86 000544.09 — Timeout Engine Configuration Message.................................................................... 87 Timeout Engine Configuration Message Diagnostic Procedure....................................................... 87 000777.02 — Torque Converter Clutch Slippage........................................................................ 88 Torque Converter Clutch Slippage Diagnostic Procedure........................................................... 88 000777.03 — Torque Converter Lockup Solenoid Short to Power......................................................... 90 Torque Converter Lockup Solenoid Short to Power Diagnostic Procedure............................................ 90 000777.04 — Torque Converter Lockup Solenoid Short to Ground........................................................ 91 Torque Converter Lockup Solenoid Short to Ground Diagnostic Procedure........................................... 91 000777.05 — Torque Converter Lockup Solenoid Open Circuit........................................................... 92 Torque Converter Lockup Solenoid Open Circuit Diagnostic Procedure.............................................. 92 000928.03 — Axle Disconnect Solenoid Short to Power................................................................. 93 Axle Disconnect Solenoid Short to Power Diagnostic Procedure.................................................... 93 000928.04 — Axle Disconnect Solenoid High Current................................................................... 94 Axle Disconnect Solenoid High Current Diagnostic Procedure...................................................... 94 000928.05 — Axle Disconnect Solenoid Open Circuit................................................................... 96 Axle Disconnect Solenoid Open Circuit Diagnostic Procedure...................................................... 96 001785.09 — Engine Speed Limit Function Does Not Work Properly...................................................... 97 002033.09 — Controller Area Network (CAN) Communication Lost for Vehicle Control Unit (VCU)......................... 97 Controller Area Network (CAN) Communication Lost for Vehicle Control Unit (VCU) Diagnostic Procedure............ 97 002141.09 — Controller Area Network (CAN) Communication Lost for Sealed Switch Module (SSM)......................... 99 Controller Area network (CAN) Communication Lost for Sealed Switch Module (SSM) Diagnostic Procedure............ 99 004201.03 — Converter Input Speed Sensor Open or Short.............................................................. 101 004201.04 — Converter Input Speed Sensor Short to Ground............................................................ 102 004201.12 — Converter Input Speed Sensor Fault...................................................................... 103 522344.00 — Torque Converter Overtemperature........................................................................ 103 Torque Converter Overtemperature Diagnostic Procedure........................................................... 103 522350.15 — Transmission Input Torque Overload...................................................................... 104 Transmission Input Torque Overload Diagnostic Procedure......................................................... 104 522364.07 — Transmission Clutch Calibration Failed.................................................................. 105 Transmission Clutch Calibration Failed Diagnostic Procedure..................................................... 105 522364.13 — Transmission Clutch Calibration Fault................................................................... 106 Transmission Clutch Calibration Fault Diagnostic Procedure...................................................... 106 522365.13 — Limp Home Mode.......................................................................................... 107 Limp Home Mode Diagnostic Procedure............................................................................. 107 522366.13 — Application Invalid..................................................................................... 107 Application Invalid Diagnostic Procedure........................................................................ 108 522367.13 — Transmission Control Unit (TCU) Configuration Invalid................................................... 108 Transmission Control Unit (TCU) Configuration Invalid Diagnostic Procedure...................................... 108 522368.02 — Transmission Control Unit (TCU) Memory Failure.......................................................... 109 TCU Memory Failure Diagnostic Procedure......................................................................... 109 522369.03 — Remote Display Short to Power........................................................................... 110 Remote Display Short to Power Diagnostic Procedure.............................................................. 110 522370.02 — Transmission Control Unit (TCU) Valve Power Supply 2 Short Circuit...................................... 111 Transmission Control Unit (TCU) Valve Power Supply 2 Short Circuit Diagnostic Procedure......................... 111 522371.02 — Transmission Control Unit (TCU) Valve Power Supply 1 Short Circuit...................................... 112 Transmission Control Unit (TCU) Valve Power Supply 1 Short Circuit Diagnostic Procedure......................... 113 522373.03 — Power Supply High Voltage............................................................................... 113 Power Supply High Voltage Diagnostic Procedure.................................................................. 113 522373.04 — Power Supply Low Voltage................................................................................ 114 Power Supply Low Voltage Diagnostic Procedure................................................................... 114 522374.03 — Sensor Supply Short to Power............................................................................ 115 Sensor Supply Short to Power Diagnostic Procedure............................................................... 115 522374.04 — Sensor Supply Short to Ground........................................................................... 116 Sensor Supply Short to Ground Diagnostic Procedure.............................................................. 116 522375.00 — Transmission Oil Filter Restricted...................................................................... 117 Transmission Oil Filter Restricted Diagnostic Procedure......................................................... 118 522376.00 — Transmission Oil Temperature Over Maximum Value......................................................... 119 Transmission Oil Temperature Over Maximum Value Diagnostic Procedure............................................ 119 522379.03 — Park Brake Solenoid Short to Power...................................................................... 120 Park Brake Solenoid Short to Power Diagnostic Procedure......................................................... 120 522379.04 — Park Brake Solenoid Short to Ground..................................................................... 121 Park Brake Solenoid Short to Ground Diagnostic Procedure........................................................ 121 522379.05 — Park Brake Solenoid Open Circuit........................................................................ 122 Park Brake Solenoid Open Circuit Diagnostic Procedure........................................................... 122 522382.03 — Backup Alarm Short to Power............................................................................. 123 Backup Alarm Short to Power Diagnostic Procedure................................................................ 123 522382.04 — Backup Alarm Short to Ground............................................................................ 124 Backup Alarm Short to Ground Diagnostic Procedure............................................................... 124 522383.02 — Transmission Clutch KR Slippage......................................................................... 126 Transmission Clutch KR Slippage Diagnostic Procedure............................................................ 126 522383.03 — Transmission Clutch Reverse Solenoid Short to Power..................................................... 128 Transmission Clutch Reverse Solenoid Short to Power Diagnostic Procedure........................................ 128 522383.04 — Transmission Clutch Reverse Solenoid Short to Ground.................................................... 129 Transmission Clutch Reverse Solenoid Short to Ground Diagnostic Procedure....................................... 129 522383.05 — Transmission Clutch Reverse Solenoid Open Circuit....................................................... 131 Transmission Clutch Reverse Solenoid Open Circuit Diagnostic Procedure.......................................... 131 522386.02 — Transmission Clutch KV Slippage......................................................................... 132 Transmission Clutch KV Slippage Diagnostic Procedure............................................................ 132 522386.03 — Transmission Clutch Forward Solenoid Short to Power..................................................... 134 Transmission Clutch Forward Solenoid Short to Power Diagnostic Procedure........................................ 134 522386.04 — Transmission Clutch Forward Solenoid Short to Ground.................................................... 136 Transmission Clutch Forward Solenoid Short to Ground Diagnostic Procedure....................................... 136 522386.05 — Transmission Clutch Forward Solenoid Open Circuit....................................................... 137 Transmission Clutch Forward Solenoid Open Circuit Diagnostic Procedure.......................................... 137 522389.02 — Transmission Clutch K4 Slippage......................................................................... 139 Transmission Clutch K4 Slippage Diagnostic Procedure............................................................ 139 522389.03 — Transmission Clutch K4 Solenoid Short to Power.......................................................... 140 Transmission Clutch K4 Solenoid Short to Power Diagnostic Procedure............................................. 141 522389.04 — Transmission Clutch K4 Solenoid Short to Ground......................................................... 142 Transmission Clutch K4 Solenoid Short to Ground Diagnostic Procedure............................................ 142 522389.05 — Transmission Clutch K4 Solenoid Open Circuit............................................................ 144 Transmission Clutch K4 Solenoid Open Circuit Diagnostic Procedure............................................... 144 522392.02 — Transmission Clutch K3 Slippage......................................................................... 145 Transmission Clutch K3 Slippage Diagnostic Procedure............................................................ 145 522392.03 — Transmission Clutch K3 Solenoid Short to Power.......................................................... 147 Transmission Clutch K3 Solenoid Short to Power Diagnostic Procedure............................................. 147 522392.04 — Transmission Clutch K3 Solenoid Short to Ground......................................................... 148 Transmission Clutch K3 Solenoid Short to Ground Diagnostic Procedure............................................ 148 522392.05 — Transmission Clutch K3 Solenoid Open Circuit............................................................ 150 Transmission Clutch K3 Solenoid Open Circuit Diagnostic Procedure............................................... 150 522395.02 — Transmission Clutch K2 Slippage......................................................................... 151 Transmission Clutch K2 Slippage Diagnostic Procedure............................................................ 151 522395.03 — Transmission Clutch K2 Solenoid Short to Power.......................................................... 153 Transmission Clutch K2 Solenoid Short to Power Diagnostic Procedure............................................. 153 522395.04 — Transmission Clutch K2 Solenoid Short to Ground......................................................... 154 Transmission Clutch K2 Solenoid Short to Ground Diagnostic Procedure............................................ 154 522395.05 — Transmission Clutch K2 Solenoid Open Circuit............................................................ 156 Transmission Clutch K2 Solenoid Open Circuit Diagnostic Procedure............................................... 156 522399.02 — Transmission Clutch K1 Slippage......................................................................... 157 Transmission Clutch K1 Slippage Diagnostic Procedure............................................................ 157 522399.03 — Transmission Clutch K1 Solenoid Short to Power.......................................................... 159 Transmission Clutch K1 Solenoid Short to Power Diagnostic Procedure............................................. 159 522399.04 — Transmission Clutch K1 Solenoid Short to Ground......................................................... 160 Transmission Clutch K1 Solenoid Short to Ground Diagnostic Procedure............................................ 160 522399.05 — Transmission Clutch K1 Solenoid Open Circuit............................................................ 162 Transmission Clutch K1 Solenoid Open Circuit Diagnostic Procedure............................................... 162 522401.02 — Transmission Output Shaft Speed Sensor Fault............................................................ 163 Transmission Output Shaft Speed Sensor Fault Diagnostic Procedure............................................... 163 522401.03 — Transmission Output Shaft Open or Short to Power........................................................ 164 Transmission Output Shaft Open or Short to Power Diagnostic Procedure........................................... 164 522401.04 — Transmission Output Shaft Short to Ground............................................................... 166 Transmission Output Shaft Short to Ground Diagnostic Procedure.................................................. 167 522401.12 — Transmission Output Shaft Fault......................................................................... 168 Transmission Output Shaft Fault Diagnostic Procedure............................................................ 168 522401.15 — Transmission Output Shaft Overspeed..................................................................... 169 Transmission Output Shaft Overspeed Diagnostic Procedure........................................................ 169 522402.03 — Clutch Speed Sensor Open or Short....................................................................... 170 Transmission Clutch Speed Sensor Open or Short Diagnostic Procedure............................................. 170 522402.04 — Transmission Clutch Speed Sensor Short to Ground........................................................ 171 Transmission Clutch Speed Sensor Short to Ground Diagnostic Procedure........................................... 171 522402.12 — Transmission Clutch Speed Sensor Fault.................................................................. 172 Transmission Clutch Speed Sensor Fault Diagnostic Procedure..................................................... 173 522403.03 — Torque Converter Output Speed Sensor Open or Short to Power............................................. 173 Torque Converter Output Speed Sensor Open or Short to Power Diagnostic Procedure................................ 173 522403.04 — Torque Converter Output Speed Sensor Short to Ground.................................................... 175 Torque Converter Output Speed Sensor Short to Ground Diagnostic Procedure....................................... 175 522403.12 — Torque Converter Output Speed Sensor Fault.............................................................. 176 Torque Converter Output Speed Sensor Fault Diagnostic Procedure................................................. 176 522404.03 — Torque Converter Input Speed Sensor Open or Short to Power.............................................. 177 Torque Converter Input Speed Sensor Open or Short to Power Diagnostic Procedure................................. 177 522404.04 — Torque Converter Input Speed Sensor Short to Ground..................................................... 179 Torque Converter Input Speed Sensor Short to Ground Diagnostic Procedure........................................ 179 522404.12 — Torque Converter Input Speed Fault...................................................................... 180 Torque Converter Input Speed Sensor Fault Diagnostic Procedure.................................................. 180 522406.03 — Transmission Oil Temperature Sensor Open or Short to Power.............................................. 181 Transmission Oil Temperature Sensor Open or Short to Power Diagnostic Procedure................................. 181 522406.04 — Transmission Oil Temperature Sensor Short to Ground..................................................... 183 Transmission Oil Temperature Sensor Short to Ground Diagnostic Procedure........................................ 183 522407.03 — Transmission Clutch Cut-Off Sensor Short to Power....................................................... 185 Transmission Clutch Cut-Off Sensor Short to Power Diagnostic Procedure.......................................... 185 522407.04 — Transmission Clutch Cut-Off Sensor Open or Short to Ground.............................................. 185 Transmission Clutch Cut-Off Sensor Open or Short to Ground Diagnostic Procedure................................. 186 522409.05 — 2nd FNR (Pilot Control Joystick FNR) Open Circuit....................................................... 188 2nd FNR (Pilot Control Joystick FNR) Open Circuit Diagnostic Procedure.......................................... 188 2nd FNR (Pilot Control Joystick FNR) Open Circuit Diagnostic Procedure.......................................... 189 522409.12 — 2nd FNR (Pilot Control Joystick FNR) Multiple Inputs.................................................... 190 2nd FNR (Pilot Control Joystick FNR) Multiple Inputs Diagnostic Procedure....................................... 190 2nd FNR Multiple Inputs Diagnostic Procedure (Joystick Steering FNR)............................................ 192 522411.05 — 1st FNR Open Circuit.................................................................................... 194 1st FNR (Steering Column FNR) Open Circuit Diagnostic Procedure................................................. 194 1st FNR (Pilot Control Joystick FNR) Open Circuit Diagnostic Procedure.......................................... 195 522411.12 — 1st FNR Multiple Inputs................................................................................. 196 1st FNR (Steering Column FNR) Multiple Inputs Diagnostic Procedure.............................................. 196 1st FNR Multiple Inputs (Pilot Control Joystick FNR) Diagnostic Procedure....................................... 197 522412.12 — Gear Selection Error.................................................................................... 199 Gear Selection Error Diagnostic Procedure....................................................................... 199 522419.02 — Transmission Clutch Cut-Off Disabled.................................................................... 201 Clutch Cut-off Disabled Diagnostic Procedure.................................................................... 201 522420.02 — Manual Down Shift Disabled.............................................................................. 202 Manual Downshift Disabled Diagnostic Procedure.................................................................. 202 522421.02 — Automatic to 1st Disabled............................................................................... 203 Automatic to 1st Disabled Diagnostic Procedure.................................................................. 203 524048.00 — Transmission Output Torque Exceeded..................................................................... 203 Transmission Output Torque Exceeded Diagnostic Procedure........................................................ 203 524049.00 — Transmission Input Torque Exceeded...................................................................... 204 Transmission Input Torque Exceeded Diagnostic Procedure......................................................... 204 524287.00 — Configure Machine Model................................................................................. 204 Configure Machine Model Diagnostic Procedure.................................................................... 204 524287.02 — Communication Error..................................................................................... 205 Vehicle Control Unit (VCU) Diagnostic Trouble Codes..................................................................... 207 Vehicle Control Unit (VCU) Diagnostic Trouble Codes................................................................. 207 000075.00 — Front Axle Oil High Temperature......................................................................... 207 Front Axle Oil High Temperature Diagnostic Procedure............................................................ 207 000075.04 — Front Axle Oil Temp Sensor Short to Ground.............................................................. 208 Front Axle Oil Temp Sensor Short to Ground Diagnostic Procedure................................................. 208 000096.04 — Fuel Level Short to Ground.............................................................................. 209 Fuel Level Short to Ground Diagnostic Procedure................................................................. 209 000096.05 — Fuel Level Open or Short................................................................................ 210 Fuel Level Open or Short Diagnostic Procedure................................................................... 210 000167.16 — Alternator High Voltage................................................................................. 212 Alternator High Voltage Diagnostic Procedure.................................................................... 212 000167.18 — Alternator Low Voltage.................................................................................. 212 Alternator Low Voltage Diagnostic Procedure..................................................................... 213 000168.16 — High Battery Voltage.................................................................................... 213 High Battery Voltage Diagnostic Procedure....................................................................... 213 000171.04 — Ambient Air Short to Ground............................................................................. 215 000234.02 — Invalid Transmission Control Unit (TCU) Software Revision............................................... 215 Invalid TCU Software Revision Diagnostic Procedure.............................................................. 215 000237.02 — Vehicle Identification Number (VIN) Messages Mismatch................................................... 216 000237.13 — Vehicle Identification Number (VIN) Options Not Learned................................................. 216 000237.31 — Vehicle Identification Number (VIN) Messages Null or Missing............................................ 217 000444.18 — Battery Voltage Imbalance............................................................................... 217 Battery Voltage Imbalance Diagnostic Procedure.................................................................. 217 000521.00 — Brake Pedal High Voltage................................................................................ 218 Brake Pedal High Voltage Diagnostic Procedure................................................................... 218 000578.00 — Rear Axle Oil High Temperature.......................................................................... 218 Rear Axle Oil High Temperature Diagnostic Procedure............................................................. 219 000578.04 — Rear Axle Oil Temp Sensor Short to Ground............................................................... 219 Rear Axle Oil Temp Sensor Short to Ground Diagnostic Procedure.................................................. 219 000628.12 — Controller Not Programmed............................................................................... 221 Controller Not Programmed Diagnostic Procedure.................................................................. 221 000629.12 — Vehicle Control Unit (VCU) Watchdog Time Out............................................................ 221 Vehicle Control Unit (VCU) Watchdog Time Out Diagnostic Procedure............................................... 221 000639.12 — Vehicle Control Unit (VCU) Controller Area Network (CAN) Failure........................................ 222 Vehicle Control Unit (VCU) Controller Area Network (CAN) Failure Diagnostic Procedure........................... 222 000639.14 — Vehicle Control Unit (VCU) Controller Area Network (CAN) 1 Bus Off...................................... 222 Vehicle Control Unit (VCU) Controller Area Network (CAN) 1 Bus Off Diagnostic Procedure......................... 222 000746.03 — Differential Lock Solenoid Short to Power............................................................... 223 Differential Lock Solenoid Short to Power Diagnostic Procedure.................................................. 223 000746.05 — Differential Lock Solenoid Open......................................................................... 224 Differential Lock Solenoid Open Diagnostic Procedure............................................................ 224 000746.06 — Differential Lock Solenoid High Current................................................................. 226 Differential Lock Solenoid High Current Diagnostic Procedure.................................................... 226 000785.03 — Pilot Solenoid Short to Power........................................................................... 227 Pilot Solenoid Short to Power Diagnostic Procedure.............................................................. 227 000785.05 — Pilot Solenoid Open or Short............................................................................ 228 Pilot Solenoid Open or Shorted Diagnostic Procedure............................................................. 228 000785.06 — Pilot Solenoid High Current............................................................................. 230 Pilot Solenoid High Current Diagnostic Procedure................................................................ 230 000880.03 — Brake Lights Short to Power............................................................................. 232 Brake Lights Shorted to Power Diagnostic Procedure.............................................................. 232 000880.05 — Brake Lights Open or Short.............................................................................. 233 Brake Lights Open or Short Diagnostic Procedure................................................................. 233 000880.06 — Brake Lights High Current............................................................................... 234 Brake Lights High Current Diagnostic Procedure.................................................................. 234 000920.03 — Alarm Short to Power.................................................................................... 236 000920.05 — Alarm Open Circuit...................................................................................... 237 000920.06 — Alarm Short to Ground................................................................................... 238 000977.03 — Reversing Fan Solenoid Short to Power................................................................... 238 Reversing Fan Solenoid Short to Power Diagnostic Procedure...................................................... 238 000977.05 — Reversing Fan Solenoid Open or Short.................................................................... 239 Reversing Fan Solenoid Open or Short Diagnostic Procedure....................................................... 239 000977.06 — Reversing Fan Solenoid High Current..................................................................... 241 Reversng Fan Solenoid High Current Diagnostic Procedure......................................................... 241 001069.02 — Tire Size Incorrect..................................................................................... 242 Tire Size Incorrect Diagnostic Procedure........................................................................ 242 001071.03 — Proportional Fan Solenoid High Side (HS) Short to Power................................................. 243 Proportional Fan Solenoid High Side (HS) Short to Power Diagnostic Procedure.................................... 243 001071.05 — Proportional Fan Solenoid High Side (HS) Open or Short.................................................. 244 Proportional Fan Solenoid High Side (HS) Open or Short Diagnostic Procedure..................................... 244 001071.06 — Proportional Fan Solenoid High Side (HS) High Current................................................... 246 Proportional Fan Solenoid High Side (HS) High Current Diagnostic Procedure...................................... 246 001071.13 — Proportional Fan Solenoid Out of Calibration............................................................ 247 001071.16 — Proportional Fan Solenoid Low Side (LS) High Current.................................................... 247 Proportional Fan Solenoid Low Side (LS) High Current Diagnostic Procedure....................................... 247 001071.17 — Proportional Fan Solenoid Low Side (LS) Open or Short................................................... 249 Proportional Fan Solenoid Low Side (LS) Open or Short Diagnostic Procedure...................................... 249 001071.18 — Proportional Fan Solenoid Low Side (LS) Short to Power.................................................. 251 Proportional Fan Solenoid Low Side (LS) Short to Power Diagnostic Procedure..................................... 251 001231.12 — Vehicle Control Unit (VCU) Controller Area Network (CAN) 2 Failure...................................... 252 Vehicle Control Unit (VCU) Controller Area Network (CAN) 2 Failure Diagnostic Procedure......................... 252 001231.14 — Vehicle Control Unit (VCU) Controller Area Network (CAN) 2 Bus Off...................................... 253 Vehicle Control Unit (VCU) Controller Area Network (CAN) 2 Bus Off Diagnostic Procedure......................... 253 001503.04 — Arm Rest Down Switch Short to Ground.................................................................... 254 Arm Rest Down Switch Short to Ground Diagnostic Procedure....................................................... 254 001503.11 — Arm Rest Position Undetermined.......................................................................... 255 Arm Rest Position Undetermined Diagnostic Procedure............................................................. 255 001550.03 — Air Conditioner Clutch Short to Power................................................................... 258 Air Conditioner Clutch Short to Power Diagnostic Procedure...................................................... 258 001550.06 — Air Conditioner Clutch High Current..................................................................... 259 Air Conditioner Clutch High Current Diagnostic Procedure........................................................ 259 001565.04 — Arm Rest Up Switch Short to Ground...................................................................... 260 Arm Rest Up Switch Short to Ground Diagnostic Procedure......................................................... 260 001638.00 — Hydraulic Oil High Temperature.......................................................................... 261 Hydraulic Oil High Temperature Diagnostic Procedure............................................................. 262 001638.04 — Hydraulic Oil Temperature Short to Ground............................................................... 262 Hydraulic Oil Temperature Sensor Short to Ground Diagnostic Procedure........................................... 262 001639.02 — Fan Speed Sensor Out of Synchronization................................................................. 264 Fan Speed Sensor Out of Synchronization Diagnostic Procedure.................................................... 264 001639.04 — Fan Speed Sensor Short to Ground........................................................................ 265 Fan Speed Sensor Short to Ground Diagnostic Procedure........................................................... 265 001639.05 — Fan Speed Sensor Open Circuit........................................................................... 266 Fan Speed Sensor Open Circuit................................................................................... 266 001639.07 — Fan Speed Did Not Lower During Reversal................................................................. 268 001639.08 — Fan Speed Sensor No Signal.............................................................................. 269 Fan Speed Sensor No Signal Diagnostic Procedure................................................................. 269 001639.10 — Fan Speed Sensor Fault.................................................................................. 270 Fan Speed Sensor Fault Diagnostic Procedure..................................................................... 270 001639.13 — Fan Speed Sensor Out of Calibration..................................................................... 271 001713.01 — Hydraulic Oil Filter Restricted......................................................................... 271 Hydraulic Oil Filter Restricted Diagnostic Procedure............................................................ 271 001762.03 — Hydraulic Pressure Sensor Short to Power................................................................ 272 Hydraulic Pressure Sensor Short to Power Diagnostic Procedure................................................... 272 001762.04 — Hydraulic Pressure Sensor Open or Short................................................................. 273 Hydraulic Pressure Sensor Open or Shorted Diagnostic Procedure.................................................. 273 001841.03 — Blackout Brake Lights Short to Power.................................................................... 275 Blackout Brake Lights Short to Power Diagnostic Procedure....................................................... 275 001841.05 — Blackout Brake Lights Open or Short..................................................................... 276 Blackout Brake Lights Open or Short Diagnostic Procedure........................................................ 276 001841.06 — Blackout Brake Lights High Current...................................................................... 278 Blackout Brake Lights High Current Diagnostic Procedure......................................................... 278 001842.03 — Blackout Lights Short to Power.......................................................................... 279 Blackout Lights Short to Power Diagnostic Procedure............................................................. 279 001842.05 — Blackout Lights Open or Short........................................................................... 280 Blackout Lights Open or Short Diagnostic Procedure.............................................................. 280 001842.06 — Blackout Lights High Current............................................................................ 283 Blackout Lights High Current Diagnostic Procedue................................................................ 283 002000.09 — Controller Area Network (CAN) Communication Lost for Engine Control Unit (ECU).......................... 285 Controller Area Network (CAN) Communication Lost for Engine Control Unit (ECU) Diagnostic Procedure............. 285 002003.09 — Controller Area Network (CAN) Communication Lost for Transmission Control Unit (TCU).................... 287 Controller Area Network (CAN) Communication Lost for Transmission Control Unit (TCU) Diagnostic Procedure....... 287 002040.09 — Controller Area Network (CAN) Communication Lost for Advanced Displaying Unit (ADU)..................... 289 Controller Area Network (CAN) Communication Lost for Advanced Displaying Unit (ADU) Diagnostic Procedure........ 289 002051.09 — Controller Area Network (CAN) Communication Lost for Tire Pressure Monitoring System (TPMS)............. 290 CAN Communication Lost for TPMS Diagnostic Procedure............................................................ 290 002052.09 — Controller Area Network (CAN) Communication Lost for Joystick Steering Controller (JSC)................. 292 Controller Area Network (CAN) Communication Lost for Joystick Steering Controller (JSC) Diagnostic Procedure.... 292 002129.09 — Controller Area Network (CAN) Communication Lost for Joystick Steering Valve (JSV)...................... 293 Controller Area Network (CAN) Communication Lost for Joystick Steering Valve (JSV) Diagnostic Procedure......... 293 002132.09 — Controller Area Network (CAN) Communication Lost for Radar Object Detection (ROD)....................... 295 Controller Area Network (CAN) Communication Lost for Radar Object Detection (ROD) Diagnostic Procedure.......... 295 002141.09 — Controller Area Network (CAN) Communication Lost for Sealed Switch Module (SSM)......................... 296 Controller Area Network (CAN) Communication Lost for Sealed Switch Module (SSM) Diagnostic Procedure............ 296 002169.09 — Controller Area Network (CAN) Communication Lost for Ground Speed Radar (RDR)........................... 298 Controller Area Network (CAN) Communication Lost for Ground Speed Radar (RDR) Diagnostic Procedure.............. 298 002251.09 — Controller Area Network (CAN) Lost for JDlink........................................................... 300 002350.03 — Drive Lamps Short to Power.............................................................................. 300 Drive Lamps Short to Power Diagnostic Procedure................................................................. 300 002350.05 — Drive Lamps Open or Short............................................................................... 301 Drive Lamps Open or Short Diagnostic Procedure.................................................................. 301 002350.06 — Drive Lamps High Current................................................................................ 303 Drive Lamps High Current Diagnostic Procedure................................................................... 303 002355.03 — Front Work Lights Short to Power........................................................................ 304 Front Work Lights Shorted to Power.............................................................................. 304 002355.05 — Front Work Lights Open or Short......................................................................... 305 Front Work Lights Open or Short Diagnostic Procedure............................................................ 305 002355.06 — Front Work Lights High Current.......................................................................... 307 Front Work Lights High Current Diagnostic Procedure............................................................. 307 002356.03 — Front Work Lights Short to Power........................................................................ 308 Front Work Lights Short to Power Diagnostic Procedure........................................................... 308 002356.05 — Front Work Lights Open or Short......................................................................... 309 Front Work Lights Open or Short Diagnostic Procedure............................................................ 309 002356.06 — Front Work Lights High Current.......................................................................... 311 Front Work Lights High Current Diagnostic Procedure............................................................. 311 002359.03 — Machine Work Lights Short to Power...................................................................... 312 Machine Work Lights Short to Power Diagnostic Procedure......................................................... 312 002359.05 — Machine Work Lights Open or Short....................................................................... 313 Machine Work Lights Open or Short Diagnostic Procedure.......................................................... 313 002359.06 — Machine Work Lights High Current........................................................................ 315 Machine Work Lights High Current Diagnostic Procedure........................................................... 315 002362.03 — Rear Work Lights Short to Power......................................................................... 316 Rear Work Lights Short to Power Diagnostic Procedure............................................................ 317 002362.05 — Rear Work Lights Open or Short.......................................................................... 317 Rear Work Lights Open or Shorted Diagnostic Procedure........................................................... 318 002362.06 — Rear Work Lights High Current........................................................................... 319 Rear Work Lights High Current Diagnostic Procedure.............................................................. 319 002367.04 — Left Turn Switch Short to Ground........................................................................ 320 Left Turn Switch Short to Ground Diagnostic Procedure........................................................... 321 002368.03 — Left Turn Lights Short to Power......................................................................... 322 Left Turn Lights Short to Power Diagnostic Procedure............................................................ 322 002368.05 — Left Turn Lights Open or Short.......................................................................... 323 Left Turn Lights Open or Short Diagnostic Procedure............................................................. 323 002368.06 — Left Turn Lights High Current........................................................................... 325 Left Turn Lights High Current Diagnostic Procedure.............................................................. 325 002369.04 — Right Turn Switch Short to Ground....................................................................... 327 Right Turn Switch Short to Ground Diagnostic Procedure.......................................................... 327 002370.03 — Right Turn Lights Short to Power........................................................................ 328 Right Turn Lights Short to Power Diagnostic Procedure........................................................... 328 002370.05 — Right Turn Lights Open or Short......................................................................... 329 Right Turn Lights Open or Short Diagnostic Procedure............................................................ 329 002370.06 — Right Turn Lights High Current.......................................................................... 331 Right Turn Lights High Current Diagnostic Procedure............................................................. 331 002378.03 — Marker/Tail Lights Short to Power....................................................................... 333 Marker/Tail Lights Short to Power Diagnostic Procedure.......................................................... 333 002378.05 — Marker/Tail Lights Open Circuit......................................................................... 335 002378.06 — Marker/Tail Lights High Current......................................................................... 336 Marker/Tail Lights High Current Diagnostic Procedure............................................................ 336 002386.03 — Beacon Light Short to Power............................................................................. 337 Beacon Light Short to Power Diagnostic Procedure................................................................ 337 002386.06 — Beacon Light High Current............................................................................... 338 Beacon Light High Current Diagnostic Procedure.................................................................. 338 002650.03 — Lockout Fan Solenoid Short to Power..................................................................... 340 Lockout Fan Solenoid Short to Power Diagnostic Procedure........................................................ 340 002650.05 — Lockout Fan Solenoid Open or Short...................................................................... 340 Lockout Fan Solenoid Open or Short Diagnostic Procedure......................................................... 341 002650.06 — Lockout Fan Solenoid High Current....................................................................... 342 Lockout Fan Solenoid High Current Diagnostic Procedure.......................................................... 342 002680.03 — Return-to-Carry (RTC)/Float Detent Short to Power....................................................... 343 Return-to-Carry (RTC)/Float Detent Short to Power Diagnostic Procedure.......................................... 344 002680.06 — Return-to-Carry (RTC)/Float Detent High Current......................................................... 344 Return-to-Carry (RTC)/Float Detent High Current Diagnostic Procedure............................................ 344 002697.02 — Timeout Joystick Steering Controller (JSC) Message...................................................... 346 Timeout Joystick Steering Controller (JSC) Message Diagnostic Procedure......................................... 346 002717.03 — Return-to-Dig (RTD) Detent Short to Power............................................................... 347 Return-to-Dig (RTD) Detent Short to Power Diagnostic Procedure.................................................. 347 002717.06 — Return-to-Dig (RTD) Detent High Current................................................................. 348 Return-to-Dig (RTD) Detent High Current Diagnostic Procedure.................................................... 348 002754.03 — Boom Height Kickout (BHKO) Detent Short to Power........................................................ 349 Boom Height Kickout (BHKO) Detent Short to Power Diagnostic Procedure........................................... 349 002754.06 — Boom Height Kickout (BHKO) Detent High Current.......................................................... 350 Boom Height Kickout (BHKO) Detent High Current Diagnostic Procedure............................................. 350 002873.04 — Engine Light Switch Short to Ground..................................................................... 351 Engine Light Switch Short to Ground Diagnostic Procedure........................................................ 351 002873.18 — Engine Light Switch Short to Ground..................................................................... 352 Engine Light Switch Short to Ground Diagnostic Procedure........................................................ 353 002875.04 — Hazard Wakeup Short to Ground........................................................................... 354 Hazard Wakeup Shorted to Ground Diagnostic Procedure............................................................ 354 003509.04 — Vehicle Control Unit (VCU) Sensor 1 Voltage Low......................................................... 355 Vehicle Control Unit (VCU) Sensor 1 Voltage Low Diagnostic Procedure............................................ 355 003510.04 — Vehicle Control Unit (VCU) Sensor 2 Voltage Low......................................................... 356 Vehicle Control Unit (VCU) Sensor 2 Voltage Low Diagnostic Procedure............................................ 357 003511.04 — Vehicle Control Unit (VCU) Sensor 3 Voltage Low......................................................... 358 Vehicle Control Unit (VCU) Sensor 3 Voltage Low Diagnostic Procedure............................................ 358 003598.02 — 7 V Supply Voltage Low.................................................................................. 359 7 V Supply Voltage Low Diagnostic Procedure..................................................................... 359 004086.03 — HPM Sensor Short to Power............................................................................... 359 Hydraulic Power Management (HPM) Pressure Sensor Short to Power Diagnostic Procedure............................ 359 004086.04 — HPM Sensor Open or Short................................................................................ 360 Hydraulic Power Management (HPM) Pressure Sensor (B65) Open or Short Diagnostic Procedure....................... 360 520194.02 — Invalid Vehicle Identification Number (VIN)............................................................. 362 521379.00 — Hydraulic Tank Pressure High............................................................................ 363 521379.03 — Hydraulic Tank Pressure Short to Power.................................................................. 364 521379.04 — Hydraulic Tank Pressure Short to Ground................................................................. 365 521379.17 — Hydraulic Tank Pressure Low............................................................................. 366 521379.31 — Hydraulic Tank Pressure Low............................................................................. 367 521948.02 — Engine Tier Level Invalid............................................................................... 367 Engine Tier Level Invalid Diagnostic Procedure.................................................................. 367 521985.04 — Central Processing Unit (CPU) Switched Power Voltage Low................................................ 368 Central Processing Unit (CPU) Switched Power Voltage Low Diagnostic Procedure................................... 368 521986.04 — Unswitched Power Voltage Low............................................................................ 370 Unswitched Power Voltage Low Diagnostic Procedure............................................................... 370 522280.01 — Brake Pressure Low...................................................................................... 371 Brake Pressure Low Diagnostic Procedure......................................................................... 371 522341.03 — Heated Mirror Short to Power............................................................................ 372 Heated Mirror Short to Power Diagnostic Procedure............................................................... 372 522341.05 — Heated Mirror Open Circuit.............................................................................. 373 Heated Mirror Open Circuit Diagnostic Procedure................................................................. 373 522341.06 — Heated Mirror High Current.............................................................................. 375 Heated Mirror High Current Diagnostic Procedure................................................................. 375 522426.04 — Rear Wiper Park Short to Ground......................................................................... 376 Rear Wiper Park Short to Ground Diagnostic Procedure............................................................ 376 522427.04 — Front Wiper Park Short to Ground........................................................................ 377 Front Wiper Park Short to Ground Diagnostic Procedure........................................................... 377 522431.02 — Memory Test Failure..................................................................................... 378 Memory Test Failure Diagnostic Procedure........................................................................ 378 522432.03 — Rear Wiper High Speed Shorted to Power.................................................................. 379 Rear Wiper High Speed Shorted to Power Diagnostic Procedure..................................................... 379 522432.05 — Rear Wiper High Speed Open Circuit...................................................................... 380 Rear Wiper High Speed Open Circuit.............................................................................. 380 522432.06 — Rear Wiper High Speed High Current...................................................................... 381 Rear Wiper High Speed High Current Diagnostic Procedure......................................................... 382 522433.03 — Rear Wiper Low Speed Short to Power..................................................................... 383 Rear Wiper Low Speed Short to Power Diagnostic Procedure........................................................ 383 522433.05 — Rear Wiper Low Speed Open Circuit....................................................................... 384 Rear Wiper Low Speed Open Circuit Diagnostic Procedure.......................................................... 384 522433.06 — Rear Wiper Low Speed High Current....................................................................... 385 Rear Wiper Low Speed High Current Diagnostic Procedure.......................................................... 386 522434.03 — Front Wiper Low Speed Short to Power.................................................................... 387 Front Wiper Low Speed Short to Power Diagnostic Procedure....................................................... 387 522434.05 — Front Wiper Low Speed Open Circuit...................................................................... 388 Front Wiper Low Speed Open Circuit Diagnostic Procedure......................................................... 388 522434.06 — Front Wiper Low Speed High Current...................................................................... 389 Front Wiper Low Speed High Current Diagnostic Procedure......................................................... 390 522435.03 — Front Wiper High Speed Short to Power................................................................... 391 Front Wiper High Speed Short to Power Diagnostic Procedure...................................................... 391 522435.05 — Front Wiper High Speed Open Circuit..................................................................... 392 Front Wiper High Speed Open Circuit Diagnostic Procedure........................................................ 392 522435.06 — Front Wiper High Speed High Current..................................................................... 393 Front Wiper High Speed High Current Diagnostic Procedure........................................................ 394 522436.03 — Bucket Position Short to Power.......................................................................... 395 Bucket Position Short to Power Diagnostic Procedure............................................................. 395 522436.04 — Bucket Position Open or Short........................................................................... 396 Bucket Position Open or Short Diagnostic Procedure.............................................................. 396 522437.04 — Return-to-Dig (RTD) Switch Short to Ground.............................................................. 398 Return-to-Dig (RTD) Switch Short to Ground Diagnostic Procedure................................................. 398 522438.03 — Pin Disconnect Solenoid Short to Power.................................................................. 399 Pin Disconnect Solenoid Short to Power Diagnostic Procedure..................................................... 399 522438.05 — Pin Disconnect Solenoid Open Circuit.................................................................... 400 Pin Disconnect Solenoid Open or Short Diagnostic Procedure...................................................... 400 522438.06 — Pin Disconnect Solenoid High Current.................................................................... 402 Pin Disconnect Solenoid High Current Diagnostic Procedure....................................................... 402 522543.03 — Boom Cylinder Rod Pressure Sensor Open or Short......................................................... 403 Boom Cylinder Rod Pressure Sensor Open or Short Diagnostic Procedure............................................ 403 522543.04 — Boom Cylinder Rod Pressure Sensor Short to Ground....................................................... 404 Boom Cylinder Rod Pressure Sensor Short to Ground Diagnostic Procedure.......................................... 404 522544.03 — Boom Cylinder Head Pressure Sensor Open or Short........................................................ 405 Boom Cyl Head Press Open or Short Diagnostic Procedure.......................................................... 406 522544.04 — Boom Cylinder Head Pressure Sensor Short to Ground...................................................... 407 Boom Cylinder Head Pressure Sensor Short to Ground Diagnostic Procedure......................................... 407 522620.03 — Vehicle Horn Short to Power............................................................................. 408 Vehicle Horn Short to Power Diagnostic Procedure................................................................ 408 522620.06 — Vehicle Horn High Current............................................................................... 409 Vehicle Horn High Current Diagnostic Procedure.................................................................. 409 522796.03 — Rear Washer Pump Short to Power......................................................................... 410 Rear Washer Pump Short to Power Diagnostic Procedure............................................................ 410 522796.05 — Rear Washer Pump Open Circuit........................................................................... 411 Rear Washer Pump Open or Short Diagnostic Procedure............................................................. 411 522796.06 — Rear Washer Pump High Current........................................................................... 413 Rear Washer Pump High Current Diagnostic Procedure.............................................................. 413 522797.03 — Front Washer Pump Short to Power........................................................................ 414 Front Washer Pump Short to Power Diagnostic Procedure........................................................... 414 522797.05 — Front Washer Pump Open Circuit.......................................................................... 415 Front Washer Pump Open or Short Diagnostic Procedure............................................................ 415 522797.06 — Front Washer Pump High Current.......................................................................... 417 Front Washer Pump High Current Diagnostic Procedure............................................................. 417 523137.01 — Steering System Pressure Low............................................................................ 418 Steering Pressure Low Diagnostic Procedure...................................................................... 419 523137.03 — Steering Pressure Sensor Short to Power................................................................. 419 Steering Pressure Sensor Short to Power Diagnostic Procedure.................................................... 419 523137.04 — Steering Pressure Sensor Short to Ground................................................................ 420 Steering Pressure Sensor Open or Short Diagnostic Procedure..................................................... 420 523137.05 — Steering Pressure Sensor Open Circuit................................................................... 422 Steering Pressure Sensor Open or Short Diagnostic Procedure..................................................... 422 523137.12 — Steering Pressure Sensor Invalid........................................................................ 424 Steering Pressure Sensor Invalid Diagnostic Procedure........................................................... 424 523219.04 — Switched Power Voltage Low.............................................................................. 425 Switched Power Voltage Low Diagnostic Procedure................................................................. 425 523440.04 — Unswitched Power Voltage Low............................................................................ 426 Unswitched Power Voltage Low Diagnostic Procedure............................................................... 426 523489.03 — Engine Light Short to Power............................................................................. 428 Engine Light Short to Power Diagnostic Procedure................................................................ 428 523489.05 — Engine Light Open Circuit............................................................................... 429 Engine Light Open Circuit Diagnostic Procedure.................................................................. 429 523489.06 — Engine Light Short to Ground............................................................................ 430 Engine Light Short to Ground Diagnostic Procedure............................................................... 430 523560.03 — Tank Light Short to Power............................................................................... 432 523560.05 — Tank Light Open Circuit................................................................................. 433 523560.06 — Tank Light Short to Ground.............................................................................. 434 523577.03 — Secondary Steering Pump Shorted to Power................................................................ 434 Secondary Steering Pump Shorted to Power Diagnostic Procedure................................................... 434 523577.05 — Secondary Steering Pump Open Circuit.................................................................... 435 Secondary Steering Pump Open or Short Diagnostic Procedure...................................................... 436 523577.06 — Secondary Steering Pump High Current.................................................................... 437 Secondary Steering Pump High Current Diagnostic Procedure....................................................... 437 523689.04 — Differential Lock Switch Short to Ground................................................................ 439 Differential Lock Switch Short to Ground Diagnostic Procedure................................................... 439 523767.04 — Joystick Steering Activation Switch Short to Ground..................................................... 440 Joystick Steering Activation Switch Short to Ground Diagnostic Procedure........................................ 440 523767.10 — Joystick Steering Activation Switch Button Stuck........................................................ 441 Joystick Steering Activation Switch Button Stuck Diagnostic Procedure........................................... 441 523786.03 — Boom Position Sensor Short to Power..................................................................... 442 Boom Position Sensor Short to Power Diagnostic Procedure........................................................ 443 523786.06 — Boom Position Sensor Short to Ground.................................................................... 443 523795.03 — Joystick Steering Valve (JSV) Power Short to Power...................................................... 445 JSV Power Short Diagnostic Procedure............................................................................ 445 523795.05 — Joystick Steering Valve (JSV) Power Open or Shorted..................................................... 445 JSV Power Open or ShortDiagnostic Procedure..................................................................... 446 523795.06 — Joystick Steering Valve (JSV) High Current.............................................................. 447 JSV High Current Diagnostic Procedure........................................................................... 447 523837.01 — Brake Pressure Low—Rear................................................................................. 448 Brake Pressure Low—Rear Diagnostic Procedure.................................................................... 448 523837.03 — Rear Brake Pressure Sensor Short to Power............................................................... 449 Rear Brake Pressure Sensor Short to Power Diagnostic Procedure.................................................. 449 523837.04 — Rear Brake Pressure Open or Short....................................................................... 450 Rear Brake Pressure Open or Short Diagnostic Procedure.......................................................... 450 523840.01 — Brake Pressure Low—Front................................................................................ 451 Brake Pressure Low—Front Diagnostic Procedure................................................................... 451 523840.03 — Front Brake Pressure Sensor Short to Power.............................................................. 452 Front Brake Pressure Sensor Short to Power Diagnostic Procedure................................................. 452 523840.04 — Front Brake Pressure Sensor Open or Short............................................................... 453 Front Brake Pressure Sensor Open or Short Diagnostic Procedure.................................................. 453 523865.04 — Add Truck Switch Short to Ground........................................................................ 455 Add Truck Switch Short to Ground Diagnostic Procedure........................................................... 455 523867.04 — Counter Switch Short to Ground.......................................................................... 456 Counter Switch Short to Ground Diagnostic Procedure............................................................. 456 523868.04 — Add Bucket Switch Short to Ground....................................................................... 457 Add Bucket Switch Short to Ground Diagnostic Procedure.......................................................... 457 523911.03 — Hydraulic Power Management Solenoid High Side Short to Power............................................ 458 Hydraulic Power Management Solenoid High Side Short to Power Diagnostic Procedure............................... 459 523911.05 — Hydraulic Power Management Solenoid High Side Open Circuit.............................................. 460 Hydraulic Power Management Solenoid High Side Open Circuit Diagnostic Procedure................................. 460 523911.06 — Hydraulic Power Management Solenoid High Side High Current.............................................. 461 Hydraulic Power Management Solenoid High Side High Current Diagnostic Procedure................................. 462 523911.13 — Hydraulic Power Management System Out of Calibration.................................................... 463 523911.16 — Hydraulic Power Management Solenoid Low Side High Current............................................... 463 Hydraulic Power Management Solenoid Low Side High Current Diagnostic Procedure.................................. 463 523911.17 — Hydraulic Power Management Solenoid Low Side Open Circuit............................................... 464 Hydraulic Power Management Solenoid Low Side Open Circuit Diagnostic Procedure.................................. 464 523911.18 — Hydraulic Power Management Solenoid Low Side Short to Power............................................. 466 Hydraulic Power Management Solenoid Low Side Short to Power Diagnostic Procedure................................ 466 523948.03 — Ride Control Solenoid Short to Power.................................................................... 467 Ride Control Solenoid Short to Power Diagnostic Procedure....................................................... 468 523948.05 — Ride Control Solenoid Open Circuit...................................................................... 468 Ride Control Solenoid Open Circuit Diagnostic Procedure......................................................... 468 523948.06 — Ride Control Solenoid High Current...................................................................... 470 Ride Control Solenoid High Current Diagnostic Procedure......................................................... 470 524044.01 — Axle Oil Filter Restricted.............................................................................. 471 Axle Oil Filter Restricted Diagnostic Procedure................................................................. 471 524044.03 — Axle Oil Filter Short to Power.......................................................................... 472 Axle Oil Filter Short to Power Diagnostic Procedure............................................................. 472 524250.31 — Inspect Park Brake...................................................................................... 473 Inspect Park Brake Diagnostic Procedure......................................................................... 473 524265.19 — Checksum Error.......................................................................................... 474 Check Sum Error Diagnostic Procedure............................................................................ 474 Sealed Switch Module (SSM) Diagnostic Trouble Codes..................................................................... 475 Sealed Switch Module (SSM) Diagnostic Trouble Codes................................................................. 475 000629.12 — Sealed Switch Module (SSM) Watchdog Time Out............................................................ 475 SSM Watchdog Time Out Diagnostic Procedure...................................................................... 475 002033.09 — Controller Area Network (CAN) Communication Lost For Vehicle Control Unit (VCU)......................... 475 SSM Lost Communications Diagnostic Procedure.................................................................... 476 002634.04 — Sealed Switch Module (SSM) Ignition Relay Signal Short to Ground........................................ 477 Sealed Switch Module (SSM) Ignition Relay Signal Short to Ground Diagnostic Procedure........................... 477 002634.05 — Sealed Switch Module (SSM) Ignition Relay Signal Open Circuit........................................... 478 Sealed Switch Module (SSM) Ignition Relay Signal Open Circuit Diagnostic Procedure.............................. 478 520752.04 — Button 17 Keypad Stuck.................................................................................. 479 Button 17 Keypad Stuck Diagnostic Procedure..................................................................... 479 520752.09 — Button 17 Light-Emitting Diode (LED) Message............................................................ 480 Button 17 Light-Emitting Diode (LED) Message Diagnostic Procedure............................................... 480 520753.04 — Front Washer Keypad Stuck............................................................................... 482 Front Washer Keypad Stuck Diagnostic Procedure.................................................................. 482 520753.09 — Lost Front Washer Light-Emitting Diode (LED) Message.................................................... 483 520754.04 — Front Wiper Keypad Stuck................................................................................ 483 Front Wiper Keypad Stuck Diagnostic Procedure................................................................... 483 520754.09 — Lost Front Wiper Light-Emitting Diode (LED) Message..................................................... 484 Lost Front Wiper Light-Emitting Diode (LED) Message Diagnostic Procedure........................................ 484 520755.04 — Drive Lights Keypad Stuck............................................................................... 485 Drive Lights Keypad Stuck Diagnostic Procedure.................................................................. 485 520755.09 — Lost Drive Lights Light-Emitting Diode (LED) Message.................................................... 486 Lost Drive Lights Light-Emitting Diode (LED) Message Diagnostic Procedure....................................... 486 523335.04 — Work Lights Keypad Stuck................................................................................ 488 Work Lights Keypad Stuck Diagnostic Procedure................................................................... 488 523335.09 — Lost Work Lights Light-Emitting Diode (LED) Message..................................................... 488 Lost Work Lights Light-Emitting Diode (LED) Message Diagnostic Procedure........................................ 489 523336.04 — Rear Wiper Keypad Stuck................................................................................. 490 Rear Wiper Keypad Stuck Diagnostic Procedure.................................................................... 490 523336.09 — Lost Rear Wiper Light-Emitting Diode (LED) Message...................................................... 491 Lost Rear Wiper Light-Emitting Diode (LED) Message Diagnostic Procedure......................................... 491 523338.04 — Rear Washer Keypad Stuck................................................................................ 492 Rear Washer Keypad Stuck Diagnostic Procedure................................................................... 492 523338.09 — Lost Rear Washer Light-Emitting Diode (LED) Message..................................................... 493 523339.04 — Axle Disconnect Keypad Stuck............................................................................ 493 Axle Disconnect Keypad Stuck Diagnostic Procedure............................................................... 494 523339.09 — Lost Axle Disconnect Light-Emitting Diode (LED) Message................................................. 494 Lost Axle Disconnect Light-Emitting Diode (LED) Message Diagnostic Procedure.................................... 494 523340.04 — Button 21 Keypad Stuck.................................................................................. 496 Button 21 Keypad Stuck Diagnostic Procedure..................................................................... 496 523340.09 — Button 21 Light-Emitting Diode (LED) Message............................................................ 497 Button 21 Light-Emitting Diode (LED) Message Diagnostic Procedure............................................... 497 523849.04 — Air Conditioner Keypad Stuck............................................................................ 498 Air Conditioner Keypad Stuck Diagnostic Procedure............................................................... 498 523349.09 — Lost Air Conditioner Light-Emitting Diode (LED) Message................................................. 499 Lost Air Conditioner Light-Emitting Diode (LED) Message Diagnostic Procedure.................................... 499 523850.04 — Pin Disconnect Keypad Stuck............................................................................. 500 Pin Disconnect Keypad Stuck Diagnostic Procedure................................................................ 500 523850.09 — Lost Pin Disconnect Light-Emitting Diode (LED) Message.................................................. 501 Lost Pin Disconnect Light-Emitting Diode (LED) Message Diagnostic Procedure..................................... 501 523852.04 — Spin Control Keypad Stuck............................................................................... 503 Spin Control Keypad Stuck Diagnostic Procedure.................................................................. 503 523852.09 — Lost Spin Control Light-Emitting Diode (LED) Message.................................................... 503 Lost Spin Control Light-Emitting Diode (LED) Message Diagnostic Procedure....................................... 504 523854.04 — Differential Lock Keypad Stuck.......................................................................... 505 Differential Lock Keypad Stuck Diagnostic Procedure............................................................. 505 523854.09 — Lost Differential Lock Light-Emitting Diode (LED) Message............................................... 506 Lost Differential Lock Light-Emitting Diode (LED) Message Diagnostic Procedure.................................. 506 523855.04 — Return To Carry Keypad Stuck............................................................................ 507 Return-to-Carry Keypad Stuck Diagnostic Procedure............................................................... 507 523855.09 — Lost Return To Carry Light-Emitting Diode (LED) Message................................................. 508 Lost Return To Carry Light-Emitting Diode (LED) Message Diagnostic Procedure.................................... 508 523856.04 — Boom Height Kick Out Keypad Stuck....................................................................... 510 Boom Height Kickout Keypad Stuck Diagnostic Procedure........................................................... 510 523856.09 — Lost Boom Height Kick Out Light-Emitting Diode (LED) Message............................................ 510 Lost Boom Height Kickout Light-Emitting Diode (LED) Message Diagnostic Procedure................................ 511 523857.04 — Clutch Cut-Off Keypad Stuck............................................................................. 512 Clutch Cut-Off Keypad Stuck Diagnostic Procedure................................................................ 512 523857.09 — Lost Clutch Cut-Off Light-Emitting Diode (LED) Message.................................................. 513 Lost Clutch Cut-Off Light-Emitting Diode (LED) Message Diagnostic Procedure..................................... 513 523858.04 — Ride Control Keypad Stuck............................................................................... 514 Ride Control Keypad Stuck Diagnostic Procedure.................................................................. 514 523858.09 — Lost Ride Control Light-Emitting Diode (LED) Message.................................................... 515 Lost Ride Control Light-Emitting Diode (LED) Message Diagnostic Procedure....................................... 515 523860.04 — Auto Transmission Keypad Stuck.......................................................................... 517 Auto Transmission Keypad Stuck Diagnostic Procedure............................................................. 517 523860.09 — Lost Auto Transmission Light-Emitting Diode (LED) Message............................................... 517 Lost Auto Transmission Light-Emitting Diode (LED) Message Diagnostic Procedure.................................. 518 523861.04 — Return To Dig Keypad Stuck.............................................................................. 519 Return-to-Dig Keypad Stuck Diagnostic Procedure................................................................. 519 523861.09 — Lost Return To Dig Light-Emitting Diode (LED) Message................................................... 520 Lost Return To Dig Light-Emitting Diode (LED) Message Diagnostic Procedure...................................... 520 523862.04 — Park Brake Keypad Stuck................................................................................. 521 Park Brake Keypad Stuck Diagnostic Procedure.................................................................... 521 523862.09 — Lost Park Brake Light-Emitting Diode (LED) Message...................................................... 522 Lost Park Brake Light-Emitting Diode (LED) Message Diagnostic Procedure......................................... 522 523863.04 — Pilot Enable Keypad Stuck............................................................................... 524 Pilot Enable Keypad Stuck Diagnostic Procedure.................................................................. 524 523863.09 — Lost Pilot Enable Light-Emitting Diode (LED) Message.................................................... 524 Lost Pilot Enable Light-Emitting Diode (LED) Message Diagnostic Procedure....................................... 525 523864.04 — Hazards Keypad Stuck.................................................................................... 526 Hazards Keypad Stuck Diagnostic Procedure....................................................................... 526 523864.09 — Lost Hazard Light-Emitting Diode (LED) Message.......................................................... 527 Lost Hazard Light-Emitting Diode (LED) Message Diagnostic Procedure............................................. 527 523865.04 — Beacon Light Keypad Stuck............................................................................... 528 Beacon Light Keypad Stuck Diagnostic Procedure.................................................................. 528 523865.09 — Lost Beacon Light-Emitting Diode (LED) Message.......................................................... 529 Lost Beacon Light-Emitting Diode (LED) Message Diagnostic Procedure............................................. 529 523867.04 — Ignition Off Keypad Stuck............................................................................... 531 Ignition Off Keypad Stuck Diagnostic Procedure.................................................................. 531 523867.09 — Lost Ignition Off Light-Emitting Diode (LED) Message.................................................... 532 523868.04 — Ignition On Keypad Stuck................................................................................ 532 Ignition On Keypad Stuck Stuck Diagnostic Procedure............................................................. 532 523868.09 — Lost Ignition On Light-Emitting Diode (LED) Message..................................................... 533 Lost Ignition On Light-Emitting Diode (LED) Message Diagnostic Procedure........................................ 533 Advanced Display Unit (ADU) Diagnostic Trouble Codes.................................................................... 535 Advanced Display Unit (ADU) Diagnostic Trouble Codes................................................................ 535 000158.03 — Switched Power Voltage High............................................................................. 535 Switched Power Voltage High Diagnostic Procedure................................................................ 535 000158.04 — Switched Power Voltage Low.............................................................................. 536 Switched Power Voltage Low Diagnostic Procedure................................................................. 536 000168.03 — High Battery Voltage.................................................................................... 537 High Battery Voltage Diagnostic Procedure....................................................................... 537 000168.04 — Low Battery Voltage..................................................................................... 538 Low Battery Voltage Diagnostic Procedure........................................................................ 538 000442.00 — Display Temp High....................................................................................... 539 Display Temp High Diagnostic Procedure.......................................................................... 540 000442.01 — Display Temp Low........................................................................................ 540 Display Temp Low Diagnostic Procedure........................................................................... 540 001491.11 — LCD Backlight Failure................................................................................... 541 LCD Backlight Failure Diagnostic Procedure...................................................................... 541 003597.02 — 5 Volt Power Supply Invalid............................................................................. 541 5 Volt Power Supply Invalid Diagnostic Procedure................................................................ 541 003598.02 — 1.5 Volt Power Supply Invalid........................................................................... 542 1.5 Volt Power Supply Invalid Diagnostic Procedure.............................................................. 542 003599.02 — 3.3 Volt Power Supply Invalid........................................................................... 542 3.3 Volt Power Supply Invalid Diagnostic Procedure.............................................................. 542 523436.14 — ADU Watchdog Time Out................................................................................... 543 ADU Watchdog Time Out Diagnostic Procedure...................................................................... 543 523438.31 — Memory Error............................................................................................ 543 Memory Error Diagnostic Procedure............................................................................... 543 523651.02 — Memory Stack Overflow................................................................................... 544 Memory Stack Overflow Diagnostic Procedure...................................................................... 544 523773.03 — CAN HIGH Voltage High................................................................................... 544 CAN HIGH Voltage High Diagnostic Procedure...................................................................... 544 523773.04 — CAN HIGH Voltage Low.................................................................................... 545 CAN HIGH Voltage Low Diagnostic Procedure....................................................................... 545 523774.03 — CAN LOW Voltage High.................................................................................... 546 CAN LOW Voltage High Diagnostic Procedure....................................................................... 546 523774.04 — CAN LOW Voltage Low..................................................................................... 546 CAN LOW Voltage Low Diagnostic Procedure........................................................................ 546 524076.10 — Information Button Stuck................................................................................ 547 Information Button Stuck Diagnostic Procedure................................................................... 547 524077.10 — Back Key Button Stuck................................................................................... 548 Back Key Button Stuck Diagnostic Procedure...................................................................... 548 524078.10 — Menu Select Button Stuck................................................................................ 548 Menu Select Button Stuck Diagnostic Procedure................................................................... 548 524080.10 — Down Arrow Button Stuck................................................................................. 549 Down Arrow Button Stuck Diagnostic Procedure.................................................................... 549 524082.10 — Up Arrow Button Stuck................................................................................... 550 Up Arrow Button Stuck Diagnostic Procedure...................................................................... 550 Radar Object Detection (ROD) Diagnostic Trouble Codes................................................................... 551 Radar Object Detection (ROD) Diagnostic Trouble Codes............................................................... 551 000896.12 — ROD Unit Failure........................................................................................ 551 ROD Unit Failure Diagnostic Procedure........................................................................... 551 Ground Speed Radar (RDR) Diagnostic Trouble Codes....................................................................... 553 Ground Speed Radar (RDR) Diagnostic Trouble Codes................................................................... 553 000628.12 — Controller Not Programmed............................................................................... 553 Controller Not Programmed Diagnostic Procedure.................................................................. 553 523456.18 — Degraded Mode........................................................................................... 553 Degraded Mode Diagnostic Procedure.............................................................................. 553 Joystick Steering Valve (JSV) Diagnostic Trouble Codes.................................................................. 555 Joystick Steering Valve (JSV) Diagnostic Trouble Codes.............................................................. 555 000627.03 — Supply High Voltage.................................................................................... 555 Power Supply Voltage High Diagnostic Procedure.................................................................. 555 000627.04 — Supply Voltage Low...................................................................................... 555 Supply Voltage Low Diagnostic Procedure......................................................................... 555 000628.12 — Memory Error............................................................................................ 556 Memory Error Diagnostic Procedure............................................................................... 556 000630.12 — Memory Error............................................................................................ 557 Memory Error Diagnostic Procedure............................................................................... 557 000638.12 — Memory Error............................................................................................ 557 Memory Error Diagnostic Procedure............................................................................... 557 298965.12 — Control ASIC............................................................................................ 558 Control ASIC Diagnostic Procedure............................................................................... 558 298970.02 — Invalid Option.......................................................................................... 558 Invalid Option Diagnostic Procedure............................................................................. 558 298971.02 — Invalid Valve State..................................................................................... 558 Invalid Valve State Diagnostic Procedure........................................................................ 558 298972.02 — Invalid Valve State..................................................................................... 559 Invalid Valve State Diagnostic Procedure........................................................................ 559 298973.02 — Port Flow Greater Than 100%............................................................................. 559 Port Flow Greater Than 100% Diagnostic Procedure................................................................ 559 298974.02 — Port Flow Error Float................................................................................... 560 Port Flow Error Float Diagnostic Procedure...................................................................... 560 298975.02 — Port Flow Error Block................................................................................... 560 Port Flow Error Block Diagnostic Procedure...................................................................... 560 298976.02 — Invert Port Error....................................................................................... 560 Invert Port Error Diagnostic Procedure.......................................................................... 560 298977.02 — Shape Error............................................................................................. 561 298978.02 — Invalid Slope Command................................................................................... 561 Invalid Slope Command Diagnostic Procedure...................................................................... 561 298979.02 — Dead Band Error......................................................................................... 561 298980.02 — Invalid Float Command................................................................................... 561 Program Controller.............................................................................................. 561 298981.02 — Invalid Ramps Command................................................................................... 562 Invalid Ramps Command Diagnostic Procedure...................................................................... 562 298982.02 — Invalid Scale Command................................................................................... 562 Invalid Scale Command Diagnostic Procedure...................................................................... 562 298983.02 — Flow Command Error...................................................................................... 563 Flow Command Error Diagnostic Procedure......................................................................... 563 298984.02 — CAN ID Invalid.......................................................................................... 563 CAN ID Invalid Diagnostic Procedure............................................................................. 563 298985.19 — CAN Communication Lost For VCU.......................................................................... 563 CAN Communication Lost for VCU Diagnostic Procedure............................................................. 564 298986.07 — Spool Fail Float Position............................................................................... 565 Spool Fail Float Position Diagnostic Procedure.................................................................. 565 298987.07 — Spool Position Wrong Direction.......................................................................... 565 Spool Position Wrong Direction Diagnostic Procedure............................................................. 566 298988.07 — Spool Position Greater Than Reference................................................................... 566 Spool Position Greater Than Reference Diagnostic Procedure...................................................... 566 298989.07 — Spool Not at Neutral.................................................................................... 566 Spool Not at Neutral Diagnostic Procedure....................................................................... 566 298990.07 — Spool Float Position Error.............................................................................. 567 Spool Float Position Error Diagnostic Procedure................................................................. 567 298991.07 — Main Spool Stuck........................................................................................ 567 Main Spool Stuck Diagnostic Procedure........................................................................... 567 298992.11 — Self Test Failure....................................................................................... 567 Self Test Failure Diagnostic Procedure.......................................................................... 567 298993.11 — Component Failure....................................................................................... 568 Component Failure Diagnostic Procedure.......................................................................... 568 298994.11 — Memory Error............................................................................................ 568 Memory Error Diagnostic Procedure............................................................................... 568 298994.12 — LVDT Wiring Error....................................................................................... 569 LVDT Wiring Error Diagnostic Procedure.......................................................................... 569 298995.11 — Memory Test Failure..................................................................................... 569 Memory Test Failure Diagnostic Procedure........................................................................ 569 298998.13 — Invalid Mechanical Spool Values......................................................................... 569 Invalid Mechanical Spool Values Diagnostic Procedure............................................................ 569 298999.13 — Memory Error............................................................................................ 570 299001.12 — Memory Error............................................................................................ 570 Memory Error Diagnostic Procedure............................................................................... 570 299002.11 — Software Error.......................................................................................... 570 Software Error Diagnostic Procedure............................................................................. 570 299003.11 — Software Error.......................................................................................... 571 Software Error Diagnostic Procedure............................................................................. 571 299004.11 — Software Error.......................................................................................... 571 Software Error Diagnostic Procedure............................................................................. 572 299006.12 — Software Error.......................................................................................... 572 299007.12 — Memory Test Failure..................................................................................... 572 Memory Test Failure Diagnostic Procedure........................................................................ 572 Joystick Steering Controller (JSC) Diagnostic Trouble Codes............................................................. 573 Joystick Steering Controller (JSC) Diagnostic Trouble Codes......................................................... 573 002697.03 — Joystick Position Sensor Voltage Above Normal........................................................... 573 Joystick Position Sensor Voltage Above Normal Diagnostic Procedure.............................................. 573 002697.04 — Joystick Position Sensor Voltage Below Normal........................................................... 573 Joystick Position Sensor Voltage Below Normal Diagnostic Procedure.............................................. 573 002697.13 — Joystick Out of Calibration............................................................................. 573 Joystick Out of Calibration Diagnostic Procedure................................................................ 574 002697.14 — Joystick Redundant Sensor Failure....................................................................... 574 Joystick Redundant Sensor Failure Diagnostic Procedure.......................................................... 574 Tire Pressure Monitoring (TPM) System Diagnostic Trouble Codes.......................................................... 575 Tire Pressure Monitoring (TPM) System Diagnostic Trouble Codes...................................................... 575 000108.12 — Ambient Pressure Fault.................................................................................. 575 Ambient Pressure Fault Diagnostic Procedure..................................................................... 575 000241.01 — Second Level Alarm Low Pressure......................................................................... 576 Second Level Alarm Low Pressure Diagnostic Procedure............................................................ 576 000241.16 — First Level Alarm High Pressure......................................................................... 578 First Level Alarm High Pressure Diagnostic Procedure............................................................ 578 000241.18 — First Level Alarm Low Pressure.......................................................................... 579 First Level Alarm Low Pressure Diagnostic Procedure............................................................. 580 000242.16 — Tire High Temperature................................................................................... 581 Tire High Temperature Diagnostic Procedure...................................................................... 581 000929.12 — Sensor Fault............................................................................................ 583 Sensor Fault Diagnostic Procedure............................................................................... 583 000929.31 — Memory Error............................................................................................ 584 Memory Error Diagnostic Procedure............................................................................... 584 001697.04 — TPM Sensor Low Battery.................................................................................. 584 TPM Sensor Low Battery Diagnostic Procedure..................................................................... 584 Operational Checkout Procedure.............................................................................................. 587 Operational Checkout Procedure.......................................................................................... 589 Operational Checkout................................................................................................ 589 Diagnostic Trouble Code Check................................................................................... 589 Operational Checks—Ignition OFF, Engine OFF Checks.............................................................. 589 Operational Checks—Ignition ON, Engine OFF Checks............................................................... 590 Operational Checks—Ignition ON, Engine ON Checks................................................................ 597 Engine...................................................................................................................... 623 Theory of Operation..................................................................................................... 625 John Deere Engine................................................................................................... 625 Exhaust Aftertreatment.............................................................................................. 625 Cold Start Aid Theory of Operation.................................................................................. 625 Fast Fill Fuel System Theory of Operation........................................................................... 626 System Diagrams......................................................................................................... 628 Engine Cooling System Component Location............................................................................ 628 Engine Fuel System Component Location............................................................................... 630 Engine Intake and Exhaust Component Location........................................................................ 633 Diagnostic Information.................................................................................................. 641 John Deere Engine................................................................................................... 641 Engine Cranks and Will Not Start.................................................................................... 641 Engine Cranks and Will Not Start Diagnostic Procedure........................................................... 641 Engine Misfires or Runs Irregularly................................................................................. 642 Engine Misfires or Runs Irregularly Diagnostic Procedure........................................................ 642 Engine Does Not Develop Full Power.................................................................................. 642 Engine Does Not Develop Full Power Diagnostic Procedure......................................................... 643 Engine Emits Excessive White Exhaust Smoke.......................................................................... 643 Engine Emits Excessive White Exhaust Smoke Diagnostic Procedure................................................. 644 Engine Emits Excessive Black or Gray Exhaust Smoke.................................................................. 644 Engine Emits Excessive Black or Gray Exhaust Smoke Diagnostic Procedure......................................... 644 Engine Will Not Crank............................................................................................... 644 Engine Will Not Crank Diagnostic Procedure...................................................................... 645 Abnormal Engine Noise............................................................................................... 646 Abnormal Engine Noise Diagnostic Procedure...................................................................... 646 Excessive Fuel Consumption.......................................................................................... 646 Fuel in Coolant..................................................................................................... 646 Fuel in Oil......................................................................................................... 646 Fuel in Oil Diagnostic Procedure................................................................................ 646 Fast Fill Fuel System Underfill..................................................................................... 647 Fast Fill Fuel System Underfill Diagnostic Procedure............................................................ 647 Fast Fill Fuel System Overfill...................................................................................... 647 Fast Fill Fuel System Overfill Diagnostic Procedure............................................................. 648 Fast Fill Fuel System Nozzle Leaks at Receiver...................................................................... 648 Fast Fill Fuel System Nozzle Leaks at Receiver Diagnostic Procedure............................................. 648 Adjustments............................................................................................................. 649 John Deere Engine................................................................................................... 649 Service Filter Cleaning............................................................................................. 649 Tests................................................................................................................... 651 John Deere Engine................................................................................................... 651 Fluid Sampling Procedure—If Equipped................................................................................ 652 Engine Idle Speeds and Auto Shutdown Check.......................................................................... 656 Engine Slow Idle Speed Adjustment................................................................................... 657 Exhaust Emissions Test Point........................................................................................ 658 Electrical System........................................................................................................... 661 Theory of Operation..................................................................................................... 663 Start and Charge Circuits Theory of Operation....................................................................... 663 Controller Area Network (CAN) Circuit Theory of Operation........................................................... 669 Engine Control Unit (ECU) Circuit Theory of Operation............................................................... 685 Exhaust Aftertreatment Circuit Theory of Operation.................................................................. 713 Vehicle Control Unit (VCU) Circuit Theory of Operation.............................................................. 733 Transmission Control Unit (TCU) Circuit Theory of Operation......................................................... 771 Park Brake Circuit Theory of Operation.............................................................................. 787 Advanced Display Unit (ADU) Circuit Theory of Operation............................................................. 793 Joystick Steering Circuit Theory of Operation....................................................................... 797 Radar Object Detection (ROD) Circuit Theory of Operation............................................................ 801 Auto-Differential Lock Circuit Theory of Operation.................................................................. 805 Embedded Payload Scale (EPS) Circuit Theory of Operation............................................................ 809 Tire Pressure Monitoring (TPM) System Theory of Operation........................................................... 815 JDLink™ Circuit Theory of Operation................................................................................. 819 System Diagrams......................................................................................................... 823 Electrical Diagram Information...................................................................................... 823 Electrical Schematic Symbols........................................................................................ 829 Fuse and Relay Specifications....................................................................................... 832 System Functional Schematic, Wiring Diagram, and Component Location Master Legend................................... 834 System Functional Schematic......................................................................................... 840 Power and Ground Cables (W1) Component Location..................................................................... 844 Loader Frame Harness (W2) Component Location........................................................................ 845 Loader Frame Harness (W2) Wiring Diagram............................................................................ 847 Load Center Harness (W3) Component Location......................................................................... 855 Load Center Harness (W3) Wiring Diagram............................................................................. 863 Front Console Harness (W4) Component Location....................................................................... 930 Front Console Harness (W4) Wiring Diagram........................................................................... 931 Engine Frame Harness (W5) Component Location........................................................................ 933 Engine Frame Harness (W5) Wiring Diagram............................................................................ 941 Engine Harness (W6) Component Location.............................................................................. 961 Engine Harness (W6) Wiring Diagram.................................................................................. 975 Transmission Harness (W10) Component Location.......................................................................1008 Transmission Harness (W10) Wiring Diagram...........................................................................1011 Rear Frame Harness (W13) Component Location.........................................................................1014 Rear Frame Harness (W13) Wiring Diagram.............................................................................1017 Secondary Steering Harness (W17) Component Location.................................................................1020 Secondary Steering Harness (W17) Wiring Diagram.....................................................................1021 Cab Roof Harness (W19) Component Location...........................................................................1022 Cab Roof Harness (W19) Wiring Diagram...............................................................................1023 Heater and Air Conditioner Harness (W20) Component Location.........................................................1026 Heater and Air Conditioner Harness (W20) Wiring Diagram.............................................................1028 Radar Object Detection (ROD) Harness (W21) Component Location.......................................................1030 Radar Object Detection (ROD) Harness (W21) Wiring Diagram...........................................................1033 Joystick Steering Harness (W22) Component Location..................................................................1036 Joystick Steering Harness (W22) Wiring Diagram......................................................................1037 Radio Harness (W23) Component Location..............................................................................1041 Radio Harness (W23) Wiring Diagram..................................................................................1044 Ground Speed Radar (RDR) Harness (W31) Component Location...........................................................1044 Ground Speed Radar (RDR) Harness (W31) Wiring Diagram...............................................................1045 Low-Pressure Fuel System Harness (W32) Component Location...........................................................1045 Low-Pressure Fuel System Harness (W32) Wiring Diagram...............................................................1047 Tire Pressure Monitoring (TPM) System Harness (W35) Component Location..............................................1050 Tire Pressure Monitoring (TPM) System Harness (W35) Wiring Diagram..................................................1051 Surge Tank Light Harness (W34) Component Location...................................................................1052 Surge Tank Light Harness (W34) Wiring Diagram.......................................................................1057 Auxiliary Radio Input Harness (W41) Component Location—.............................................................1063 Auxiliary Radio Input Harness (W41) Wiring Diagram..................................................................1064 Satellite Radio Harness (W44) Component Location....................................................................1065 Satellite Radio Harness (W44) Wiring Diagram........................................................................1065 Aftertreatment Harness (W45) Component Location.....................................................................1066 Aftertreatment Harness (W45) Wiring Diagram.........................................................................1069 Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Component Location.............................................1076 Diesel Exhaust Fluid (DEF) Dosing Unit Harness (W46) Wiring Diagram.................................................1081 Surge Tank Harness (W47) Component Location.........................................................................1088 Surge Tank Harness (W47) Wiring Diagram.............................................................................1089 Starter Excitation Jumper Harness (W52) Component Location..........................................................1089 Starter Excitation Jumper Harness (W52) Wiring Diagram..............................................................1090 Modular Telematics Gateway (MTG) and Satellite (SAT) Harnesses (W6002 and W6003) Component Location.................1092 Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram.....................................................1094 Satellite (SAT) Harness (W6003) Wiring Diagram......................................................................1096 Engine Application Harness (W6010) Component Location...............................................................1098 Engine Application Harness (W6010) Wiring Diagram...................................................................1099 Starter and Alternator Harness (W6011) Component Location...........................................................1103 Starter and Alternator Harness (W6011) Wiring Diagram...............................................................1106 Diagnostic Information..................................................................................................1109 Service ADVISOR™ Diagnostic Application.............................................................................1109 Service ADVISOR™ Connection Procedure...............................................................................1109 Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application.......................................1111 Intermittent Diagnostic Trouble Code (DTC) Diagnostics..............................................................1114 Diagnostic Trouble Codes—After Machine Repair.......................................................................1114 JDLink™ Connection Procedure........................................................................................1114 Embedded Payload Scale (EPS) Diagnostics............................................................................1115 EPS Diagnostics.................................................................................................1115 TPM—SmartWave® Advanced Maintenance Tool Diagnostics................................................................1117 Monitor Operation.......................................................................................................1119 Advanced Display Unit (ADU)—Lock Up Clutch—If Equipped..............................................................1119 Advanced Display Unit (ADU)—Service Mode............................................................................1119 Advanced Display Unit (ADU)—Clear Codes.............................................................................1120 Advanced Display Unit (ADU)—Auto Idle...............................................................................1120 Advanced Display Unit (ADU)—Auto Shutdown...........................................................................1121 Advanced Display Unit (ADU)—Main Menu...............................................................................1121 Advanced Display Unit (ADU)—Enable Options..........................................................................1121 Advanced Display Unit (ADU)—Tire Size...............................................................................1122 Advanced Display Unit (ADU)—Fan Speed...............................................................................1122 Advanced Display Unit (ADU)—Maximum High Gear.......................................................................1122 Advanced Display Unit (ADU)—Low Idle Adjust.........................................................................1123 Advanced Display Unit (ADU)—Service Cleaning........................................................................1123 Advanced Display Unit (ADU)—Auto Cleaning Settings..................................................................1124 Advanced Display Unit (ADU)—Tire Pressure Monitor––If Equipped......................................................1124 Advanced Display Unit (ADU)—Fan Speed Calibration...................................................................1124 Advanced Display Unit (ADU)—Transmission Clutch Calibration.........................................................1125 Advanced Display Unit (ADU)—Software Delivery.......................................................................1126 Diagnostic Test Box.....................................................................................................1127 Setup and Functional Test...........................................................................................1127 Two Wire Sensor Circuit Check—Out of Range High.....................................................................1132 Two Wire Sensor Circuit Check—Out of Range Low......................................................................1134 Three Wire Sensor Circuit Check—Out of Range High...................................................................1135 Three Wire Sensor Circuit Check—Out of Range Low....................................................................1137 Adjustments.............................................................................................................1139 Boom Height Kickout (BHKO) Adjustment...............................................................................1139 Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Calibration..........................................1140 Return-to-Carry (RTC) Adjustment....................................................................................1141 Return-to-Dig (RTD) Adjustment—Z-Bar Linkage........................................................................1142 Return-to-Dig (RTD) Adjustment—Powerllel Linkage....................................................................1145 Change Backup Alarm Volume..........................................................................................1145 TPM—Activating Tire Pressure Monitoring System......................................................................1146 TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool...................................................1146 TPM—Programming Using Sensor Identification Numbers.................................................................1148 TPM—Cold Inflation Pressure Setup...................................................................................1148 TPM—Alarm Setup.....................................................................................................1149 TPM—Delete Sensors..................................................................................................1149 Tests...................................................................................................................1151 Electrical Component Specifications.................................................................................1151 CAN Circuit Test....................................................................................................1156 Controller Area Network (CAN) Diagnostics ......................................................................1156 Alternator Test.....................................................................................................1161 Accelerator Pedal Sensor Test.......................................................................................1162 Accelerator Pedal Sensor Test Diagnostic Procedure..............................................................1162 Hydraulic Pressure Sensor Test......................................................................................1163 Hydraulic Pressure Sensor Diagnostic Procedure..................................................................1163 Transmission Control Valve Solenoid Check...........................................................................1165 Clutch Cut-Off Sensor Check.........................................................................................1166 Connector Terminal Test.............................................................................................1167 Connector Terminal Test Diagnostic Procedure....................................................................1167 Power Train.................................................................................................................1170 Theory of Operation.....................................................................................................1171 TeamMate™ Axles.....................................................................................................1171 Power Train Operation...............................................................................................1171 Standard Torque Converter Operation.................................................................................1172 Torque Converter With Lockup Clutch Operation.......................................................................1174 Transmission Operation..............................................................................................1175 Transmission Operation—First Gear Forward...........................................................................1176 Transmission Clutch Pack Engagement and Solenoids Activated.........................................................1180 Transmission Filter Bypass Valve Operation..........................................................................1181 Clutch Pack Operation...............................................................................................1183 Transmission Hydraulic System.......................................................................................1184 Transmission Control Valve Component Operation......................................................................1185 Transmission Clutch Modulation Operation............................................................................1188 Thermal Bypass Valve Operation......................................................................................1190 Standard Differential Operation.....................................................................................1191 Differential Lock Operation.........................................................................................1191 Axle Circulation Dual Pump Operation................................................................................1192 Park Brake Operation................................................................................................1194 System Diagrams.........................................................................................................1197 Transmission System Schematic—First Forward.........................................................................1197 Transmission System Schematic—First Forward Lockup Torque Converter.................................................1201 Power Train Component Location......................................................................................1203 Power Train Cooling System Component Location.......................................................................1204 Transmission Component Location.....................................................................................1206 Diagnostic Information..................................................................................................1209 Transmission Clutch Slippage........................................................................................1209 Transmission Clutch Slippage Diagnostic Procedure...............................................................1209 Machine Will Not Move in Either Direction...........................................................................1210 Machine Will Not Move in Either Direction Diagnostic Procedure..................................................1210 Machine Will Not Shift Correctly....................................................................................1214 Machine Will Not Shift Correctly Diagnostic Procedure...........................................................1214 Transmission System Pressure Is Low in Neutral......................................................................1217 Transmission System Pressure Is Low in Neutral Diagnostic Procedure.............................................1217 Transmission Pressure Is Low (One or Two Gear Ranges)...............................................................1218 Transmission Pressure Is Low (One or Two Gear Ranges) Diagnostic Procedure......................................1218 Transmission Shifts Too Slow........................................................................................1219 Transmission Shifts Too Slow Diagnostic Procedure...............................................................1219 Transmission Shifts Too Fast........................................................................................1221 Transmission Shifts Too Fast Diagnostic Procedure...............................................................1221 Machine Creeps in Neutral...........................................................................................1222 Machine Creeps in Neutral Diagnostic Procedure..................................................................1223 Transmission Hydraulic System Overheats.............................................................................1224 Transmission Hydraulic System Overheats Diagnostic Procedure....................................................1224 Transmission Excessive Noise........................................................................................1226 Transmission Excessive Noise Diagnostic Procedure...............................................................1226 Oil Aerated.........................................................................................................1227 Oil Aerated Diagnostic Procedure................................................................................1228 Oil Ejected from Filler Tube........................................................................................1228 Oil Ejected from Filler Tube Diagnostic Procedure...............................................................1228 Machine Vibrates....................................................................................................1228 Machine Vibrates Diagnostic Procedure...........................................................................1229 Machine Power and Acceleration Low..................................................................................1229 Machine Power and Acceleration Low Diagnostic Procedure.........................................................1230 Torque Converter Stall RPM..........................................................................................1230 Torque Converter Stall RPM Diagnostic Procedure.................................................................1231 Differential Lock Will Not Engage...................................................................................1232 Differential Lock Will Not Engage Diagnostic Procedure..........................................................1232 Differential Lock Slips and Chatters................................................................................1233 Differential Lock Slips and Chatters Diagnostic Procedure.......................................................1233 Differential Lock Will Not Disengage................................................................................1233 Differential Lock Will Not Disengage Diagnostic Procedure.......................................................1234 Differential Oil Level Rises........................................................................................1234 Differential Oil Level Rises Diagnostic Procedure...............................................................1234 Differential Oil Level Low..........................................................................................1235 Differential Oil Level Low Diagnostic Procedure.................................................................1235 Differential and Axle Noise Excessive...............................................................................1235 Differential and Axle Noise Excessive Diagnostic Procedure......................................................1235 Axle Wheel Hub Face Seal Leaking....................................................................................1237 Axle Wheel Hub Face Seal Leaking Diagnostic Procedure...........................................................1237 Axle Overheats......................................................................................................1237 Axle Overheats Diagnostic Procedure.............................................................................1237 Service Brakes Poor or Do Not Apply.................................................................................1239 Service Brakes Poor or Do Not Apply Diagnostic Procedure........................................................1239 Service Brakes Aggressive...........................................................................................1240 Service Brakes Aggressive Diagnostic Procedure..................................................................1240 Service Brakes Dragging.............................................................................................1241 Service Brakes Dragging Diagnostic Procedure....................................................................1241 Service Brakes Lock Up..............................................................................................1242 Service Brakes Lock Up Diagnostic Procedure.....................................................................1242 Service Brakes Chatter..............................................................................................1243 Service Brakes Chatter Diagnostic Procedure.....................................................................1243 Service Brake Warning Light On......................................................................................1244 Service Brake Warning Light On Diagnostic Procedure.............................................................1244 Driveline Excessive Vibration or Noise..............................................................................1245 Driveline Excessive Vibration or Noise Diagnostic Procedure.....................................................1245 Park Brake Will Not Hold............................................................................................1247 Park Brake Will Not Hold Diagnostic Procedure...................................................................1247 Park Brake Will Not Release.........................................................................................1248 Park Brake Will Not Release Diagnostic Procedure................................................................1248 Park Brake Overheats................................................................................................1250 Park Brake Overheats Diagnostic Procedure.......................................................................1250 Park Brake Light Flashes When Shifting From Forward to Reverse......................................................1251 Park Brake Light Flashes When Shifting From Forward to Reverse Diagnostic Procedure.............................1251 Park Brake Light Flashes During Each Shift..........................................................................1251 Park Brake Light Flashes During Each Shift Diagnostic Procedure.................................................1251 Park Brake Light Does Not Come On...................................................................................1252 Park Brake Light Does Not Come On Diagnostic Procedure..........................................................1252 Park Brake Will Not Apply...........................................................................................1254 Park Brake Will Not Apply Diagnostic Procedure..................................................................1254 Adjustments.............................................................................................................1255 Service Brake Bleeding Procedure....................................................................................1255 External Service Brake Inspection...................................................................................1256 Transmission Control Unit (TCU)—Electronic Clutch Calibration.......................................................1258 Tests...................................................................................................................1259 Transmission Oil Sampling Procedure.................................................................................1259 Transmission Oil Warm-Up Procedure..................................................................................1259 Park Brake Pressure Test............................................................................................1260 Park Brake Drag Test................................................................................................1261 Transmission Pump Flow Test.........................................................................................1263 Transmission System Pressure Test...................................................................................1264 Transmission Clutch Pressure Test...................................................................................1266 Transmission Element Leakage Test...................................................................................1268 Transmission Lube Pressure Test.....................................................................................1270 Torque Converter—In Pressure Test...................................................................................1272 Torque Converter—Out Pressure Test..................................................................................1273 Torque Converter Relief Pressure Test...............................................................................1275 Torque Converter—Out Flow Test......................................................................................1277 Torque Converter Stall Speed Test...................................................................................1279 Lockup Torque Converter (LUTC) Pressure Test........................................................................1280 Transmission Oil Cooler Thermal Bypass Valve Temperature Test.......................................................1282 Transmission Oil Cooler Thermal Bypass Valve Pressure Test..........................................................1284 Transmission Oil Cooler Restriction Test............................................................................1285 Axle Circulation Dual Pump Flow Test................................................................................1287 Axle Oil Cooler Restriction Test....................................................................................1288 Axle Breather Test..................................................................................................1290 Differential Lock Pressure Test.....................................................................................1291 Hydraulic System............................................................................................................1295 Theory of Operation.....................................................................................................1297 Loader Hydraulic System Operation...................................................................................1297 Main Hydraulic Pump Operation.......................................................................................1298 Hydraulic Pump Manifold Operation...................................................................................1302 Hydraulic Fan Pump Operation........................................................................................1304 Hydraulic Fan Operation.............................................................................................1306 Hydraulic Reversing Fan Operation...................................................................................1308 Orbital Steering System Component Operation.........................................................................1311 Orbital Steering Valve Operation....................................................................................1312 Joystick Steering Valve Operation...................................................................................1313 Secondary Steering System Operation.................................................................................1315 Secondary Steering Valve Operation..................................................................................1316 Pilot Pressure Reducing Valve Operation.............................................................................1318 Service Brake Hydraulic System Operation............................................................................1318 Service Brake Accumulator Operation.................................................................................1319 Service Brake Valve Operation.......................................................................................1320 Pin Disconnect Operation............................................................................................1321 Pilot Control Lever Operation.......................................................................................1322 Control Valve Pilot Orifice Check Valve Operation...................................................................1323 Loader Control Valve Operation......................................................................................1324 Boom Section Operation—Boom Down and Steering.......................................................................1326 Bucket Section Operation—Boom Raise and Bucket Dump.................................................................1328 Bucket Section Operation—Boom Raise and Bucket Dump (High-Lift Option)..............................................1330 Auxiliary Section—Operating and Boom Raise..........................................................................1332 Auxiliary Section—Spool Stroke Adjuster Operation...................................................................1334 Loader Control Valve—Outlet Section Operation.......................................................................1335 Load Sense Circuit Operation—Neutral................................................................................1337 Load Sense Circuit Operation—Steering...............................................................................1338 Load Sense Circuit Operation—Steering and Boom Down.................................................................1339 Load Sense Circuit Operation—Boom Raise and Bucket Dump.............................................................1340 Main Relief Valve Operation.........................................................................................1341 Load Sense Relief Valve Operation...................................................................................1342 Circuit Relief With Anticavitation Valve Operation..................................................................1343 Anticavitation Valve Operation......................................................................................1345 Hydraulic Return Filter Operation...................................................................................1346 Ride Control Operation..............................................................................................1348 System Diagrams.........................................................................................................1352 Hydraulic System Schematic..........................................................................................1352 Steering and Hydraulic Cooling Fan Circuit Component Location.......................................................1355 Loader and Hydraulic Cooling Circuit Component Location.............................................................1363 Ride Control, Pin Disconnect, and Hydraulic Filter Circuit Component Location.......................................1367 Service Brake, Park Brake, Differential Lock, and Axle Cooling Circuit Component Location...........................1371 Hydraulic Pump Manifold.............................................................................................1374 Diagnostic Information..................................................................................................1377 No Hydraulic Functions..............................................................................................1377 No Hydraulic Functions Diagnostic Procedure.....................................................................1377 Hydraulic Functions Slow............................................................................................1377 Hydraulic Functions Slow Diagnostic Procedure...................................................................1377 Main Hydraulic Pump Noisy...........................................................................................1380 Main Hydraulic Pump Noisy Diagnostic Procedure..................................................................1380 No Orbital Steering Function........................................................................................1381 No Orbital Steering Function Diagnostic Procedure...............................................................1381 Boom Float Function Not Working.....................................................................................1382 Boom Float Function Not Working Diagnostic Procedure............................................................1382 One Hydraulic Function Not Working..................................................................................1383 One Hydraulic Function Not Working Diagnostic Procedure.........................................................1383 Hydraulic Function Drifts Down......................................................................................1385 Hydraulic Function Drifts Down Diagnostic Procedure.............................................................1385 Boom Down Does Not Work (Engine Off)................................................................................1386 Boom Down Does Not Work (Engine Off) Diagnostic Procedure.......................................................1386 Ride Control Not Working............................................................................................1387 Ride Control Not Working Procedure..............................................................................1387 Oil Overheats.......................................................................................................1388 Oil Overheats Diagnostic Procedure..............................................................................1388 Hydraulic Oil Foams.................................................................................................1389 Hydraulic Oil Foams Diagnostic Procedure........................................................................1389 Pin Disconnect Cylinders Will Not Retract...........................................................................1390 Pin Disconnect Cylinders Will Not Retract Diagnostic Procedure..................................................1390 Constant Steering Required to Maintain Straight Travel..............................................................1391 Constant Steering Required to Maintain Straight Travel Diagnostic Procedure.....................................1391 Slow Steering Wheel Movement Will Not Cause Frame Movement..........................................................1392 Slow Steering Wheel Movement Will Not Cause Frame Movement Diagnostic Procedure.................................1392 Steering Wheel Turns Without Resistance and Causes No Frame Movement................................................1392 Steering Wheel Turns Without Resistance and Causes No Frame Movement Diagnostic Procedure.......................1392 Steering Erratic....................................................................................................1392 Steering Erratic Diagnostic Procedure...........................................................................1393 Steering Wheel Free Play............................................................................................1393 Steering Wheel Free Play Diagnostic Procedure...................................................................1393 Orbital Steering Valve Binds or Locks Up............................................................................1393 Orbital Steering Valve Binds or Locks Up Diagnostic Procedure...................................................1393 Steering Wheel Turns by Itself......................................................................................1394 Steering Wheel Turns by Itself Diagnostic Procedure.............................................................1394 Machine Turns in Opposite Direction as Steering Wheel...............................................................1394 Machine Turns in Opposite Direction as Steering Wheel Diagnostic Procedure......................................1394 Steering Wheel Kickback.............................................................................................1394 Steering Wheel Kickback Diagnostic Procedure....................................................................1395 Orbital Steering Jerky..............................................................................................1395 Orbital Steering Jerky Diagnostic Procedure.....................................................................1395 No Joystick Steering Function.......................................................................................1395 No Joystick Steering Function Diagnostic Procedure..............................................................1395 Secondary Steering Motor Will Not Operate...........................................................................1396 Secondary Steering Motor Will Not Operate Diagnostic Procedure..................................................1396 Secondary Steering Pump Runs But Will Not Steer Machine.............................................................1397 Secondary Steering Pump Runs But Will Not Steer Machine Diagnostic Procedure....................................1397 Hydraulic Fan Does Not Reach Full Speed.............................................................................1397 Hydraulic Fan Does Not Reach Full Speed Diagnostic Procedure....................................................1397 Hydraulic Fan Runs at Full Speed Only...............................................................................1399 Hydraulic Fan Runs at Full Speed Only Diagnostic Procedure......................................................1399 Hydraulic Fan Does Not Spin.........................................................................................1400 Hydraulic Fan Does Not Spin Diagnostic Procedure................................................................1400 Hydraulic Fan Will Not Reverse Direction............................................................................1401 Hydraulic Fan Will Not Reverse Direction Diagnostic Procedure...................................................1401 Adjustments.............................................................................................................1403 Pilot Control Lever Adjustment......................................................................................1403 Auxiliary Pilot Control Lever Adjustment............................................................................1403 Ride Control Accumulator Gas Charge Procedure.......................................................................1404 Ride Control Accumulator Draining Procedure.........................................................................1405 Auxiliary Valve Section—Stroke Adjustment...........................................................................1406 Test....................................................................................................................1407 Hydraulic Oil Sampling Procedure....................................................................................1407 Hydraulic Oil Warm-Up Procedure.....................................................................................1407 Vacuum Pump Installation............................................................................................1408 Hydraulic Reservoir Pressure Release Procedure......................................................................1408 Hydraulic System Pressure and Accumulators Discharge................................................................1409 JT02156A Digital Pressure and Temperature Analyzer Kit Installation.................................................1410 Hydraulic System Operating and Standby Pressure Test................................................................1411 Main Hydraulic Pump Control Valve Test and Adjustment...............................................................1412 Load Sense Relief Valve Pressure Test and Adjustment................................................................1415 Main Hydraulic Pump Flow Test.......................................................................................1416 Main Hydraulic Pump Case Drain Test.................................................................................1420 Main Relief Valve Pressure Test.....................................................................................1421 Circuit Relief With Anticavitation Valve Pressure Test..............................................................1424 Loader Cylinder Drift Test..........................................................................................1426 Boom, Bucket, and Steering Cylinder Leakage Test....................................................................1427 Hydraulic Oil Cooler Restriction Test...............................................................................1428 Steering Cylinder Drift Test........................................................................................1430 Joystick Steering Valve Pressure Test...............................................................................1433 Joystick Steering Circuit Relief Valve Pressure Test................................................................1435 Secondary Steering Pump Pressure Relief Valve Test..................................................................1436 Secondary Steering Valve—Hydraulic System Isolation Check Valve Leakage Test........................................1438 Secondary Steering Valve—Secondary Steering Pump Isolation Check Valve Leakage Test.................................1440 Pilot Control Valve Pressure Test...................................................................................1442 Auxiliary Pilot Control Valve Pressure Test.........................................................................1446 Pilot Pressure Reducing Valve Pressure Test.........................................................................1449 Pilot Accumulator Gas Precharge Test................................................................................1451 Cycle Time Test.....................................................................................................1452 Service Brake Accumulator Gas Precharge and Low Brake Pressure Warning Test.........................................1453 Service Brake Valve Pressure Test...................................................................................1455 Service Brake Valve Leakage Test....................................................................................1457 Service Brake Accumulator Inlet Check Valve Leakage Test............................................................1459 Pin Disconnect Pressure Test........................................................................................1460 Hydraulic Fan Pump Pressure Test....................................................................................1463 Hydraulic Fan Pump Control Test and Adjustment......................................................................1465 Hydraulic Fan Motor Speed Sensor Test...............................................................................1470 Hydraulic Fan Pump Flow Test........................................................................................1471 Hydraulic Fan Pump Case Drain Test..................................................................................1473 Hydraulic Fan Motor Case Drain Test.................................................................................1475 Hydraulic Reversing Fan Test........................................................................................1477 Hydraulic Oil Filter Inspection Procedure...........................................................................1478 Heating and Air Conditioning................................................................................................1479 Theory of Operation.....................................................................................................1481 Air Conditioning System Cycle of Operation..........................................................................1481 System Diagrams.........................................................................................................1484 Air Conditioner and Heater Component Location.......................................................................1484 Diagnostic Information..................................................................................................1487 Air Conditioning System Does Not Operate............................................................................1487 Air Conditioning System Does Not Operate Diagnostic Procedure...................................................1487 Air Conditioning Does Not Cool Interior of Cab......................................................................1489 Air Conditioning Does Not Cool Interior of Cab Diagnostic Procedure.............................................1489 Air Conditioning Runs Constantly, Too Cold..........................................................................1491 Air Conditioning Runs Constantly, Too Cold Diagnostic Procedure.................................................1491 Heating System Does Not Operate.....................................................................................1491 Heating System Does Not Operate Diagnostic Procedure............................................................1492 Heater Does Not Warm Interior of Cab................................................................................1493 Heater Does Not Warm Interior of Cab Diagnostic Procedure.......................................................1493 Interior Windows Continue to Fog....................................................................................1494 Interior Windows Continue to Fog Diagnostic Procedure...........................................................1494 Tests...................................................................................................................1495 Refrigerant Cautions and Proper Handling............................................................................1495 R134a Oil Charge Capacity...........................................................................................1495 R134a Refrigerant Charge Capacity...................................................................................1495 Refrigerant Hoses and Tubing Inspection.............................................................................1496 R134a Air Conditioning System Test..................................................................................1497 Operating Pressure Diagnostic Chart.................................................................................1498 Air Conditioner High/Low Pressure Switch Test.......................................................................1499 Air Conditioner Freeze Control Switch Test..........................................................................1500 Refrigerant Leak Testing............................................................................................1500 Page Number..................................................................................................................... 5 Section 9000................................................................................................................ 7 Group 01................................................................................................................ 9 Section 9001................................................................................................................ 49 Group 10................................................................................................................ 51 Group 20................................................................................................................ 81 Group 30................................................................................................................ 207 Group 40................................................................................................................ 475 Group 50................................................................................................................ 535 Group 60................................................................................................................ 551 Group 70................................................................................................................ 553 Group 80................................................................................................................ 555 Group 90................................................................................................................ 573 Group 100............................................................................................................... 575 Section 9005................................................................................................................ 587 Group 10................................................................................................................ 589 Section 9010................................................................................................................ 623 Group 05................................................................................................................ 625 Group 10................................................................................................................ 628 Group 15................................................................................................................ 641 Group 20................................................................................................................ 649 Group 25................................................................................................................ 651 Section 9015................................................................................................................ 661 Group 05................................................................................................................ 663 Group 10................................................................................................................ 823 Group 15................................................................................................................1109 Group 16................................................................................................................1119 Group 17................................................................................................................1127 Group 20................................................................................................................1139 Group 25................................................................................................................1151 Section 9020................................................................................................................1170 Group 05................................................................................................................1171 Group 10................................................................................................................1197 Group 15................................................................................................................1209 Group 20................................................................................................................1255 Group 25................................................................................................................1259 Section 9025................................................................................................................1295 Group 05................................................................................................................1297 Group 10................................................................................................................1352 Group 15................................................................................................................1377 Group 20................................................................................................................1403 Group 25................................................................................................................1407 Section 9031................................................................................................................1479 Group 05................................................................................................................1481 Group 10................................................................................................................1484 Group 15................................................................................................................1487 Group 25................................................................................................................1495
S.S 21/02/2025
